A wind power tower cylinder door frame automatic welding device and method

Abstract

The application relates to the technical field of wind power tower manufacturing, and discloses a wind power tower door frame automatic welding device and method. The device comprises a bearing frame, X-axis, Y-axis and Z-axis three groups of walking mechanisms are respectively installed on the bearing frame, and an executing mechanism is installed on the Z-axis walking mechanism. The executing mechanism comprises an adjusting assembly, a rotating assembly, a welding gun, a laser sensor assembly and a mechanical sensor assembly. The adjusting assembly is used for driving the welding gun to move along the Z-axis direction, the rotating assembly is used for driving the welding gun to rotate, the laser sensor assembly is used for detecting the position deviation between the welding gun and a weld, and the mechanical sensor assembly is used for detecting the contact force change between the welding gun and the weld. A control system receives a position signal and drives the adjusting assembly to perform height compensation, receives a mechanical signal and drives the rotating assembly to perform angle adjustment, and the height and angle of the welding gun are cooperatively and adaptively adjusted. The application realizes adaptive welding of the special-shaped curved surface weld of the tower door frame, and improves the welding quality and production efficiency.

Description

Technical Field

[0001] This application relates to the field of wind turbine tower manufacturing technology, and in particular to an automatic welding device and method for wind turbine tower door frames. Background Technology

[0002] As a core supporting component of wind turbine generators, the portal frame structure of the wind turbine tower directly affects its structural strength and safety. The welding quality requirements for the portal frame and the tower body are extremely high. The welds must possess excellent continuity, density, and mechanical properties to withstand the harsh effects of complex outdoor wind loads and temperature variations. Currently, the welding of wind turbine tower portal frames is mostly done manually or semi-automatically, resulting in low production efficiency, high labor intensity, and difficulty in meeting the demands of mass production and high quality.

[0003] In related technologies, some automated welding devices have already been proposed. For example, Chinese utility model patent CN215658360U discloses an automated welding device for the door frame of a wind turbine tower safety door. This device includes a clamp and a welding mechanism. The clamp's spacing is adjusted using fasteners to fix door frames of different specifications. The welding mechanism includes a submerged arc welding machine with its welding torch positioned above the clamp. The device also includes a vertical reduction motor and a horizontal reduction motor, which drive the welding torch to move vertically and horizontally via vertical and horizontal screws to adjust the torch's position.

[0004] However, the aforementioned technologies still have some problems: First, the welding torch of the device can only be adjusted linearly in the vertical and horizontal directions. However, the tower frame is mostly an irregular structure with curvature, which easily leads to welding defects such as uneven weld width and excessive weld height during welding. Second, the device requires readjustment of the fixture position or replacement of suitable fixtures for different specifications of frames. The operation is cumbersome and the changeover time is long. It is difficult to achieve rapid switching of welding for different tower frame models. The equipment has poor versatility and restricts the improvement of production efficiency. Third, in the existing technology, when welding manually or semi-automatically, the distance and angle between the welding torch and the weld bead depend on manual experience control, and the weld alignment relies on visual identification. The labor intensity is high and it is easily affected by fatigue and human error, which affects the welding quality. Summary of the Invention

[0005] In order to achieve adaptive welding of irregular curved surface welds on tower door frames, improve the versatility of welding equipment for door frames of different specifications, and reduce the impact of operator welding skills on welding quality, thereby improving welding quality and production efficiency, this application provides an automatic welding device and method for wind turbine tower door frames.

[0006] On the one hand, the automatic welding device for wind turbine tower door frame provided in this application adopts the following technical solution: An automatic welding device for wind turbine tower frame includes a support frame, an X-axis traveling mechanism mounted on the support frame, a Y-axis traveling mechanism mounted on the X-axis traveling mechanism, a Z-axis traveling mechanism mounted on the Y-axis traveling mechanism, and an actuator mounted on the Z-axis traveling mechanism. The X-axis, Y-axis, and Z-axis traveling mechanisms drive the actuator to move in the X, Y, and Z axis directions, respectively. The actuator includes an adjustment component with a rotating component mounted at its bottom. A welding torch is mounted at one end of the rotating component. The adjustment component drives the welding torch to move along the Z-axis, and the rotating component drives the welding torch to rotate. The actuator also includes a laser sensor component and a force sensor component. The laser sensor component detects the positional deviation between the welding torch and the weld seam, and the force sensor component detects changes in the contact force between the welding torch and the weld seam. The device also includes a control system. The control system receives positional deviation signals and drives the adjustment component to perform height compensation, and receives force signals and drives the rotating component to perform angle adjustment, thereby achieving coordinated adaptive adjustment of the welding torch height and angle.

[0007] By adopting the above technical solution, the laser sensor component detects the positional deviation between the welding torch and the weld seam in real time, and the force sensor component detects the change in contact force between the welding torch and the weld seam in real time. The control system drives the adjustment component to perform height compensation based on the positional deviation signal and drives the rotation component to perform angle adjustment based on the force signal, realizing the coordinated adaptive adjustment of the welding torch height and angle. This allows the welding torch posture to be adjusted in real time according to the curvature of the weld seam, solving the defects of uneven weld seam width and excessive weld height when welding irregular curved surfaces. At the same time, the X-axis, Y-axis, and Z-axis travel mechanisms constitute a three-dimensional motion platform. With the adjustment and rotation components of the actuator, the three-axis travel range is sufficient to cover the welding area of ​​tower frame of different specifications. Moreover, the height and angle of the welding torch can be adaptively adjusted. Therefore, there is no need to change the track or customize the tooling for different specifications of the frame, which can adapt to the welding needs of various tower frame models, improving the versatility of the equipment and the welding efficiency. In addition, no manual intervention is required throughout the welding process, avoiding the influence of human factors on the welding quality and ensuring the consistency and stability of the welding quality.

[0008] Optionally, the adjustment assembly includes an electro-hydraulic actuator, the piston rod of which extends and retracts along the Z-axis; the rotation assembly includes a housing, which is fixedly connected to the bottom end of the piston rod of the electro-hydraulic actuator, and a rotary motor is installed inside the housing, with the welding torch located at the output end of the rotary motor.

[0009] By adopting the above technical solution, the electro-hydraulic actuator has strong load capacity and high control precision, which can meet the response speed and thrust requirements for high-frequency fine adjustment in the Z-axis direction during the welding process. The rotary motor drives the welding torch to swing, thereby changing the angle between the welding torch and the weld, thus adapting to the process requirements of welding angle for welds with different curvatures.

[0010] Optionally, the laser sensor assembly includes a laser sensor mounted on one side of the housing, with its working surface in the same horizontal plane as the axis of the rotary motor shaft; the force sensor assembly includes a force sensor mounted on the housing and located at the end of the rotary motor away from the welding torch, with the force sensor interface aligned with the rotary motor shaft, and the axis of the rotary motor shaft intersecting the axis of the welding torch.

[0011] By adopting the above technical solution, the working surface of the laser sensor and the axis of the rotary motor shaft are located in the same horizontal plane, ensuring the consistency between the detection data and the actual position of the welding torch; the mechanical sensor is aligned with the rotary motor shaft, ensuring that the detection axis intersects with the welding torch axis, thus improving the detection accuracy.

[0012] Optionally, the X-axis traveling mechanism includes two sets of parallel X-axis linear modules, which are respectively installed on the top of both sides of the support frame along the X-axis direction; the X-axis linear module includes an X-axis guide rail and an X-axis slide table slidably connected to the X-axis guide rail, and the two ends of the Y-axis traveling mechanism are respectively installed on the two X-axis slide tables.

[0013] By adopting the above technical solution, the two sets of parallel linear modules improve the load-bearing capacity and motion stability, and ensure the positioning accuracy of the actuator during large stroke movement in the X-axis direction.

[0014] Optionally, the Y-axis traveling mechanism includes a Y-axis body, on which two sets of Y-axis linear modules are arranged at intervals along the vertical direction, and the Y-axis linear modules extend along the Y-axis direction; each set of Y-axis linear modules includes two Y-axis slides, and the two Y-axis slides corresponding to the upper and lower positions form a slide group, and the Z-axis traveling mechanism is installed on the two slide groups.

[0015] By adopting the above technical solution, two sets of Y-axis linear modules are arranged at intervals along the vertical direction on the Y-axis main body, and each set of Y-axis linear modules is equipped with two Y-axis slides. The upper and lower corresponding slides jointly support the Z-axis traveling mechanism, which improves the load-bearing capacity and motion rigidity of the Z-axis traveling mechanism and the actuator when moving in the Y-axis direction, and ensures the stability and positioning accuracy of the actuator during the large stroke movement in the Y-axis direction.

[0016] Optionally, the Z-axis traveling mechanism includes two sets of Z-axis linear modules, which are arranged at intervals along the Y-axis and respectively mounted on two sets of slides. Each Z-axis linear module includes a mounting frame, in which a ball screw is rotatably connected. The ball screw extends axially along the Z-axis, and a Z-axis slide is slidably connected within the mounting frame. The ball screw is threadedly connected to the Z-axis slide. A mounting plate is connected between the two Z-axis slides, and the actuator is detachably connected to the mounting plate.

[0017] By adopting the above technical solution, the Z-axis traveling mechanism uses a ball screw as the transmission element. The ball screw achieves rolling friction transmission through the rolling balls, resulting in high transmission efficiency and low friction torque, accurately converting rotary motion into linear motion. Due to the small lead of the ball screw, the slide moves a short distance per revolution of the rotary motor, achieving micron-level precision positioning. Simultaneously, the ball screw has excellent self-locking performance, maintaining its current position after positioning without slippage, ensuring the stability of the initial positioning. The Z-axis traveling mechanism is responsible for lifting the actuator to the initial welding height and keeping it stationary, while the electro-hydraulic actuator handles high-frequency fine-tuning during the welding process. The functions of the two are decoupled, and the short stroke but high precision characteristics of the ball screw perfectly meet the requirements for precise positioning in the Z-axis direction.

[0018] Optionally, the control system includes a host computer and a PLC controller. The host computer and the PLC controller are connected for communication. The PLC controller is electrically connected to the X-axis traveling mechanism, the Y-axis traveling mechanism, the Z-axis traveling mechanism, the adjustment component, and the rotation component, respectively. The host computer receives the position deviation signal fed back by the laser sensor component and the mechanical signal fed back by the mechanical sensor component. After processing, it outputs control commands to the PLC controller. The PLC controller drives the actions of each traveling mechanism and the actuator according to the control commands.

[0019] By adopting the above technical solution, the host computer and the PLC controller form a collaborative control architecture. The host computer is responsible for receiving feedback signals from the laser sensor components and the force sensor components, performing force control and position control fusion calculations, and outputting control commands; the PLC controller is responsible for responding to control commands in real time and driving the actions of each traveling mechanism and actuator. This division of labor between the host and PLC—with the host computer focusing on data processing and decision-making, and the PLC controller focusing on real-time driving and response—ensures both the flexibility of the control strategy calculations and the real-time performance of the actuator actions, thereby improving the response speed and reliability of the control system.

[0020] Optionally, the control system also includes an interactive unit, which is mounted on the support frame and communicates with the host computer. The interactive unit is used for operators to input commands to the control system and to view various parameters and status information of the welding operation in real time.

[0021] By adopting the above technical solution, the interactive machine serves as a human-computer interaction terminal, allowing operators to input commands to the control system, manually debug equipment, perform teaching simulations, and monitor the operation status in real time, thereby improving the convenience and safety of equipment use.

[0022] On the other hand, this application also provides a welding method using the above-mentioned automatic welding device for wind turbine tower frame, comprising the following steps: S1: The actuator is moved to the welding position of the tower door frame by the X-axis traveling mechanism, the Y-axis traveling mechanism and the Z-axis traveling mechanism, and the Z-axis traveling mechanism lifts the actuator to the initial welding height; S2: Start the welding operation. During the welding feed, the laser sensor assembly detects the positional deviation between the welding torch and the weld seam. The control system drives the adjustment assembly to compensate the height of the welding torch according to the positional deviation signal. The force sensor assembly detects the change in contact force between the welding torch and the weld seam. The control system drives the rotation assembly to adjust the angle of the welding torch according to the force signal. S3: After welding is completed, the control system controls each walking mechanism to reset.

[0023] By adopting the above technical solution, after the welding operation starts, the laser sensor assembly detects the positional deviation between the welding torch and the weld in real time. The control system drives the adjustment assembly to compensate for the height of the welding torch based on the positional deviation signal. The force sensor assembly detects the change in contact force between the welding torch and the weld in real time. The control system drives the rotation assembly to adjust the angle of the welding torch based on the force signal. Position compensation and angle adjustment are performed in parallel without interference, ensuring that the welding torch maintains the optimal extension and welding angle throughout the welding process. This method organically combines position control and force control, ensuring both the spatial positional accuracy of the welding torch and the weld and the stability of the contact state between them. It effectively suppresses vibration and sudden changes in contact force during the welding process, ensuring the consistency of the width, reinforcement height, and penetration depth of the entire weld.

[0024] Optionally, in step S2, when welding the straight edge of the door frame, the adjusting component and the rotating component maintain their initial positions; when welding the curved edge of the door frame, the control system synchronously drives the adjusting component and the rotating component to move according to the position deviation signal fed back by the laser sensor component and the mechanical signal fed back by the mechanical sensor component, so as to realize the coordinated adaptive adjustment of the welding torch height and angle.

[0025] By adopting the above technical solution, when welding the straight edge of the door frame, the height and angle of the weld remain basically unchanged. The adjustment and rotation components maintain their initial positions, and only the X-axis and Y-axis travel mechanisms drive the actuator to feed along the weld direction. The control logic is simple and efficient. When welding the curved edge of the door frame, the height and angle of the weld change in real time with the curvature. The control system drives the adjustment component to perform height compensation based on the position deviation signal fed back by the laser sensor component, and simultaneously drives the rotation component to adjust the angle based on the mechanical signal fed back by the mechanical sensor component. This ensures that the welding torch always tracks the weld in the optimal posture, realizing intelligent switching between straight and curved edge welding and adaptive control throughout the entire process.

[0026] This application includes at least one of the following beneficial technical effects: 1. By setting adjustment and rotation components in the actuator, which independently undertake the Z-axis height compensation and angle adjustment functions during the welding process, and processing the feedback signals of the laser sensor component and the mechanical sensor component in conjunction with the control system, the coordinated adaptive adjustment of the welding torch height and angle during the welding process is realized. This allows the welding torch posture to be adjusted in real time according to the change of weld curvature, realizing adaptive welding of irregular curved surface welds in tower frame, and effectively solving the problems of uneven weld width and excessive excess height when welding irregular curved surfaces. 2. By combining the mechanical sensor component with the laser sensor component to form a dual-sensor feedback system, the synchronous monitoring of position deviation and contact force state during the welding process is realized. This enables the control system to not only respond to position deviation by height compensation, but also respond to contact force changes by angle adjustment, which significantly improves the stability of the welding process and the consistency of weld quality. 3. A three-dimensional motion platform is formed by the X-axis, Y-axis and Z-axis traveling mechanisms. With the adaptive adjustment capability of the actuator, the three-axis travel range is sufficient to cover the welding area of ​​tower door frames of different specifications. Moreover, the height and angle of the welding torch can be adaptively adjusted. There is no need to change the track or customize the tooling for different specifications of door frames. It can adapt to the welding needs of various tower door frames, improving the versatility and welding efficiency of the equipment. 4. By decoupling the functions of the Z-axis traveling mechanism and the adjustment component: the Z-axis traveling mechanism is responsible for coarse positioning and the adjustment component is responsible for fine tracking. This ensures both the initial positioning accuracy of welding and meets the response requirements of high-frequency fine adjustment during welding. The two work together to achieve optimized coordination between positioning and tracking, which effectively improves welding accuracy. Attached Figure Description

[0027] To more clearly illustrate the technical solution of this patent, the drawings used in the description will be briefly introduced below. Obviously, the drawings described below are only some embodiments of this patent. For those skilled in the art, other drawings can be obtained from these drawings without creative effort.

[0028] Figure 1 This is a schematic diagram of the overall structure of an embodiment of this application; Figure 2 This is a partial structural diagram of an embodiment of this application, mainly used to illustrate the load-bearing frame; Figure 3 This is a partial structural diagram of an embodiment of this application, mainly used to illustrate the Y-axis traveling mechanism; Figure 4 This is a partial structural diagram of an embodiment of this application, mainly used to illustrate the Z-axis traveling mechanism; Figure 5 This is a partial structural diagram of an embodiment of this application, mainly used to illustrate the actuator; Figure 6 This is a partial structural diagram of an embodiment of this application, mainly used to illustrate the rotating component; Figure 7 This is a partial structural control principle diagram of an embodiment of this application, mainly used to illustrate the control system.

[0029] Key reference numerals in the attached drawings: 1. Bearing frame; 11. Frame body; 12. Multi-hole work plate; 13. X-axis cable tray; 2. X-axis traveling mechanism; 21. X-axis linear module; 211. X-axis guide rail; 212. X-axis slide; 213. Limiting block; 3. Y-axis traveling mechanism; 31. Y-axis body; 311. Reinforcing rib; 32. Y-axis linear module; 321. Y-axis slide; 33. Slide assembly; 34. Y-axis cable tray; 35. Y-axis moving cable chain; 4. Z-axis traveling mechanism; 41. Z-axis linear module; 411. Mounting bracket; 412. Ball screw; 413. Drive motor; 414. Z-axis slide; 415. Proximity switch; 42. Z-axis moving cable chain; 5. 51. Actuator; 52. Adjustment assembly; 53. Electro-hydraulic actuator; 54. Fixed base; 55. Rotating assembly; 56. Housing; 57. Rotary motor; 58. Reducer; 59. Welding assembly; 50. Welding torch; 51. Adapter; 52. Mechanical sensor assembly; 53. Mechanical sensor; 54. Bracket; 55. Laser sensor assembly; 55. Laser sensor; 55. Fastening screw; 55. Mounting hole; 60. Control system; 61. Host computer; 62. PLC controller; 63. Output module; 64. Interactive machine; 641. Interactive machine wiring duct; 70. Electrical cabinet; 81. Mounting plate; 82. Connecting plate; 83. Fixing bracket. Detailed Implementation

[0030] To make the objectives, features, and advantages of this patent more apparent and understandable, the technical solutions of this patent will be clearly and completely described below with reference to the accompanying drawings of the specific embodiments. Obviously, the embodiments described below are only some embodiments of this patent, and not all embodiments. Based on the embodiments of this patent, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this patent.

[0031] The following is in conjunction with the appendix Figure 1-7 This application will be described in further detail.

[0032] Example 1 Embodiment 1 of this application discloses an automatic welding device for wind turbine tower door frame.

[0033] Reference Figure 1An automatic welding device for wind turbine tower door frames includes a support frame 1, an X-axis traveling mechanism 2 mounted on the support frame 1, a Y-axis traveling mechanism 3 mounted on the X-axis traveling mechanism 2, a Z-axis traveling mechanism 4 mounted on the Y-axis traveling mechanism 3, and an actuator 5 mounted on the Z-axis traveling mechanism 4. The X-axis traveling mechanism 2, Y-axis traveling mechanism 3, and Z-axis traveling mechanism 4 drive the actuator 5 to move in the X, Y, and Z axis directions, respectively. An electrical cabinet 7 is mounted on the Y-axis traveling mechanism 3 to house a control system 6. The control system 6 is electrically connected to the X-axis traveling mechanism 2, Y-axis traveling mechanism 3, Z-axis traveling mechanism 4, and actuator 5, respectively. During welding, the support frame 1 spans above the tower, the X-axis traveling mechanism 2 is arranged along the length of the tower, and the Y-axis traveling mechanism 3 is arranged radially along the tower. The three traveling mechanisms move the actuator 5 to the weld between the door frame and the tower. During the welding process, the actuator 5 adaptively adjusts its height and angle under the control of the control system 6 to achieve automatic welding of the irregular curved surface weld of the tower door frame.

[0034] Reference Figure 2 The load-bearing frame 1 is a truss structure, which is lighter and more modular than the traditional gantry structure, with dimensions of 6000mm × 3000mm × 2000mm (length × width × height). The load-bearing frame 1 includes a frame body 11, a multi-hole work plate 12, and X-axis cable trays 13. The multi-hole work plate 12 is bolted to both sides of the frame body 11 parallel to the X-axis and is used to store measuring instruments and tools. An X-axis cable tray 13 is installed on the top of both sides of the frame body 11 in the X-axis direction. Both X-axis cable trays 13 are arranged along the X-axis direction of the frame body 11, and the signal and power lines of the X-axis traveling mechanism 2 are integrated within the X-axis cable trays 13. The X-axis cable trays 13 are covered with anti-static and dustproof protective covers to effectively prevent welding slag and dust from entering the X-axis cable trays 13, thereby protecting the equipment wiring.

[0035] Reference Figure 1The X-axis traveling mechanism 2 includes two sets of parallel X-axis linear modules 21, which are respectively installed on the top of both sides of the frame body 11 along the X-axis direction. In this embodiment, the X-axis linear module 21 is a linear motor module, which includes an X-axis guide rail 211 fixedly installed on the top of the frame body 11 and an X-axis slide 212 slidably connected to the X-axis guide rail 211. The stator of the linear motor is integrated on the X-axis guide rail 211, and the mover that cooperates with the stator is integrated on the X-axis slide 212. The stator and the mover directly drive the X-axis slide 212 to perform reciprocating linear motion along the X-axis guide rail 211 through electromagnetic force. The X-axis linear module 21 has a closed structure, and its X-axis guide rail 211, stator and mover are all encapsulated inside the module housing. Only the X-axis slide 212 protrudes from the housing for connection and support. The X-axis linear module 21 has a built-in position feedback system for real-time detection of the slide position and feedback to the control system 6. The X-axis linear module 21 is equipped with a linear motor driver. The linear motor driver receives control commands from the control system 6, converts the control commands into drive current, and outputs it to the stator to drive the slide table to move along a preset trajectory. The linear motor driver is installed in the electrical cabinet 7. The structure of the linear motor module is existing technology and will not be described in detail here.

[0036] Reference Figure 1 Limit blocks 213 are installed at both ends of the X-axis guide rail 211, and photoelectric switches are embedded in the limit blocks 213. When the X-axis slide 212 moves to the end of its stroke, the photoelectric switch triggers a signal, causing the control system 6 to force the linear motor to brake until it stops. At the same time, the limit blocks 213 are also covered with a buffer layer. In this embodiment, the buffer layer is made of high-density rubber. When the photoelectric limit fails or the braking distance is insufficient, the buffer can absorb the impact energy of the slide, realizing dual protection of electrical and mechanical limit.

[0037] Reference Figure 1 and Figure 3The Y-axis traveling mechanism 3 includes a Y-axis body 31, which extends along the Y-axis direction of the supporting frame 1, and its two ends are fixedly connected to two X-axis slides 212. Reinforcing ribs 311 are provided on both sides of the connection between the Y-axis body 31 and the X-axis slides 212. The reinforcing ribs 311 are fixedly connected to the Y-axis body 31 and the X-axis slides 212 by bolts to improve the connection rigidity and stability between the Y-axis body 31 and the X-axis slides 212. Two sets of Y-axis linear modules 32 are installed on the vertical side of the Y-axis body 31 along its length. The two sets of Y-axis linear modules 32 are arranged at intervals along the vertical direction and both extend along the Y-axis direction. Each set of Y-axis linear modules 32 has two Y-axis slides 321. The two Y-axis slides 321 in the two sets of Y-axis linear modules 32 that are vertically aligned form a slide group 33, thus forming two slide groups 33 arranged along the Y-axis direction. The Y-axis linear module 32 also uses a linear motor module. Except for the number of slides, the structure of the Y-axis linear module 32 is the same as that of the X-axis linear module 21, which will not be described in detail here.

[0038] Reference Figure 4 The Z-axis traveling mechanism 4 includes two sets of Z-axis linear modules 41, which are spaced apart along the Y-axis and extend along the Z-axis. The two sets of Z-axis linear modules 41 are bolted to two sets of slide groups 33. Each Z-axis linear module 41 includes a mounting frame 411, which is bolted to the side of the slide group 33 opposite to the Y-axis main body 31. The length of the mounting frame 411 extends along the Z-axis. A ball screw 412 is rotatably connected inside the mounting frame 411, with its length parallel to that of the mounting frame 411. A drive motor 413 is mounted on the top of the mounting frame 411, and the drive motor 413 and the ball screw 412 are coaxially connected via a reducer. The ball screw 412 has a short stroke but high precision, meeting the high Z-axis precision requirements for tower frame welding. A Z-axis slide 414 is slidably connected inside the mounting bracket 411. The Z-axis slide 414 is threadedly connected to a ball screw 412, and the rotation of the ball screw 412 drives the Z-axis slide 414 to slide up and down. Proximity switches 415 are installed at both ends of the mounting bracket 411. When the Z-axis slide 414 approaches its upper or lower limit position, the proximity switch 415 sends a signal to the control system 6, and the control system 6 executes a stop feed command.

[0039] Reference Figures 4-6A mounting plate 81 is bolted between two Z-axis slides 414. A connecting plate 82 is bolted to the back of the actuator 5. During installation, the connecting plate 82 is bolted to the vertical side of the mounting plate 81 away from the Z-axis linear module 41, and the actuator 5 is centrally mounted between the two Z-axis linear modules 41 along the Y-axis. The actuator 5 includes an adjustment component 51, which is mounted on the connecting plate 82. The adjustment component 51 drives the welding torch 531 to move along the Z-axis to compensate for height deviation. A rotating component 52 is mounted at the bottom of the adjustment component 51. The rotating component 52 drives the welding torch 531 to rotate around the horizontal axis to adjust the welding angle. A welding component 53 is provided at the end of the rotating component 52. The welding component 53 is used to perform welding operations. The rotating assembly 52 is also equipped with a mechanical sensor assembly 54 and a laser sensor assembly 55. The mechanical sensor assembly 54 is used to detect the mechanical parameters of the welding torch 531 during operation and feed them back to the control system 6. The laser sensor assembly 55 is used to detect the relative position between the welding torch 531 and the weld and feed it back to the control system 6.

[0040] Reference Figure 5 In this embodiment, the adjustment component 51 is an electro-hydraulic actuator 511. The electro-hydraulic actuator 511 has a strong load capacity and high control precision, which can meet the response speed and thrust requirements for high-frequency fine adjustment in the Z-axis direction during welding. The electro-hydraulic actuator 511 is mounted on the side of the connecting plate 82 away from the mounting plate 81 via a fixed base 512.

[0041] Reference Figure 5 and Figure 6 The rotating assembly 52 includes a housing 521, within which a rotary motor 522 and a reducer 523 are installed. The housing 521 is divided into upper and lower parts connected by bolts, with the upper part fixedly connected to the bottom end of the piston rod of the electro-hydraulic actuator 511. The output end of the rotary motor 522 is connected to the welding assembly 53 via the reducer 523. The motor shaft of the rotary motor 522 is parallel to the X-axis, and the rotary motor 522 drives the welding assembly 53 to rotate 120° around the motor axis of the rotary motor 522.

[0042] Reference Figure 5 and Figure 6The welding assembly 53 includes a welding torch 531 and an adapter 532. The adapter 532 is fixedly connected to the output end of the reducer 523 and consists of two parts connected by bolts. The welding torch 531 is clamped and fixed between the two parts of the adapter 532. The adapter 532 is coaxially arranged with the motor shaft of the rotary motor 522, and the vertical axis of the welding torch 531 intersects the horizontal axis of the adapter 532. The rotary motor 523 drives the adapter 532 to rotate, and the adapter 532 drives the welding torch 531 to swing within a 120° range to change the angle between the welding torch 531 and the weld, thereby adapting to the process requirements of welding angle for welds with different curvatures. When welding the curved edge of the door frame, the weld curvature changes continuously at different positions. The rotary motor 523 adjusts the angle of the welding torch 531 in real time according to the signal fed back by the sensor detection component, so that the welding wire is always aligned with the root of the weld at the optimal pointing angle, ensuring the consistency of penetration depth and weld formation.

[0043] Reference Figure 5 The mechanical sensor assembly 54 includes a mechanical sensor 541 and a bracket 542. The bracket 542 is fixedly connected to the end of the housing 521 away from the welding torch 531. The mechanical sensor 541 is mounted on the bracket 542, and its interface is aligned with the shaft of the rotary motor 522 to ensure that the detection axis intersects with the axis of the welding torch 531, thereby improving detection accuracy. The mechanical sensor 541 is used to detect the force, torque, and vibration parameters of the welding torch 531 during its operation. When the welding torch 531 contacts the weld seam, it experiences a reaction force from the weld seam. The magnitude and direction of this force directly reflect the contact state between the welding torch 531 and the weld seam. After collecting the above mechanical parameters, the mechanical sensor 541 transmits the mechanical signal to the control system 6 after analog-to-digital conversion via the output module 63. The control system 6 determines whether the current contact state of the welding torch 531 is stable based on the changes in the mechanical signal. When the mechanical signal deviates from the preset threshold, it indicates that a sudden change in contact force or abnormal vibration has occurred during the welding process. Based on this, the control system 6 outputs a control command to drive the rotary motor 523 to rotate and adjust the welding angle of the welding torch 531 to maintain the contact force between the welding torch 531 and the weld within the preset range, thereby suppressing the shaking and sudden change in contact force during the welding process and ensuring the stability of the welding process and the quality of the weld.

[0044] Reference Figure 5The laser sensor assembly 55 includes a laser sensor 551 and a fastening screw 552. A mounting hole 553 is provided on the vertical side of the housing 521, extending along the Y-axis. The fastening screw 552 passes through the laser sensor 551 and is fixedly connected to it. The fastening screw 552 is coaxially inserted into the mounting hole 553 and threadedly connected to it. The screwing depth of the fastening screw 552 in the mounting hole 553 is adjustable. By rotating the fastening screw 552, the laser sensor 551 can be moved along the Y-axis, thus adjusting its position in the Y-axis direction. The working surface of the laser sensor 551 faces vertically downwards, and its working surface is located in the same horizontal plane as the axis of the rotary motor 522. The laser beam is projected onto the weld surface along the Z-axis. When the welding torch 531 deviates in height in the Z-axis direction, the distance value measured by the laser sensor 551 changes accordingly. The control system 6 calculates the height deviation based on the change in distance value and drives the electro-hydraulic actuator 511 to compensate, thereby achieving precise height control of the welding torch 531 in the Z-axis direction.

[0045] Reference Figure 1 and Figure 4 The electrical cabinet 7 is mounted on the Y-axis body 31 and located on the side opposite to the actuator 5. A mounting plate 81 is bolted to a mounting bracket 83 at one end along the Y-axis direction. A Z-axis moving cable chain 42 is vertically mounted on the mounting bracket 83. The Z-axis moving cable chain 42 integrates the signal and power lines of the Z-axis linear module 41 and the actuator 5. A Y-axis cable tray 34 is fixedly connected to the top of the Y-axis body 31 and is arranged along the Y-axis direction. A Y-axis moving cable chain 35 is installed within the Y-axis cable tray 34, integrating the signal and power lines of the Y-axis linear module 32. The cables exiting the Z-axis moving cable chain 42 enter the Y-axis moving cable chain 35 and are connected to the electrical cabinet 7 together with the cables within the Y-axis moving cable chain 35. The Y-axis moving cable chain 35 and the Z-axis moving cable chain 42 are used to achieve orderly management of the cables within the travel range of the actuator 5, preventing cables from becoming tangled or worn during movement.

[0046] Reference Figure 2 and Figure 7 The control system 6 includes a host computer 61, a PLC controller 62, an output module 63, and an interactive unit 64. The host computer 61, PLC controller 62, output module 63, and other electrical components are all installed in the electrical cabinet 7. The interactive unit 64 is installed on one side of the frame body 11 along the X-axis direction, serving as an operation terminal for manual equipment debugging, teaching simulation, and real-time monitoring of the operation status. An interactive unit wiring trough 641 is fixedly connected to the back of the interactive unit 64, and the signal and power lines of the interactive unit 64 are integrated within the wiring trough 641. After exiting the wiring trough 641, the signal and power lines of the interactive unit 64 converge in an adjacent X-axis wiring trough 13.

[0047] Reference Figure 7 The host computer 61, as the core data processing and decision-making unit of the control system 6, is built using the LabVIEW platform. It is used to run the X, Y, and Z-axis traveling mechanisms and actuators 5, perform force control and position control fusion control strategy calculations, display work information, and upload production information. The host computer 61 communicates with the PLC controller 62 via TCP / IP protocol to send calculated control commands to the PLC controller 62. The host computer 61 also communicates with the interactive machine 64, the force sensor 541, and the laser sensor 551 via RS485 serial port protocol to receive signals collected by the force sensor 541 and the laser sensor 551, and to upload work information and download process parameters. The host computer 61 also communicates with the company's MES system to upload production information and achieve digital management of the production process. The PLC controller 62, as the execution unit of the control system 6, receives control commands from the host computer 61 and drives the X-axis traveling mechanism 2, Y-axis traveling mechanism 3, Z-axis traveling mechanism 4, and actuators 5 to perform corresponding actions. Output module 63, acting as a real-time processor, is connected between the force sensor 541 and the host computer 61. Output module 63 performs analog-to-digital conversion on the analog signal output by the force sensor 541, converting it into a digital signal and transmitting it to the host computer 61 via RS485 serial communication. The position signal output by the laser sensor 551 is a digital signal, which does not require analog-to-digital conversion by output module 63 and is directly transmitted to the host computer 61 via RS485 serial communication. Thus, the force sensor 541 and the laser sensor 551 respectively feed back the mechanical and position parameters of the welding process to the host computer 61 through their respective signal paths, providing a data basis for the host computer 61 to execute the force control and position control fusion control strategy calculations. Interactive interface 64 is communicatively connected to the host computer 61. Operators can input commands to the control system 6 through interactive interface 64 and can also view various parameters and status information of the welding operation in real time through interactive interface 64.

[0048] The implementation principle of Embodiment 1 of this application is as follows: Before welding, the supporting frame 1 is straddling the tower. The X-axis traveling mechanism 2 is arranged along the length of the tower, and the Y-axis traveling mechanism 3 is arranged radially along the tower. According to the instructions of the control system 6, the three traveling mechanisms move the actuator 5 to the welding position between the gate frame and the tower. The Z-axis traveling mechanism 4 lifts the actuator 5 to the initial welding height via the ball screw 412. During this process, the Z-axis ball screw 412 remains stationary after completing coarse positioning, and subsequent fine adjustments in the Z-axis direction are handled by the electro-hydraulic actuator 511.

[0049] After the welding operation starts, the X-axis traveling mechanism 2 and the Y-axis traveling mechanism 3 drive the actuator 5 to feed along the weld seam direction. The laser sensor 551 detects the relative position between the welding torch 531 and the weld seam in real time and transmits the position signal to the host computer 61. The force sensor 541 detects the force, torque, and vibration parameters of the welding torch 531 in real time during operation and transmits the force signal to the host computer 61 after analog-to-digital conversion by the output module 63. The host computer 61 performs calculations based on the force control and position control fusion control strategy, outputs control commands, and transmits them to the PLC controller 62. The PLC controller 62 drives the electro-hydraulic actuator 511 and the rotary motor 523 to move.

[0050] When welding the straight edge of the door frame, the weld height and angle remain essentially constant. The electro-hydraulic actuator 511 and rotary motor 523 maintain their initial positions, and the actuator 5 is fed along the weld direction only by the X-axis travel mechanism 2 and the Y-axis travel mechanism 3. When welding the curved edge of the door frame, the weld height and angle change in real time with the curvature: after the laser sensor 551 detects a positional deviation, the host computer 61 drives the electro-hydraulic actuator 511 to extend or retract based on a position control strategy to compensate for the height deviation of the welding torch 531 in the Z-axis direction; after the force sensor 541 detects a change in the force state, the host computer 61 drives the rotary motor 523 to rotate based on a force control strategy to adjust the welding angle of the welding torch 531. Force control and position control work together. Position control ensures the positional accuracy of the welding torch 531 and the weld, while force control ensures the stability of the contact state between the welding torch 531 and the weld. The two work together to suppress welding vibration and sudden changes in contact force, ensuring the consistency of the width, reinforcement height, and penetration depth of the entire weld.

[0051] After welding is completed, control system 6 controls each traveling mechanism to reset, waiting for the next welding operation.

[0052] Example 2 Embodiment 2 of this application discloses a welding method using an automatic welding device for wind turbine tower door frames as described in Embodiment 1, comprising the following steps: S1, Movement, Positioning, and Alignment: The actuator 5 is moved to the welding position on the tower frame via the X-axis traveling mechanism 2, Y-axis traveling mechanism 3, and Z-axis traveling mechanism 4. The Z-axis traveling mechanism 4 lifts the actuator 5 to the initial welding height. In this step, the Z-axis ball screw 412 performs coarse positioning, lifting the actuator 5 to the initial welding height and keeping it stationary. Subsequent fine adjustments in the Z-axis direction are handled by the electro-hydraulic actuator 511. The laser sensor 551 detects the initial relative position between the welding torch 531 and the weld seam, feeding the position signal back to the control system 6 to complete the initial alignment calibration.

[0053] S2, Adaptive Welding: Welding assembly 53 is started to perform welding operations. During the welding feed process, the control system 6 drives the electro-hydraulic actuator 511 to extend and retract based on a control strategy that integrates force control and position control to compensate for the height deviation of the welding torch 531 in the Z-axis direction, and drives the rotary motor 523 to rotate to adjust the welding angle of the welding torch 531. Specifically, the laser sensor 551 detects the position deviation between the welding torch 531 and the weld seam in real time and transmits the position signal to the host computer 61. The host computer 61 calculates the required height compensation amount based on the position control strategy and drives the electro-hydraulic actuator 511 to extend and retract. The force sensor 541 detects the force, torque, and vibration parameters of the welding torch 531 in real time during operation and transmits the force signal to the host computer 61 after analog-to-digital conversion by the output module 63. The host computer 61 calculates the required angle adjustment amount based on the force control strategy and drives the rotary motor 523 to rotate.

[0054] When welding the straight edge of the door frame, the weld height and angle remain essentially constant. The electro-hydraulic actuator 511 and rotary motor 523 maintain their initial positions, and the actuator 5 is fed along the weld direction only by the X-axis travel mechanism 2 and the Y-axis travel mechanism 3. When welding the curved edge of the door frame, the curvature change of the weld causes continuous changes in height and angle. Based on the real-time feedback signals from the laser sensor 551 and the mechanical sensor 541, the control system 6 synchronously drives the electro-hydraulic actuator 511 and rotary motor 523 to achieve coordinated adaptive adjustment of the height and angle of the welding torch 531.

[0055] S3, Equipment Reset: After welding is completed, the control system 6 controls each traveling mechanism to reset, waiting for the next welding operation.

[0056] The implementation principle of Embodiment 2 of this application is as follows: During the welding process, the force control and position control fusion control strategy enables the equipment to simultaneously respond to position deviations and contact force changes. Laser sensor 551 provides position deviation signals for position control closed-loop, ensuring the spatial positional accuracy of the welding torch 531 and the weld seam; force sensor 541 provides force signals for force control closed-loop, ensuring the stable contact state between the welding torch 531 and the weld seam. The two sensors are fused through a host computer 61, driving the electro-hydraulic actuator 511 for position adjustment and the rotary motor 523 for angle adjustment, respectively. Their coordinated action achieves adaptive optimization of the welding torch 531's posture during the welding process. The entire welding process requires no manual intervention; only one operator needs to monitor and set necessary parameters through the interactive computer 64 to complete all welding operations.

[0057] The above description of the disclosed embodiments enables those skilled in the art to implement or use this patent. Various modifications to these embodiments will be readily apparent to those skilled in the art, and the general principles defined herein may be implemented in other embodiments without departing from the spirit or scope of this patent. Therefore, this patent is not to be limited to the embodiments shown herein, but is to be accorded the widest scope consistent with the principles and novel features disclosed herein.

Claims

1. An automatic welding device for wind turbine tower door frame, comprising a load-bearing frame (1), characterized in that: An X-axis traveling mechanism (2) is mounted on the supporting frame (1), a Y-axis traveling mechanism (3) is mounted on the X-axis traveling mechanism (2), a Z-axis traveling mechanism (4) is mounted on the Y-axis traveling mechanism (3), and an actuator (5) is mounted on the Z-axis traveling mechanism (4); the X-axis traveling mechanism (2), Y-axis traveling mechanism (3), and Z-axis traveling mechanism (4) are used to drive the actuator (5) to move in the X-axis, Y-axis, and Z-axis directions; the actuator (5) includes an adjusting component (51), a rotating component (52) is mounted on the bottom of the adjusting component (51), a welding torch (531) is mounted on one end of the rotating component (52), and the adjusting component (51) is used to drive the welding torch (531). 531) Move along the Z-axis direction. The rotating component (52) is used to drive the welding torch (531) to rotate. The actuator (5) also includes a laser sensor component (55) and a force sensor component (54). The laser sensor component (55) is used to detect the positional deviation between the welding torch (531) and the weld. The force sensor component (54) is used to detect the change in contact force between the welding torch (531) and the weld. It also includes a control system (6). The control system (6) receives the positional deviation signal and drives the adjustment component (51) to perform height compensation. It receives the force signal and drives the rotating component (52) to perform angle adjustment, so as to realize the coordinated adaptive adjustment of the height and angle of the welding torch (531).

2. The automatic welding device for wind turbine tower door frame according to claim 1, characterized in that: The adjustment assembly (51) includes an electro-hydraulic actuator (511), the piston rod of which extends and retracts along the Z-axis; the rotation assembly (52) includes a housing (521), the housing (521) is fixedly connected to the bottom end of the piston rod of the electro-hydraulic actuator (511), a rotary motor (522) is installed inside the housing (521), and the welding torch (531) is located at the output end of the rotary motor (522).

3. The automatic welding device for wind turbine tower door frame according to claim 2, characterized in that: The laser sensor assembly (55) includes a laser sensor (551), which is mounted on one side of the housing (521) and its working surface is in the same horizontal plane as the axis of the rotary motor (522) motor shaft; the mechanical sensor assembly (54) includes a mechanical sensor (541), which is mounted on the housing (521) and located at the end of the rotary motor (522) away from the welding torch (531). The interface of the mechanical sensor (541) is aligned with the axis of the rotary motor (522) motor shaft, and the axis of the rotary motor (522) motor shaft intersects with the axis of the welding torch (531).

4. The automatic welding device for wind turbine tower door frame according to claim 1, characterized in that: The X-axis traveling mechanism (2) includes two sets of parallel X-axis linear modules (21), which are respectively installed on the top of the support frame (1) along the X-axis direction. The X-axis linear module (21) includes an X-axis guide rail (211) and an X-axis slide (212) slidably connected to the X-axis guide rail (211). The two ends of the Y-axis traveling mechanism (3) are respectively installed on the two X-axis slides (212).

5. The automatic welding device for wind turbine tower door frame according to claim 4, characterized in that: The Y-axis traveling mechanism (3) includes a Y-axis body (31), on which two sets of Y-axis linear modules (32) are arranged at intervals along the vertical direction. The Y-axis linear modules (32) extend along the Y-axis direction. Each set of Y-axis linear modules (32) includes two Y-axis slides (321). The two Y-axis slides (321) with corresponding upper and lower positions form a set of slide groups (33). The Z-axis traveling mechanism (4) is installed on the two sets of slide groups (33).

6. The automatic welding device for wind turbine tower door frame according to claim 5, characterized in that: The Z-axis traveling mechanism (4) includes two sets of Z-axis linear modules (41), which are arranged at intervals along the Y-axis and respectively mounted on two sets of slide groups (33). The Z-axis linear module (41) includes a mounting frame (411), in which a ball screw (412) is rotatably connected. The ball screw (412) extends axially along the Z-axis. A Z-axis slide (414) is slidably connected in the mounting frame (411), and the ball screw (412) is threadedly connected to the Z-axis slide (414). A mounting plate (81) is connected between the two Z-axis slides (414), and the actuator (5) is detachably connected to the mounting plate (81).

7. The automatic welding device for wind turbine tower door frame according to claim 3, characterized in that: The control system (6) includes a host computer (61) and a PLC controller (62). The host computer (61) is communicatively connected to the PLC controller (62). The PLC controller (62) is electrically connected to the X-axis walking mechanism (2), the Y-axis walking mechanism (3), the Z-axis walking mechanism (4), the adjustment component (51), and the rotation component (52), respectively. The host computer (61) receives the position deviation signal fed back by the laser sensor component (55) and the mechanical signal fed back by the mechanical sensor component (54), and outputs control commands to the PLC controller (62) after calculation. The PLC controller (62) drives each walking mechanism and the actuator (5) to move according to the control commands.

8. The automatic welding device for wind turbine tower door frame according to claim 7, characterized in that: The control system (6) also includes an interactive unit (64), which is mounted on the support frame (1) and communicates with the host computer (61). The interactive unit (64) is used for operators to input instructions to the control system (6) and to view the various parameters and status information of the welding operation in real time.

9. A welding method using the automatic welding device for wind turbine tower door frames as described in any one of claims 1-8, characterized in that, Includes the following steps: S1: The actuator (5) is moved to the welding position of the tower door frame by the X-axis traveling mechanism (2), the Y-axis traveling mechanism (3) and the Z-axis traveling mechanism (4), and the Z-axis traveling mechanism (4) lifts the actuator (5) to the initial welding height; S2: Start the welding operation. During the welding feed, the laser sensor assembly (55) detects the positional deviation between the welding torch (531) and the weld. The control system (6) drives the adjustment assembly (51) to perform height compensation on the welding torch (531) according to the positional deviation signal. The mechanical sensor assembly (54) detects the change in contact force between the welding torch (531) and the weld. The control system (6) drives the rotation assembly (52) to adjust the angle of the welding torch (531) according to the mechanical signal. S3: After welding is completed, the control system (6) controls each walking mechanism to reset.

10. The automatic welding method for wind turbine tower door frame according to claim 9, characterized in that: In step S2, when welding the straight edge of the door frame, the adjustment component (51) and the rotation component (52) maintain their initial positions; when welding the curved edge of the door frame, the control system (6) synchronously drives the adjustment component (51) and the rotation component (52) to move according to the position deviation signal fed back by the laser sensor component (55) and the mechanical signal fed back by the mechanical sensor component (54), so as to realize the coordinated adaptive adjustment of the height and angle of the welding torch (531).

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