A continuous casting main machine roller welding automation complete equipment

Abstract

The application discloses a continuous casting main machine roller welding automation complete equipment, and relates to the technical field of welding automation, comprising a workpiece conveying roller bed module; the automatic feeding and discharging clamping module comprises a servo lifting and transverse moving mechanism, a self-adaptive double chuck tool and an intelligent induction positioning assembly.The application has the advantages that: a high-precision closed-loop control automatic welding system is adopted, the traditional manual handheld welding and random control parameter operation mode is abandoned, and full-automatic surfacing welding operation of the continuous casting main machine roller surface wear-resistant layer is realized.The system is provided with an intelligent numerical control welding module, a real-time welding seam tracking device and a constant current and constant voltage energy supply system, can automatically match a welding track, a walking speed, a wire feeding rate and a heat input parameter according to the diameter, the length and the wear area size of the main machine roller of different specifications, supports layered gradient automatic surfacing welding, realizes whole-process digital precise regulation and control in the welding process, the heat input amount is stable and controllable, and defects such as pores and slag inclusion in manual welding are effectively avoided.

Description

Technical Field

[0001] This invention relates to the field of welding automation technology, specifically to a complete set of automated equipment for welding rolls of a continuous casting main machine. Background Technology

[0002] The continuous casting main roll is the core support and guiding component of the steel continuous casting unit. It comes into direct contact with the high-temperature red-hot billet, circulating cooling water, and iron oxide scale, and is subjected to extreme and harsh working conditions such as high-temperature alternation, wet and dry alternation, extrusion friction, and oxidation corrosion for a long time. The equipment continuously withstands the heavy pressure of the billet, rolling shear friction, and periodic thermal shock. The working surface wear rate is high and the working conditions are harsh, requiring extremely high requirements for the surface performance and overall stability of the roll body.

[0003] In production, the continuous casting main machine rolls must meet the core requirements of high precision, high stability, and high durability: the roll surface roundness, coaxiality, and surface finish must meet the standards precisely, without pits, scratches, cracks, or peeling defects. The roll surface must have excellent wear resistance, high temperature resistance, water vapor corrosion resistance, and thermal fatigue resistance, and be able to adapt to 24-hour continuous operation of the production line to ensure stable billet forming quality, reduce unplanned downtime for maintenance, and ensure the overall production cycle.

[0004] Currently, continuous casting main machine rolls manufactured using traditional manual welding repair processes frequently fail, becoming a major bottleneck restricting production and increasing maintenance costs. First, the roller surface wears too quickly. The thickness of the manually welded layer is uneven, the weld beads are messy, and the surface flatness is poor. During operation, the frictional resistance with the cast billet and iron sheet is high, which easily leads to local rapid wear and groove wear, resulting in out-of-tolerance roller diameter and failure of guiding accuracy. Second, the coating peels off. The heat input of manual welding is unstable, the fusion effect between the welded layer and the substrate is poor, and the bonding strength is low. Under high temperature and water cooling alternating conditions, the wear-resistant layer is prone to peeling, falling off, and pitting, completely losing its protective performance. Third, thermal fatigue cracking occurs frequently. The manual preheating is not standardized and the welding stress is large. The roller body generates micro-cracks under repeated hot and cold shocks and continues to expand, causing the roller body to crack and be scrapped. Fourth, the product quality is highly variable and the service life is short. It relies entirely on manual experience operation. There is no uniform standard for repair quality. The wear resistance of batch rollers is inconsistent, the average service life is short, and frequent equipment replacement significantly increases spare parts costs and downtime losses.

[0005] To address the core pain points of continuous casting main machine rolls prepared by traditional manual welding processes, such as poor wear resistance, uneven wear, easy spalling and cracking, short service life, and unstable quality, a complete set of automated welding equipment for continuous casting main machine rolls is proposed. Summary of the Invention

[0006] To address the shortcomings of existing technologies, this invention provides an automated complete set of equipment for welding rolls of continuous casting main machines. It has the advantages of automated and precise welding, constant temperature preheating, intelligent detection, and unmanned integrated loading and unloading, and solves the problems of insufficient wear resistance and human operation error in traditional processes.

[0007] To achieve the above objectives, the present invention provides the following technical solution: an automated complete set of equipment for continuous casting main machine roll welding, comprising a protective fence, a workpiece conveying roller module, an automated loading and unloading clamping module, an intelligent constant temperature preheating module, several fully automated welding and surfacing modules, an automated detection module, an intelligent electrical control module, and an auxiliary cooling and protection module. The automated loading and unloading clamping module includes a servo lifting and traversing mechanism, an adaptive double chuck fixture, and an intelligent sensing and positioning component. The intelligent constant temperature preheating module includes a surround heating component, a multi-point temperature sensor, and an intelligent temperature control system. The fully automated welding and surfacing modules include a CNC welding main machine, an intelligent wire feeding mechanism, a weld seam tracking system, and a parameter closed-loop control system. The automated detection module includes laser dimension detection, machine vision defect recognition, and data acquisition and analysis components. The intelligent electrical control module includes a PLC numerical control system, a touch operation terminal, and a parameter storage module. The auxiliary cooling and protection module includes a gradient slow cooling system and dust removal and noise reduction components. The protective fence is a frame-type enclosed structure, arranged around the entire equipment to form a safe working space. The automated loading and unloading clamping module is fixedly installed at one end of the protective fence. The workpiece conveyor roller module is arranged horizontally along the length of the protective fence. Multiple sets of fully automatic welding and surfacing modules are arranged sequentially at intervals along the axial direction of the workpiece conveyor roller module, with each set of fully automatic welding and surfacing modules located above or to the side of the workpiece conveyor roller module. The intelligent electrical control module is electrically connected to the automated loading and unloading clamping module, the workpiece conveyor roller module, each set of fully automatic welding and surfacing modules, and the auxiliary cooling and protection module. The automated loading and unloading clamping module includes a servo lifting and traversing mechanism, an adaptive dual-chuck fixture, and an intelligent sensing and positioning component. The fixed end of the servo lifting and traversing mechanism is fixedly connected to a protective fence or ground foundation. The adaptive dual-chuck fixture is fixedly installed on the motion execution end of the servo lifting and traversing mechanism. The intelligent sensing and positioning component is fixedly installed on the clamping part of the adaptive dual-chuck fixture. The fully automated welding and surfacing module includes a CNC welding host, a constant-force intelligent wire feeding mechanism, a laser weld seam tracking system, and a welding parameter closed-loop control system. The CNC welding host is fixedly mounted on the welding frame. The discharge end of the constant-force intelligent wire feeding mechanism faces the welding torch of the CNC welding host. The detection end of the laser weld seam tracking system faces the workpiece welding area and is fixed relative to the CNC welding host. The welding parameter closed-loop control system is electrically connected to the CNC welding host, the constant-force intelligent wire feeding mechanism, and the laser weld seam tracking system. The auxiliary cooling and protection module includes a gradient slow cooling system and a fume collection and dust removal and noise reduction component. The air outlet of the gradient slow cooling system faces the processing area of ​​each group of fully automatic welding and surfacing modules, and the air intake of the fume collection and dust removal and noise reduction component is located above the welding torch of the CNC welding host.

[0008] Preferably, the servo lifting and traversing mechanism includes a gantry truss body, a three-axis servo drive mechanism, and an end effector. The bottom support of the gantry truss body is fixedly connected to the ground or a protective fence. The crossbeam of the gantry truss body spans above the workpiece conveyor roller module. The three-axis servo drive mechanism includes an X-axis servo moving unit, a Y-axis servo traversing unit, and a Z-axis servo lifting unit. The X-axis servo moving unit slides with the gantry truss body and moves along the roller axis. The Y-axis servo traversing unit is fixedly connected to the X-axis servo moving unit and moves perpendicular to the roller direction. The Z-axis servo lifting unit is fixedly connected to the Y-axis servo traversing unit and moves vertically. The end effector is fixedly installed at the bottom of the Z-axis servo lifting unit.

[0009] Specifically, the gantry truss body 311 is an integral rigid gantry frame. All three servo axes are equipped with servo motors and rack and pinion transmission pairs. The X-axis servo movement unit slides and engages with the top main beam of the gantry truss 311 via a linear slide rail. The bottom surface of the X-axis slide is bolted to the Y-axis servo transverse movement unit. The Y-axis slide is vertically fixed to the Z-axis servo lifting unit. The bottom end of the ball screw pair inside the Z-axis is rigidly locked to the end-effector 313. All servo motor cables within the three-axis servo drive mechanism 312 are uniformly connected to the intelligent electronic control module's drive output channel. The stroke of each of the three axes is equipped with original... The point limit photoelectric switch and the three-axis servo drive mechanism are fixedly connected in sequence. The end clamping actuator is fixedly connected to the bottom of the Z-axis servo lifting unit. The X-axis servo moving unit moves along the gantry truss body along the roller conveyor axis. The Y-axis servo transverse moving unit moves in the direction perpendicular to the roller conveyor. The Z-axis servo lifting unit moves vertically. All motion units work together to achieve precise three-dimensional spatial displacement of the end clamping actuator. The intelligent electronic control module outputs control commands to drive the three-axis servo drive mechanism to complete the automatic gripping, feeding, transfer and unloading actions of the continuous casting main roller.

[0010] Preferably, the adaptive double chuck fixture includes a fixed headstock chuck, a movable tailstock chuck, an axial telescopic drive assembly, and a centering guide rail. The fixed headstock chuck and the movable tailstock chuck are arranged coaxially opposite each other. The centering guide rail is horizontally fixed along the roller conveyor axis. The movable tailstock chuck slides with the centering guide rail. The fixed end of the axial telescopic drive assembly is fixed to the frame, and the output end is fixedly connected to the movable tailstock chuck. The movable tailstock chuck reciprocates along the centering guide rail to adjust the chuck spacing. Both the fixed headstock chuck and the movable tailstock chuck adopt a three-jaw self-centering structure. The inner side of the jaws is provided with an anti-slip and wear-resistant clamping surface, and the clamping concentricity error is ≤0.05mm. The end clamping actuator is an arc-shaped clamping structure that matches the adaptive double chuck fixture.

[0011] Specifically, the centering guide rail 324 has a headstock fixed chuck 321 and a frame side plate rigidly fixed at both ends, respectively. The tailstock movable chuck 322 has a linear sliding bearing embedded inside and is sleeved on the outside of the centering guide rail 324. The axial extension drive assembly 323 is a horizontal cylinder, with the cylinder body fixed to the tooling side bracket. The piston rod flange is rigidly welded to the tail of the tailstock movable chuck. Both the headstock and tailstock chucks are equipped with synchronous extension three-jaw chuck cylinders, which synchronously extend and retract radially. The intelligent sensing and positioning assembly 33 is embedded in the inner jaw of the headstock chuck, and the sensing signal line is connected to the intelligent... At the signal acquisition end of the electrical control module, the fixed chuck at the head of the bed and the movable chuck at the tail of the bed are coaxially opposite each other. The movable chuck at the tail of the bed slides with the centering guide rail. The output end of the axial telescopic drive component is fixedly connected to the movable chuck at the tail of the bed. The three-jaw self-centering structure realizes automatic centering and clamping of the roller. The axial telescopic drive component drives the movable chuck at the tail of the bed to move along the centering guide rail to adjust the clamping distance, adapting to continuous casting main machine rollers of different lengths. The intelligent sensing and positioning component detects the roller specifications and feeds back the signal. The intelligent electrical control module controls the action of the axial telescopic drive component to complete the adaptive centering and clamping of the roller.

[0012] Preferably, the workpiece conveyor roller module includes a frame, multiple independently driven roller assemblies, a roller drive motor, a transmission chain, and a station positioning mechanism. The frame is fixedly arranged horizontally. The roller assemblies are rotatably mounted on the frame via bearing seats. Adjacent roller assemblies are spaced apart and kept parallel. The roller drive motor is fixedly mounted on the top of the frame, and its output end is connected to the roller shaft of each roller assembly via a transmission chain to drive the roller assemblies to rotate synchronously. The station positioning mechanism includes a positioning cylinder, a positioning block, a return spring, and a proximity switch. The positioning cylinder is vertically mounted below the frame, and its output end passes upward through the frame and is fixed to the positioning block. The proximity switch is fixedly mounted on the side of the positioning block and is used to detect the roller's arrival signal and trigger the positioning action.

[0013] Specifically, the frame 21 is an integrally welded rectangular frame. Each set of roller assemblies 22 is equipped with seated rolling bearing seats at both ends and locked to the bottom surface of the frame beam. The roller conveyor drive motor 23 is suspended at the center of the bottom of the frame. The motor output sprocket synchronously meshes with the driven sprockets at the ends of all rollers through a single closed-loop transmission chain 24. The station positioning mechanism 25 is vertically inserted through the reserved through hole in the frame. The positioning cylinder is fixed downwards under the bottom plate of the frame, and the piston rod passes upwards through the frame and is rigidly threaded to the positioning stop. The proximity switch is locked to the side of the frame by a horizontal bracket. All motors, cylinders, proximity switches, and signals... Each line is independently connected to the intelligent electronic control module. The roller assembly is rotatably connected to the frame through a bearing seat. The roller conveyor drive motor is connected to the roller assembly through a transmission chain. The output end of the positioning cylinder is fixedly connected to the positioning block. The proximity switch is fixed to the side of the positioning block. The roller conveyor drive motor drives the roller assembly to rotate to achieve horizontal conveying of the roller body. The positioning cylinder drives the positioning block to extend to achieve positioning of the roller body at the work station. The proximity switch detects the roller body's arrival signal and transmits it to the intelligent electronic control module. The intelligent electronic control module controls the start and stop of the roller conveyor drive motor and the action of the positioning cylinder to achieve automatic conveying and precise stopping of the roller body.

[0014] Preferably, the plurality of fully automatic welding and overlay modules include a welding frame, a roller clamping mechanism, a processing drive unit, a support base, and a CNC welding host. The support base is fixedly installed on the ground or a foundation platform, and the welding frame is fixed above the support base. The roller clamping mechanism is symmetrically arranged on both sides of the conveyor roller module. The roller clamping mechanism includes a left clamping seat, a right clamping seat, a pressing cylinder, and a floating support wheel. The pressing cylinder drives the clamping seat to press against the end of the roller. The floating support wheel makes rolling contact with the circumferential surface of the roller for support. The processing drive unit includes a rotary drive motor, a reduction gearbox, a transmission pulley, and a drive roller. The output end of the rotary drive motor is connected to the reduction gearbox. The reduction gearbox is connected to the drive roller through the transmission pulley. The drive roller is tangent to the circumferential surface of the roller and drives the roller to rotate uniformly around its own axis.

[0015] Specifically, the support base 44 is anchored to the heavy-duty integrated bed with anchor bolts. The welding frame 41 is vertically erected above the support base. Two sets of roller clamping mechanisms 42 are symmetrically arranged on the left and right sides of the roller conveyor. Each set of clamping cylinders is horizontally fixed to the frame upright plate. The cylinder piston rod pushes the clamping seat. The inner side of the clamping seat is equipped with a floating support wheel. The processing drive unit 43 is fixed to the rear side of the frame. The output shaft of the rotary drive motor is connected to the input shaft of the reduction gearbox. The output end of the reduction gearbox is equipped with a drive pulley. The drive pulley is connected to the lower drive roller through a synchronous transmission belt. The drive roller is rotatably supported on the frame support. The CNC welding host 45 and the laser weld seam tracking slide are uniformly slidably mounted on the top of the welding frame horizontal guide. The entire system, including all motors, cylinders, and laser sensor cables, is connected to the closed-loop control system for welding parameters. The closed-loop system communicates bidirectionally with the intelligent electronic control module. The roller clamping mechanism is symmetrically arranged on both sides of the conveyor roller module. The output end of the clamping cylinder is fixedly connected to the clamping seat. The floating support wheel makes rolling contact with the circumferential surface of the roller. The rotary drive motor is connected to the drive roller through a reduction gearbox and a transmission pulley. The drive roller makes tangential contact with the circumferential surface of the roller. The clamping cylinder drives the clamping seat to press the end of the roller to achieve axial positioning. The floating support wheel provides auxiliary support for the roller. The rotary drive motor drives the roller to rotate at a constant speed around its own axis. The intelligent electronic control module controls the rotation speed to match the welding action, achieving continuous surfacing welding on the entire circumference of the roller surface.

[0016] Preferably, the laser weld seam tracking system includes a laser emitting head, an image receiving sensor, a signal processor, and a tracking execution slide. The laser emitting head is tilted towards the roller surface welding area. The image receiving sensor is fixed relative to the laser emitting head and receives the laser contour signal. The signal processor processes the image data and outputs a deviation signal. The tracking execution slide includes a slide base, a servo motor, a ball screw, and a sliding seat. The sliding seat is threadedly engaged with the ball screw. The welding torch of the CNC welding host is fixed on the sliding seat.

[0017] Specifically, the laser emitter and the image receiving sensor are fixed relative to each other, the signal processor is electrically connected to the image receiving sensor, the sliding seat of the tracking execution slide is threaded with the ball screw, the welding torch is fixedly connected to the sliding seat, the laser emitter projects the laser profile onto the roller surface welding area, the image receiving sensor collects the profile signal and transmits it to the signal processor, the signal processor outputs the deviation signal to the tracking execution slide, the tracking execution slide drives the welding torch to compensate for the position deviation in real time, and the intelligent electronic control module synchronously coordinates the welding parameters and tracking actions to ensure that the welding torch is always aligned with the center of the weld.

[0018] Preferably, the constant force intelligent wire feeding mechanism includes a wire feeding motor, a wire feeding wheel assembly, a wire guide tube, a tension adjustment component, and a wire feeding drive controller. The output end of the wire feeding motor is connected to the wire feeding wheel assembly for transmission. One end of the wire guide tube is connected to the outlet of the wire feeding wheel assembly, and the other end extends to the conductive tip of the welding torch. The tension adjustment component includes a pressure spring, an adjusting nut, and a pressure sensor. The pressure sensor detects the wire feeding resistance in real time and feeds it back to the wire feeding drive controller to achieve constant force wire feeding. The welding parameter closed-loop control system collects welding voltage, current, wire feeding speed, and roller rotation speed signals in real time and performs PID adjustment.

[0019] Specifically, the wire feeding motor is connected to the wire feeding wheel assembly, and the two ends of the wire guide tube are respectively connected to the wire feeding wheel assembly and the welding torch contact tip. The pressure sensor of the tension adjustment component is electrically connected to the wire feeding drive controller. The welding parameter closed-loop control system collects welding voltage, current, wire feeding speed, and roller rotation speed signals. The wire feeding motor drives the wire feeding wheel assembly to achieve continuous wire feeding. The tension adjustment component adjusts the wire feeding resistance in real time to maintain constant force wire feeding. The welding parameter closed-loop control system stabilizes the welding heat input through PID regulation. The intelligent electronic control module coordinates the wire feeding speed and roller rotation speed to ensure uniform weld formation.

[0020] Preferably, the intelligent electronic control module includes a PLC main controller, a touch operation display terminal, a data storage unit, a signal acquisition module, a drive output module, and an alarm unit. The PLC main controller communicates bidirectionally with the touch operation display terminal and the data storage unit. The input terminals of the signal acquisition module are connected to a laser weld seam tracking system, an intelligent sensing and positioning component, a proximity switch, and a pressure sensor. The output terminals of the drive output module are connected to a three-axis servo drive mechanism, a roller conveyor drive motor, a rotary drive motor, a CNC welding host, and a wire feeding motor. The PLC main controller has a built-in continuous casting host roller welding process parameter library.

[0021] Specifically, the PLC main controller communicates bidirectionally with the touch operation display terminal and data storage unit. The signal acquisition module is electrically connected to each sensor, and the drive output module is electrically connected to each actuator. The signal acquisition module transmits position, temperature, and pressure signals to the PLC main controller. The PLC main controller calls the built-in welding process parameter library for calculation and processing. The drive output module outputs control commands to drive each actuator to move. The alarm unit issues a warning signal when the equipment is abnormal, realizing full-process automated linkage control and status monitoring.

[0022] Preferably, the gradient slow cooling system includes a slow cooling fan, multiple air outlet ducts, a temperature sensor, and a segmented temperature controller. The multiple air outlet ducts are evenly arranged along the roller body axis, with the air outlets facing the welding area on the roller surface. The temperature sensor is fixed to the side of the welding area to detect the roller body temperature in real time and feed it back to the segmented temperature controller. The temperature controller adjusts the wind speed and air volume according to a preset stepped curve. The fume collection and dust removal noise reduction components include a fume hood, a negative pressure fan, a filter element, and sound-absorbing cotton. The fume hood is positioned above the welding torch.

[0023] Specifically, the slow-cooling fan is connected to multiple air outlet ducts, the temperature sensor is fixed to the side of the welding area and electrically connected to the segmented temperature controller, the fume hood is installed above the welding torch and is connected to the negative pressure fan and filter element in sequence, the temperature sensor collects the roller temperature signal in real time, the segmented temperature controller adjusts the speed and air volume of the slow-cooling fan according to the step curve to achieve gradient slow cooling, the negative pressure fan draws out welding fumes through the fume hood and purifies and discharges them, and the intelligent electronic control module controls the slow cooling and dust removal actions simultaneously to ensure the cooling quality of the roller and the cleanliness of the working environment.

[0024] Preferably, the workpiece conveyor roller module, the automated loading and unloading clamping module, several fully automatic welding and surfacing modules, and the auxiliary cooling and protection module all adopt an integrated heavy-duty rigid bed structure. The bed is welded from thick steel plates and subjected to aging treatment. The workpiece conveyor roller module, the fully automatic welding and surfacing module, and the automated loading and unloading clamping module are all fixedly installed on the same bed platform. The coaxiality error of each module is ≤0.1mm. The protective fence is equipped with a safety light curtain, a maintenance protection door, and a door lock switch. The signal output terminal of the safety light curtain is connected to the intelligent electronic control module.

[0025] Specifically, each functional module is fixedly installed on an integrated heavy-duty rigid bed platform. Safety light curtains and maintenance protection doors are set in the protective fence. The signal output terminal of the safety light curtain is connected to the signal of the intelligent electronic control module. The integrated heavy-duty rigid bed suppresses welding vibration and ensures the coaxiality accuracy of each module. When the safety light curtain detects foreign object intrusion, it transmits a signal to the intelligent electronic control module. The intelligent electronic control module immediately controls the equipment to stop in an emergency. The protective fence and safety interlock structure work together to ensure the safety of operators and equipment operation.

[0026] Compared with the prior art, the present invention provides an automated complete set of equipment for welding rolls of continuous casting main machine, which has the following beneficial effects: This automated welding equipment for continuous casting main rolls employs a high-precision closed-loop control automated welding system, abandoning the traditional manual hand-held welding and arbitrary parameter control operation mode, and realizing fully automated cladding welding of the wear-resistant layer on the surface of the continuous casting main rolls. The system is equipped with an intelligent CNC welding module, a real-time weld seam tracking device, and a constant current and constant pressure power supply system. It can automatically match the welding trajectory, travel speed, wire feed rate, and heat input parameters according to the diameter, length, and wear area size of different specifications of the main rolls. It supports layered gradient automated cladding welding, with precise digital control throughout the welding process. The heat input is stable and controllable, and the weld bead arrangement is uniform and regular, effectively avoiding defects such as porosity, slag inclusions, incomplete fusion, and weld bead overlap that occur in manual welding. Through precise cladding with special high-chromium wear-resistant alloy welding wire, a dense, uniformly hard, and firmly bonded wear-resistant protective layer is formed, thoroughly ensuring the stability and consistency of the roll surface's wear resistance performance from the welding process level.

[0027] This automated welding equipment for continuous casting main rolls employs an integrated servo-driven loading and unloading mechanism and an adaptive double chuck positioning fixture. It is compatible with continuous casting main rolls of various specifications, lengths, and weights, achieving fully automated loading, precise alignment, automatic clamping, and automatic unloading throughout the entire unmanned operation process. The equipment uses an adjustable head and tail chuck structure, which automatically adjusts the clamping distance and support height according to the roll parameters. Combined with an intelligent sensing and recognition system, it automatically identifies the roll model and processing area, eliminating the need for repeated manual calibration and positioning. The entire loading and unloading system supports one-button start, automatic reset, and continuous cyclic operation, offering high clamping accuracy and strong stability. It completely solves the problems of time-consuming and labor-intensive manual loading and unloading, clamping misalignment, and large positioning deviations, providing a precise clamping foundation for subsequent welding, preheating, and inspection processes, effectively improving overall processing efficiency and product consistency.

[0028] This automated complete set of equipment for welding rolls in continuous casting main machines is equipped with a fully automatic intelligent constant temperature preheating system. It realizes fully automated temperature control management of uniform preheating before welding, constant temperature holding during welding, and gradient slow cooling after welding. The system is equipped with multi-point infrared temperature sensors and an intelligent temperature control host, which can collect the surface temperature of the roll in real time, automatically match the preheating process parameters of the corresponding material, and accurately control the heating rate, constant temperature and holding time. It adopts a surround full-area heating structure with no heating dead corners, so as to achieve uniform temperature in the welding area of ​​the roll, effectively reduce welding temperature difference stress, release residual stress in the substrate, and avoid microcracks caused by thermal shock. The stable constant temperature process can refine the metallographic grains of the weld overlay, optimize the microstructure of the alloy layer, and significantly improve the metallurgical bonding strength between the wear-resistant coating and the substrate, thus significantly improving the wear resistance, crack resistance and spalling resistance of the roll surface.

[0029] This automated complete set of equipment for welding continuous casting main machine rolls integrates a fully automatic online inspection system. It realizes integrated intelligent inspection of roll surface quality, dimensional accuracy, and forming status after welding, replacing the traditional rough quality inspection mode of manual visual inspection and measurement. The system includes a high-precision laser dimensional inspection module, a surface defect visual recognition module, and a hardness sampling inspection auxiliary module. It can automatically detect the roll body roundness, coaxiality, and uniformity of weld overlay thickness. It can intelligently identify minor defects such as pores, cracks, unevenness, local wear, and coating peeling on the roll surface. The inspection data is uploaded to the system in real time and automatically archived. It automatically warns and marks and classifies unqualified products, realizing integrated automated operation of processing, inspection, and judgment. It eliminates the problems of manual omission, false inspection, and inconsistent judgment standards, and comprehensively ensures the quality of welding repair of continuous casting main machine rolls, ensuring that the wear resistance and appearance accuracy of each finished roll meet the standards. Attached Figure Description

[0030] Figure 1 This is a schematic diagram of the structure proposed in this invention. Figure 2 This is a first-view structural diagram of the automated loading and unloading clamping module proposed in this invention. Figure 3 This is a second-view structural diagram of the automated loading and unloading clamping module proposed in this invention. Figure 4 This is a partial structural diagram of the workpiece conveyor roller module proposed in this invention. Figure 5 This invention proposes Figure 3 A magnified structural diagram of point A in the middle.

[0031] In the diagram: 1-Protective fence, 2-Workpiece conveyor roller module, 21-Frame, 22-Roller assembly, 23-Roller drive motor, 24-Transmission chain, 25-Station positioning mechanism, 3-Automatic loading and unloading clamping module, 31-Servo lifting and traversing mechanism, 311-Gantry truss body, 312-Three-axis servo drive mechanism, 313-End clamping actuator, 32-Adaptive double chuck fixture, 321-Headstock fixed chuck, 322-Tailstock movable chuck, 323-Axial telescopic drive assembly, 324-Centering guide rail, 33-Intelligent sensing and positioning assembly, 4-Fully automatic welding and overlay module, 41-Welding frame, 42-Roller clamping mechanism, 43-Processing drive unit, 44-Support base, 45-CNC welding host. Detailed Implementation

[0032] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0033] Please see Figure 1-5 An automated welding system for continuous casting main machine rollers includes a protective fence 1, a workpiece conveyor roller module 2, an automated loading and unloading clamping module 3, an intelligent constant temperature preheating module, several fully automated welding and surfacing modules 4, an automated detection module, an intelligent electrical control module, and an auxiliary cooling and protection module. The automated loading and unloading clamping module 3 includes a servo lifting and traversing mechanism 31, an adaptive double chuck fixture 32, and an intelligent sensing and positioning component 33. The intelligent constant temperature preheating module includes a surround heating component, multi-point temperature sensors, and an intelligent temperature control system. The fully automated welding and surfacing modules 4 include a CNC welding main machine 45, an intelligent wire feeding mechanism, a weld seam tracking system, and a parameter closed-loop control system. The automated detection module includes laser dimension detection, machine vision defect recognition, and data acquisition and analysis components. The intelligent electrical control module includes a PLC numerical control system, a touch operation terminal, and a parameter storage module. The auxiliary cooling and protection module includes a gradient slow cooling system and dust removal and noise reduction components. The protective fence 1 is a frame-type enclosed structure, arranged around the entire equipment to form a safe working space. The automated loading and unloading clamping module 3 is fixedly installed at one end of the protective fence 1. The workpiece conveyor roller module 2 is arranged horizontally along the length of the protective fence 1. Multiple sets of fully automatic welding and overlay modules 4 are arranged sequentially at intervals along the axial direction of the workpiece conveyor roller module 2, and each set of fully automatic welding and overlay modules 4 is located above or to the side of the workpiece conveyor roller module 2. The intelligent electrical control module is electrically connected to the automated loading and unloading clamping module 3, the workpiece conveyor roller module 2, each set of fully automatic welding and overlay modules 4, and the auxiliary cooling and protection module. The automated loading and unloading clamping module 3 includes a servo lifting and traversing mechanism 31, an adaptive double chuck fixture 32, and an intelligent sensing and positioning component 33. The fixed end of the servo lifting and traversing mechanism 31 is fixedly connected to the protective fence 1 or the ground foundation. The adaptive double chuck fixture 32 is fixedly installed on the motion execution end of the servo lifting and traversing mechanism 31. The intelligent sensing and positioning component 33 is fixedly installed on the clamping part of the adaptive double chuck fixture 32. The fully automatic welding and surfacing module 4 includes a CNC welding host 45, a constant-force intelligent wire feeding mechanism, a laser weld seam tracking system, and a welding parameter closed-loop control system. The CNC welding host 45 is fixedly mounted on the welding frame 41. The discharge end of the constant-force intelligent wire feeding mechanism faces the welding gun part of the CNC welding host 45. The detection end of the laser weld seam tracking system faces the workpiece welding area and is fixed relative to the CNC welding host 45. The welding parameter closed-loop control system is electrically connected to the CNC welding host 45, the constant-force intelligent wire feeding mechanism, and the laser weld seam tracking system. The auxiliary cooling and protection module includes a gradient slow cooling system and a fume collection and dust removal and noise reduction component. The air outlet of the gradient slow cooling system faces the processing area of ​​each group of fully automatic welding and surfacing modules 4, and the air intake of the fume collection and dust removal and noise reduction component is located above the welding torch of the CNC welding host 45.

[0034] The servo lifting and traversing mechanism 31 includes a gantry truss body 311, a three-axis servo drive mechanism 312, and an end effector 313. The bottom support of the gantry truss body 311 is fixedly connected to the ground or the protective fence 1. The crossbeam of the gantry truss body 311 spans above the workpiece conveyor roller module 2. The three-axis servo drive mechanism 312 includes an X-axis servo moving unit, a Y-axis servo traversing unit, and a Z-axis servo lifting unit. The X-axis servo moving unit slides with the gantry truss body 311 and moves along the roller axis. The Y-axis servo traversing unit is fixedly connected to the X-axis servo moving unit and moves perpendicular to the roller axis. The Z-axis servo lifting unit is fixedly connected to the Y-axis servo traversing unit and moves vertically. The end effector 313 is fixedly installed at the bottom of the Z-axis servo lifting unit. The gantry truss body 311 is an integral rigid gantry frame. All three servo axes are equipped with servo motors and gear rack transmission pairs. The X-axis servo moving unit slides through a linear guide rail. The X-axis servo transverse unit is bolted to the bottom of the X-axis slide table on the top main beam of the gantry truss 311. The Y-axis servo lateral movement unit is vertically fixed to the Y-axis slide table, and the Z-axis servo lifting unit is vertically fixed to the Y-axis slide table. The bottom end of the ball screw pair inside the Z-axis is rigidly locked to the end clamping actuator 313. All servo motor cables in the three-axis servo drive mechanism 312 are uniformly connected to the drive output channel of the intelligent electronic control module. All three axes are equipped with origin limit photoelectric switches. Each unit of the three-axis servo drive mechanism 312 is fixedly connected in sequence. The end clamping actuator 313 is fixedly connected to the bottom end of the Z-axis servo lifting unit. The X-axis servo moving unit moves along the roller axial direction of the gantry truss body 311, the Y-axis servo transverse movement unit moves perpendicular to the roller axial direction, and the Z-axis servo lifting unit moves vertically. All motion units work together to achieve precise three-dimensional spatial displacement of the end clamping actuator 313. The intelligent electronic control module outputs control commands to drive the three-axis servo drive mechanism 312 to complete the automatic gripping, feeding, transfer and unloading actions of the continuous casting main roller.

[0035] The adaptive dual-chuck fixture 32 includes a fixed headstock chuck 321, a movable tailstock chuck 322, an axial telescopic drive assembly 323, and a centering guide rail 324. The fixed headstock chuck 321 and the movable tailstock chuck 322 are arranged coaxially opposite to each other. The centering guide rail 324 is horizontally fixed along the roller conveyor axis. The movable tailstock chuck 322 is slidably engaged with the centering guide rail 324. The fixed end of the axial telescopic drive assembly 323 is fixed to the frame 21, and the output end is fixedly connected to the movable tailstock chuck 322. 22 moves reciprocally along the centering guide rail 324 to adjust the chuck spacing. Both the headstock fixed chuck 321 and the tailstock movable chuck 322 adopt a three-jaw self-centering structure. The inner side of the jaws is provided with anti-slip and wear-resistant clamping surfaces, and the clamping concentricity error is ≤0.05mm. The end clamping actuator 313 is an arc-shaped clamping structure that matches the adaptive double chuck tooling 32. The two ends of the centering guide rail 324 are rigidly fixed to the headstock fixed chuck 321 and the frame side plate, respectively. The tailstock movable chuck 322 has a linear sliding bearing embedded inside and is sleeved on the fixed chuck. The axial telescopic drive assembly 323 is a horizontal cylinder outside the guide rail 324. The cylinder body is fixed to the tooling side bracket. The piston rod flange is rigidly welded to the tail of the movable chuck at the foot of the bed. Both the head and tail chucks are equipped with synchronous telescopic three-jaw chuck cylinders. The three jaws telescopically extend and retract synchronously. The intelligent sensing and positioning assembly 33 is embedded in the inner jaw body of the head chuck. The sensing signal line is connected to the signal acquisition terminal of the intelligent electronic control module. The fixed head chuck 321 and the movable tail chuck 322 are coaxially opposite each other. The axial extension drive component 323 slides in conjunction with the centering guide rail 324, and its output end is fixedly connected to the movable chuck 322 at the tail of the bed. The three-jaw self-centering structure realizes automatic centering and clamping of the roller. The axial extension drive component 323 drives the movable chuck 322 at the tail of the bed to move along the centering guide rail 324 to adjust the clamping distance, adapting to continuous casting main machine rollers of different lengths. The intelligent sensing and positioning component 33 detects the roller specifications and feeds back a signal. The intelligent electronic control module controls the action of the axial extension drive component 323 to complete the adaptive centering and clamping of the roller.

[0036] The workpiece conveyor roller module 2 includes a frame 21, multiple independently driven roller assemblies 22, a roller drive motor 23, a transmission chain 24, and a station positioning mechanism 25. The frame 21 is fixedly arranged in the horizontal direction. The roller assemblies 22 are rotatably mounted on the frame 21 through bearing seats. Adjacent roller assemblies 22 are spaced apart and kept parallel. The roller drive motor 23 is fixedly mounted on the top of the frame 21, and its output end is connected to the roller shaft of each roller assembly 22 through the transmission chain 24 to drive the roller assembly. The components 22 rotate synchronously. The station positioning mechanism 25 includes a positioning cylinder, a positioning block, a return spring, and a proximity switch. The positioning cylinder is vertically installed below the frame 21, with its output end passing upward through the frame 21 and fixed to the positioning block. The proximity switch is fixedly installed on the side of the positioning block and is used to detect the roller's arrival signal and trigger the positioning action. The frame 21 is an integrally welded rectangular frame. Each set of roller components 22 is equipped with seated rolling bearing seats at both ends and locked to the bottom surface of the frame beam. The roller conveyor drive motor 23 is suspended from the frame. At the bottom center, the motor output sprocket synchronously meshes with all the driven sprockets at the ends of the rollers via a single closed-loop transmission chain 24. The station positioning mechanism 25 vertically penetrates the pre-reserved through hole in the frame. The positioning cylinder is fixed downwards below the bottom plate of the frame, and the piston rod passes upwards through the frame and is rigidly threaded to the positioning block. The proximity switch is locked to the side of the frame by a horizontal bracket. All motor, cylinder, and proximity switch signal lines are independently connected to the intelligent electronic control module. The roller assembly 22 is rotatably connected to the frame 21 via a bearing seat. The roller conveyor drive motor 23 is connected to the roller assembly 22 via a transmission chain 24. The output end of the positioning cylinder is fixedly connected to the positioning block. The proximity switch is fixed to the side of the positioning block. The roller conveyor drive motor 23 drives the roller assembly 22 to rotate to achieve horizontal conveying of the roller body. The positioning cylinder drives the positioning block to extend to achieve roller positioning at the station. The proximity switch detects the roller's arrival signal and transmits it to the intelligent electronic control module. The intelligent electronic control module controls the start and stop of the roller conveyor drive motor 23 and the action of the positioning cylinder to achieve automatic conveying and precise stopping of the roller body.

[0037] Several fully automatic welding and overlay modules 4 include a welding frame 41, a roller clamping mechanism 42, a processing drive unit 43, a support base 44, and a CNC welding host 45. The support base 44 is fixedly installed on the ground or a foundation platform, and the welding frame 41 is fixed above the support base 44. The roller clamping mechanism 42 is symmetrically arranged on both sides of the conveyor roller module. The roller clamping mechanism 42 includes a left clamping seat, a right clamping seat, a pressing cylinder, and a floating support wheel. The pressing cylinder drives the clamping seat to press against the end of the roller, and the floating support wheel makes rolling contact with the circumferential surface of the roller. The machining drive unit 43 includes a rotary drive motor, a gearbox, a transmission pulley, and a drive roller. The output end of the rotary drive motor is connected to the gearbox, which is connected to the drive roller via the transmission pulley. The drive roller is tangent to the circumferential surface of the roller and drives the roller to rotate uniformly around its own axis. The support base 44 is anchored to the heavy-duty integrated bed with anchor bolts. The welding frame 41 is vertically erected above the support base. Two sets of roller clamping mechanisms 42 are symmetrically arranged on the left and right sides of the roller conveyor. Each set of clamping cylinders is horizontally fixed to the vertical plate of the frame. The cylinder piston rod... The machine features a push-up clamping seat with a floating support wheel mounted on its inner side. The machining drive unit 43 is fixed to the rear of the frame. The output shaft of the rotary drive motor is connected to the input shaft of the reduction gearbox. A drive pulley is mounted on the reduction output end, and the drive pulley is connected to the lower drive roller via a synchronous transmission belt. The drive roller is rotatably supported on the frame support. The CNC welding host 45 and the laser weld seam tracking slide are uniformly slidably mounted on the transverse guide rail at the top of the welding frame. All motors, cylinders, and laser sensor cables are connected to the welding parameter closed-loop control system, which communicates bidirectionally with the intelligent electronic control module. The roller clamping mechanism 42 is symmetrically arranged on both sides of the conveyor roller module. The output end of the clamping cylinder is fixedly connected to the clamping seat. The floating support wheel rolls in contact with the circumferential surface of the roller. The rotary drive motor is connected to the drive roller through the gearbox and the transmission pulley. The drive roller is in tangential contact with the circumferential surface of the roller. The clamping cylinder drives the clamping seat to press the end of the roller to achieve axial positioning. The floating support wheel provides auxiliary support for the roller. The rotary drive motor drives the roller to rotate at a constant speed around its own axis. The intelligent electronic control module controls the rotation speed to match the welding action, so as to achieve continuous welding of the entire circumference of the roller surface.

[0038] The laser weld seam tracking system includes a laser emitter, an image receiving sensor, a signal processor, and a tracking execution slide. The laser emitter is tilted towards the roller surface welding area. The image receiving sensor is fixed relative to the laser emitter and receives the laser contour signal. The signal processor processes the image data and outputs a deviation signal. The tracking execution slide includes a slide base, a servo motor, a ball screw, and a sliding seat. The sliding seat is threadedly engaged with the ball screw. The welding torch of the CNC welding host 45 is fixed on the sliding seat. The laser emitter and the image receiving sensor are fixed relative to each other. The signal processor is electrically connected to the image receiving sensor. The sliding seat of the tracking execution slide is threadedly engaged with the ball screw. The welding torch is fixedly connected to the sliding seat. The laser emitter projects the laser contour onto the roller surface welding area. The image receiving sensor collects the contour signal and transmits it to the signal processor. The signal processor outputs a deviation signal to the tracking execution slide. The tracking execution slide drives the welding torch to compensate for position deviations in real time. The intelligent electronic control module synchronously coordinates the welding parameters and tracking actions to ensure that the welding torch is always aligned with the center of the weld.

[0039] The constant force intelligent wire feeding mechanism includes a wire feeding motor, a wire feeding wheel assembly, a wire guide tube, a tension adjustment component, and a wire feeding drive controller. The output end of the wire feeding motor is connected to the wire feeding wheel assembly. One end of the wire guide tube connects to the outlet of the wire feeding wheel assembly, and the other end extends to the contact tip of the welding torch. The tension adjustment component includes a pressure spring, an adjusting nut, and a pressure sensor. The pressure sensor detects the wire feeding resistance in real time and feeds it back to the wire feeding drive controller to achieve constant force wire feeding. The welding parameter closed-loop control system collects welding voltage, current, wire feeding speed, and roller rotation speed signals in real time and performs PID adjustment. The wire motor is connected to the wire feeding wheel assembly for transmission. The two ends of the wire guide tube are respectively connected to the wire feeding wheel assembly and the welding torch contact tip. The pressure sensor of the tension adjustment component is electrically connected to the wire feeding drive controller. The welding parameter closed-loop control system collects welding voltage, current, wire feeding speed, and roller rotation speed signals. The wire feeding motor drives the wire feeding wheel assembly to achieve continuous wire feeding. The tension adjustment component adjusts the wire feeding resistance in real time to maintain constant force wire feeding. The welding parameter closed-loop control system stabilizes the welding heat input through PID regulation. The intelligent electronic control module coordinates the wire feeding speed and roller rotation speed to ensure uniform weld formation.

[0040] The intelligent electrical control module includes a PLC main controller, a touch operation display terminal, a data storage unit, a signal acquisition module, a drive output module, and an alarm unit. The PLC main controller communicates bidirectionally with both the touch operation display terminal and the data storage unit. The input terminals of the signal acquisition module are connected to the laser weld seam tracking system, the intelligent sensing and positioning component 33, the proximity switch, and the pressure sensor, respectively. The output terminals of the drive output module are connected to the three-axis servo drive mechanism 312, the roller drive motor 23, the rotary drive motor, the CNC welding host 45, and the wire feeding motor, respectively. The PLC main controller has a built-in continuous casting host roller welding process parameter library. The PLC main controller communicates bidirectionally with the touch operation display terminal and the data storage unit. The signal acquisition module is electrically connected to each sensor, and the drive output module is electrically connected to each actuator. The signal acquisition module transmits position, temperature, and pressure signals to the PLC main controller. The PLC main controller calls the built-in welding process parameter library for calculation and processing. The drive output module outputs control commands to drive the actuators to move. The alarm unit issues a warning signal when the equipment is abnormal, realizing full-process automated linkage control and status monitoring.

[0041] The gradient cooling system includes a cooling fan, multi-section air outlet ducts, temperature sensors, and segmented temperature controllers. The multi-section air outlet ducts are evenly arranged along the roller's axial direction, with the outlets facing the welding area on the roller surface. Temperature sensors are fixed to the side of the welding area, monitoring the roller temperature in real time and feeding it back to the segmented temperature controllers. The temperature controllers adjust the fan speed and airflow according to a preset stepped curve. The fume collection and noise reduction components include a fume hood, a negative pressure fan, a filter element, and sound-absorbing cotton. The fume hood is positioned above the welding torch. The cooling fan and... Multiple air outlet ducts are connected. Temperature sensors are fixed to the side of the welding area and electrically connected to the segmented temperature controller. The fume hood is installed above the welding torch and is connected to the negative pressure fan and filter element in sequence. The temperature sensor collects the roller temperature signal in real time. The segmented temperature controller adjusts the speed and volume of the slow cooling fan according to a stepped curve to achieve gradient slow cooling. The negative pressure fan extracts welding fumes through the fume hood and purifies and discharges them. The intelligent electronic control module synchronously controls the slow cooling and dust removal actions to ensure the cooling quality of the roller and the cleanliness of the working environment.

[0042] The workpiece conveyor roller module 2, the automated loading and unloading clamping module 3, several fully automatic welding and overlay modules 4, and the auxiliary cooling and protection module all adopt an integrated heavy-duty rigid bed structure. The bed is welded from thick steel plates and subjected to aging treatment. The workpiece conveyor roller module 2, the fully automatic welding and overlay module 4, and the automated loading and unloading clamping module 3 are all fixedly installed on the same bed platform. The coaxiality error of each module is ≤0.1mm. The protective fence 1 is equipped with a safety light curtain, a maintenance protection door, and a door lock switch. The signal output end of the safety light curtain is connected to the intelligent electronic control module. Each functional module is fixedly installed on the integrated heavy-duty rigid bed platform. The safety light curtain and the maintenance protection door are set on the protective fence 1. The signal output end of the safety light curtain is connected to the intelligent electronic control module. The integrated heavy-duty rigid bed suppresses welding vibration and ensures the coaxiality accuracy of each module. When the safety light curtain detects foreign objects entering, it transmits a signal to the intelligent electronic control module. The intelligent electronic control module immediately controls the equipment to stop in an emergency. The protective fence 1 and the safety interlock structure together ensure the safety of operators and equipment operation.

[0043] All electrical components mentioned in this article are connected to an external main controller and 220V AC mains power, and the main controller can be a conventional known device such as a computer that provides control.

[0044] In use, the protective fence 1 forms a closed and safe working space around the entire equipment. The workpiece conveying roller module 2 is arranged horizontally along the axial direction and conveys the continuous casting main machine roller to the designated station. The positioning cylinder of the station positioning mechanism 25 pushes the positioning block to accurately position the roller. The proximity switch detects the positioning signal and transmits it to the intelligent electronic control module. The gantry truss body 311 of the automated loading and unloading clamping module 3 is driven by the three-axis servo drive mechanism 312 and smoothly moves the roller to the adaptive double chuck fixture 32 through the end clamping actuator 313. The fixed chuck 321 at the head of the bed and the movable chuck 322 at the tail of the bed adjust the distance along the centering guide rail 324 under the action of the axial telescopic drive component 323. The three-jaw self-centering structure is used to coaxially clamp and fix the roller, with a concentricity error ≤0.0.05mm, the intelligent sensing and positioning component 33 automatically identifies the roller specifications and processing area and feeds the data back to the PLC main controller. The intelligent constant temperature preheating module starts, and the surrounding heating component heats the roller uniformly throughout the entire area. Multi-point temperature sensors collect the roller temperature in real time and transmit it to the intelligent temperature control system. The system automatically controls the heating rate, constant temperature, and holding time according to the preset process to eliminate residual stress in the substrate and stabilize the temperature field. After preheating, the fully automatic welding and overlay module 4 starts working. The floating support wheel of the roller clamping mechanism 42 forms rolling support for the roller, and the clamping cylinder keeps it in place. The welding machine is stably clamped. The rotary drive motor drives the drive roller to rotate via the transmission pulley, which in turn drives the roller to rotate at a constant speed around its own axis. Under the guidance of the laser weld seam tracking system, the CNC welding host 45 captures the welding contour in real time through the laser emitter and image receiving sensor. The signal processor processes the deviation signal and controls the tracking execution slide to drive the welding torch to move precisely. The wire feeding motor of the constant force intelligent wire feeding mechanism drives the wire feeding wheel group to feed the wire at a constant speed. The tension adjustment component and pressure sensor work together to achieve constant force wire feeding. The welding parameter closed-loop control system collects voltage, current, wire feeding speed, and roller speed data in real time. The rotation speed signal is used for PID control to ensure stable heat input and uniform and regular weld bead arrangement, completing the layered gradient welding of the transition layer and the high-chromium wear-resistant reinforcement layer. During the welding process, the auxiliary cooling and protection module's fume collection and dust removal and noise reduction components promptly absorb welding fumes through the fume hood and negative pressure fan. The filter element and sound-absorbing cotton achieve purification and noise reduction. After welding, the gradient slow cooling system is activated. The slow cooling fan evenly discharges air along the roller axis through multiple air outlet pipes. The temperature sensor monitors the temperature in real time, and the segmented temperature controller adjusts the wind speed and air volume according to a stepped curve to achieve gradient slow cooling to release the welding heat. To prevent stress and coating cracking / peeling, the automated inspection module activates after cooling. The laser dimension inspection module and machine vision defect recognition module perform comprehensive inspections of the roller's roundness, coaxiality, weld overlay thickness, and surface defects. The data acquisition and analysis component uploads and automatically archives the inspection data in real time, automatically marking defective products with warnings. Once the inspection is passed, the adaptive double chuck fixture 32 releases, and the automated loading and unloading clamping module 3 transfers the finished roller to the unloading position. The workpiece conveyor roller module 2 outputs the finished product, and the equipment automatically resets to standby mode, completing one fully automated processing cycle.

[0045] The specific procedures are as follows: Step 1: Fully Automatic Loading and Positioning. After the equipment starts, the servo loading and unloading mechanism automatically grabs the workpiece to complete the loading. The double chuck adaptively clamps and fixes the workpiece. The intelligent system automatically identifies the roller specifications and the area to be processed, automatically calibrates the welding trajectory and processing parameters, and completes precise alignment.

[0046] Step 2: Automated constant temperature preheating. The system automatically matches the preheating process according to the workpiece material and size. The surrounding heating mechanism starts, the temperature rises at a uniform rate and is kept constant, eliminating base stress, stabilizing the workpiece temperature field, and providing standard process conditions for welding operations.

[0047] Step 3: Automated and precise cladding. The CNC welding system is started, and the intelligent wire feeding mechanism feeds the material at a uniform speed. The layered gradient cladding is completed according to the preset trajectory. First, a transition layer is clad to improve the bonding force, and then a high-chromium wear-resistant strengthening layer is clad. The welding parameters are precisely controlled throughout the process to ensure that the weld bead is uniform and the coating is dense and defect-free.

[0048] Step 4: Automated Gradient Cooling. After the welding operation is completed, the system automatically starts the gradient cooling program to slowly release the residual welding stress, stabilize the metallographic structure of the wear-resistant layer, prevent the coating from cracking and peeling, and ensure the stable wear resistance of the roller surface.

[0049] Step 5: Automated Online Inspection. After the workpiece has cooled down, the inspection module automatically starts to perform comprehensive intelligent inspection of the roller's dimensional accuracy, surface flatness, coating integrity, and surface defects, automatically determining whether the product is qualified and storing the inspection data.

[0050] Step 6: Automatic unloading and reset. After the inspection is completed, the equipment automatically releases the tooling fixture, the servo mechanism completes the unloading of the finished product, and the equipment automatically resets to standby mode, completing a single processing cycle. This allows for continuous batch automated production.

[0051] In summary, this automated welding equipment for continuous casting main rolls integrates all processes—loading, preheating, welding, inspection, and unloading—completely replacing traditional manual operation and significantly simplifying the production process and shortening the processing cycle. Traditional manual welding of a single main roll is time-consuming, cumbersome, and heavily reliant on operator skill, resulting in extremely low production efficiency. This equipment, through parameter fixing, continuous cyclical operation, and unmanned monitoring, significantly reduces auxiliary time spent on manual clamping, calibration, temperature measurement, and inspection, resulting in a substantial increase in the processing efficiency of a single workpiece and enabling continuous batch production. Simultaneously, the equipment effectively avoids rework and repair issues caused by human error, reduces ineffective work time, minimizes production line downtime losses, and comprehensively improves overall production capacity and operational efficiency. It can fully meet the large-scale, routine equipment repair and production needs of enterprises.

[0052] By implementing full-process digitalization, standardization, and intelligent management, the pain points of unstable quality and inconsistent wear resistance in traditional manual welding are completely resolved, achieving full control and traceability of product quality. First, process parameters are controllable: all parameters for welding, preheating, and cooling are automatically fixed and precisely executed by the system, eliminating arbitrary manual modifications and unifying production process standards from the source. Second, wear resistance quality is controllable: precise temperature control and welding processes refine the metallographic structure of the coating, improving the hardness, density, and bonding strength of the roller surface. Wear resistance, crack resistance, and anti-peeling performance consistently meet standards, completely solving the problems of rapid wear and easy failure in traditional products. Third, quality inspection standards are controllable: automated online inspection achieves intelligent screening of all dimensions and surfaces, preventing unqualified products from leaving the site. All inspection data is automatically archived, ensuring traceability and controllability of quality. Fourth, batch quality is controllable: completely eliminating reliance on manual experience, the wear resistance, dimensional accuracy, and forming quality of batch-produced main rollers are highly uniform, significantly improving product stability and reliability, providing a solid quality guarantee for the long-term stable operation of the continuous casting production line.

[0053] It should be noted that, in this document, relational terms such as "first" and "second" are used merely to distinguish one entity or operation from another, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Furthermore, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such a process, method, article, or apparatus. Without further limitations, an element defined by the phrase "comprising one" does not exclude the presence of other identical elements in the process, method, article, or apparatus that includes said element.

[0054] Although embodiments of the invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. An automated complete set of equipment for welding rolls of a continuous casting main machine, characterized in that: The system includes a protective fence (1), a workpiece conveyor roller module (2), an automated loading and unloading clamping module (3), an intelligent constant temperature preheating module, several fully automatic welding and overlay modules (4), an automated detection module, an intelligent electrical control module, and an auxiliary cooling and protection module. The intelligent constant temperature preheating module includes a surround heating component, a multi-point temperature sensor, and an intelligent temperature control system. The automated detection module includes laser size detection, machine vision defect recognition, and data acquisition and analysis components. The intelligent electrical control module includes a PLC numerical control system, a touch operation terminal, and a parameter storage module. The auxiliary cooling and protection module includes a gradient slow cooling system and dust removal and noise reduction components. The protective fence (1) is a frame-type closed structure, which is arranged around the equipment to form a safe working space. The automated loading and unloading clamping module (3) is fixedly installed at one end of the protective fence (1). The workpiece conveying roller module (2) is arranged horizontally along the length of the protective fence (1). The multiple sets of fully automatic welding and overlay modules (4) are arranged sequentially at intervals along the axial direction of the workpiece conveying roller module (2), and each set of fully automatic welding and overlay modules (4) is located above or to the side of the workpiece conveying roller module (2). The intelligent electrical control module is electrically connected to the automated loading and unloading clamping module (3), the workpiece conveying roller module (2), each set of fully automatic welding and overlay modules (4), and the auxiliary cooling and protection module. The automated loading and unloading clamping module (3) includes a servo lifting and traversing mechanism (31), an adaptive double chuck fixture (32), and an intelligent sensing and positioning component (33). The fixed end of the servo lifting and traversing mechanism (31) is fixedly connected to the protective fence (1) or the ground foundation. The adaptive double chuck fixture (32) is fixedly installed on the motion execution end of the servo lifting and traversing mechanism (31). The intelligent sensing and positioning component (33) is fixedly installed on the clamping part of the adaptive double chuck fixture (32). The fully automatic welding and surfacing module (4) includes a welding frame (41), a roller clamping mechanism (42), a processing drive unit (43), a support base (44), a CNC welding host (45), a constant force intelligent wire feeding mechanism, a laser weld seam tracking system, and a welding parameter closed-loop control system. The CNC welding host (45) is fixedly installed on the welding frame (41). The discharge end of the constant force intelligent wire feeding mechanism faces the welding gun part of the CNC welding host (45). The detection end of the laser weld seam tracking system faces the workpiece welding area and is fixed relative to the CNC welding host (45). The welding parameter closed-loop control system is electrically connected to the CNC welding host (45), the constant force intelligent wire feeding mechanism, and the laser weld seam tracking system. The auxiliary cooling and protection module includes a gradient slow cooling system and a fume collection and dust removal and noise reduction component. The air outlet of the gradient slow cooling system faces the processing area of ​​each group of fully automatic welding and overlay modules (4), and the air intake of the fume collection and dust removal and noise reduction component is located above the welding gun of the CNC welding host (45).

2. The automated complete set of equipment for welding rolls of a continuous casting main machine according to claim 1, characterized in that: The servo lifting and traversing mechanism (31) includes a gantry truss body (311), a three-axis servo drive mechanism (312), and an end clamping actuator (313). The bottom support of the gantry truss body (311) is fixedly connected to the ground or a protective fence (1). The crossbeam of the gantry truss body (311) spans above the workpiece conveying roller module (2). The three-axis servo drive mechanism (312) includes an X-axis servo moving unit, a Y-axis servo traversing unit, and a Z-axis servo lifting unit. The X-axis servo moving unit slides with the gantry truss body (311) and moves along the roller axis. The Y-axis servo traversing unit and the X-axis servo moving unit are fixedly connected and move perpendicular to the roller axis. The Z-axis servo lifting unit and the Y-axis servo traversing unit are fixedly connected and move vertically. The end clamping actuator (313) is fixedly installed at the bottom of the Z-axis servo lifting unit.

3. The automated complete set of equipment for welding rolls of a continuous casting main machine according to claim 2, characterized in that: The adaptive double chuck fixture (32) includes a headstock fixed chuck (321), a tailstock movable chuck (322), an axial telescopic drive assembly (323), and a centering guide rail (324). The headstock fixed chuck (321) and the tailstock movable chuck (322) are arranged coaxially opposite to each other. The centering guide rail (324) is horizontally fixed along the roller conveyor axis. The tailstock movable chuck (322) slides with the centering guide rail (324). The fixed end of the axial telescopic drive assembly (323) is... The output end is fixed to the frame (21) and fixedly connected to the footboard movable chuck (322). The footboard movable chuck (322) moves back and forth along the centering guide rail (324) to adjust the chuck spacing. The headboard fixed chuck (321) and the footboard movable chuck (322) both adopt a three-jaw self-centering structure. The inner side of the jaws is provided with anti-slip and wear-resistant clamping surface. The clamping concentricity error is ≤0.05mm. The end clamping actuator (313) is an arc-shaped clamping structure that matches the adaptive double chuck tooling (32).

4. The automated complete set of equipment for welding rolls of a continuous casting main machine according to claim 1, characterized in that: The workpiece conveyor roller module (2) includes a frame (21), multiple independently driven roller assemblies (22), a roller drive motor (23), a transmission chain (24), and a station positioning mechanism (25). The frame (21) is fixedly arranged in the horizontal direction. The roller assemblies (22) are rotatably mounted on the frame (21) through bearing seats. There is a gap between adjacent roller assemblies (22) and they are kept parallel. The roller drive motor (23) is fixedly installed on the top of the frame (21). The output end is connected to the roller shaft of each roller assembly (22) through the transmission chain (24) to drive the roller assembly (22) to rotate synchronously. The station positioning mechanism (25) includes a positioning cylinder, a positioning block, a reset spring, and a proximity switch. The positioning cylinder is vertically installed below the frame (21). The output end passes upward through the frame (21) and is fixed to the positioning block. The proximity switch is fixedly installed on the side of the positioning block and is used to detect the roller body arrival signal and trigger the positioning action.

5. The automated complete set of equipment for welding rolls of a continuous casting main machine according to claim 1, characterized in that: The support base (44) is fixedly installed on the ground or foundation platform. The welding frame (41) is fixed above the support base (44). The roller clamping mechanism (42) is symmetrically arranged on both sides of the conveyor roller module. The roller clamping mechanism (42) includes a left clamping seat, a right clamping seat, a pressing cylinder and a floating support wheel. The pressing cylinder drives the clamping seat to press against the end of the roller. The floating support wheel rolls and contacts the circumferential surface of the roller. The processing drive unit (43) includes a rotary drive motor, a gearbox, a transmission pulley and a drive roller. The output end of the rotary drive motor is connected to the gearbox. The gearbox is connected to the drive roller through the transmission pulley. The drive roller is tangent to the circumferential surface of the roller and drives the roller to rotate uniformly around its own axis.

6. The automated complete set of equipment for welding rolls of a continuous casting main machine according to claim 1, characterized in that: The laser weld seam tracking system includes a laser emitter, an image receiving sensor, a signal processor, and a tracking execution slide. The laser emitter is tilted toward the roller surface welding area. The image receiving sensor is fixed relative to the laser emitter and receives the laser contour signal. The signal processor processes the image data and outputs a deviation signal. The tracking execution slide includes a slide base, a servo motor, a ball screw, and a sliding seat. The sliding seat is threaded with the ball screw. The welding gun of the CNC welding host (45) is fixed on the sliding seat.

7. The automated complete set of equipment for welding rolls of a continuous casting main machine according to claim 1, characterized in that: The constant force intelligent wire feeding mechanism includes a wire feeding motor, a wire feeding wheel assembly, a wire guide tube, a tension adjustment component, and a wire feeding drive controller. The output end of the wire feeding motor is connected to the wire feeding wheel assembly for transmission. One end of the wire guide tube is connected to the outlet of the wire feeding wheel assembly, and the other end extends to the conductive tip of the welding torch. The tension adjustment component includes a pressure spring, an adjusting nut, and a pressure sensor. The pressure sensor detects the wire feeding resistance in real time and feeds it back to the wire feeding drive controller to achieve constant force wire feeding. The welding parameter closed-loop control system collects welding voltage, current, wire feeding speed, and roller rotation speed signals in real time and performs PID adjustment.

8. The automated complete set of equipment for welding rolls of a continuous casting main machine according to claim 1, characterized in that: The intelligent electrical control module includes a PLC main controller, a touch operation display terminal, a data storage unit, a signal acquisition module, a drive output module, and an alarm unit. The PLC main controller communicates bidirectionally with the touch operation display terminal and the data storage unit. The input end of the signal acquisition module is connected to the laser weld seam tracking system, the intelligent sensing and positioning component (33), the proximity switch, and the pressure sensor. The output end of the drive output module is connected to the three-axis servo drive mechanism (312), the roller drive motor (23), the rotary drive motor, the CNC welding host (45), and the wire feeding motor. The PLC main controller has a built-in continuous casting host roller welding process parameter library.

9. The automated complete set of equipment for welding rolls of a continuous casting main machine according to claim 1, characterized in that: The gradient slow cooling system includes a slow cooling fan, multiple air outlet ducts, a temperature sensor, and a segmented temperature controller. The multiple air outlet ducts are evenly arranged along the roller body axis, with the air outlets facing the welding area on the roller surface. The temperature sensor is fixed to the side of the welding area to detect the roller body temperature in real time and feed it back to the segmented temperature controller. The temperature controller adjusts the wind speed and air volume according to a preset stepped curve. The fume collection and dust removal noise reduction components include a fume hood, a negative pressure fan, a filter element, and sound-absorbing cotton. The fume hood is installed above the welding torch.

10. The automated complete set of equipment for welding rolls of a continuous casting main machine according to claim 1, characterized in that: The workpiece conveying roller module (2), the automated loading and unloading clamping module (3), several fully automatic welding and overlaying modules (4) and the auxiliary cooling and protection module all adopt an integrated heavy-duty rigid bed structure. The bed is formed by welding thick steel plates and undergoes aging treatment. The workpiece conveying roller module (2), the fully automatic welding and overlaying module (4) and the automated loading and unloading clamping module (3) are all fixedly installed on the same bed platform. The coaxiality error of each module is ≤0.1mm. The protective fence (1) is equipped with a safety light curtain, a maintenance protection door and a door lock switch. The signal output end of the safety light curtain is connected to the intelligent electronic control module.

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