A welding robot with adaptive adjustment function

Abstract

This invention relates to the field of welding robot technology and discloses a welding robot with adaptive adjustment function, comprising: a slide rail base, a slide table disposed above the slide rail base, a robotic arm disposed above the slide table, and a welding module disposed at the end of the robotic arm. The welding module is used to weld the connection between the steel structure body and the cross plate, and also adaptively adjusts the weld; a support platform fixedly installed on one side of the slide rail base; and a steel structure positioning module disposed on one side of the slide rail base. This invention, through multiple modules and a robotic arm, constitutes an intelligent welding system. After the steel component is hoisted to the loading station, the actual position of the steel component can be directly identified and calculated through the steel structure positioning module, automatically obtaining the positional deviation of the steel component relative to the preset welding station. This eliminates the need for repeated manual adjustments to the placement of the steel component, effectively reducing labor costs and improving the overall welding efficiency.

Description

Technical Field

[0001] This invention relates to the field of welding robot technology, specifically to a welding robot with adaptive adjustment function. Background Technology

[0002] Welding robots are industrial robots that perform welding operations and are widely used in various industrial manufacturing fields. When welding workpieces, there are differences in the size of different workpieces and the position to be welded, such as the welding of steel components.

[0003] Currently, due to the heavy weight of steel components, they are usually hoisted by cranes. After the steel components are hoisted to the welding station, the welding robot completes the welding operation according to the preset program. However, after the steel components are unloaded, positioning deviations are very likely to occur. Usually, manual adjustment of the position of the steel components is required to adjust them to the preset welding station. The adjustment process consumes a lot of manpower and slows down the overall welding processing efficiency. Summary of the Invention

[0004] To address the shortcomings of existing technologies, this invention provides a welding robot with adaptive adjustment capabilities, primarily to solve the problem that steel components require secondary adjustments after being loaded at the welding station.

[0005] To achieve the above objectives, the present invention provides the following technical solution: A welding robot with adaptive adjustment function includes: a slide rail base, a slide table above the slide rail base, a robotic arm above the slide table, and a welding module at the end of the robotic arm. The welding module is used to weld the connection between the steel structure body and the cross plate, and also adaptively adjusts the weld; a support platform, fixedly installed on one side of the slide rail base, on which the steel structure body is placed when it is placed at the welding station; a steel structure positioning module, located on one side of the slide rail base, which simulates the station where the steel structure body is placed as a grid and identifies the position of the steel structure body within the grid through a position recognition system; and a clamping and correction module, located on one side of the slide table, used to adjust the tilt angle of the cross plate.

[0006] As a further embodiment of the present invention, the steel structure positioning module includes: Mounting rods are fixedly installed at both ends on one side of the slide table, and a third distance sensor is fixedly installed at the bottom of each of the two mounting rods; The mounting box is fixedly installed at both ends of one side of the slide rail base. The mounting box contains a lifting frame. A linear motor is fixedly installed on one side of the lifting frame. A fixed bracket is fixedly installed on the mover of the linear motor. A fourth distance sensor is fixedly installed on one side of the fixed bracket. The fourth distance sensor works in conjunction with the third distance sensor.

[0007] As a further embodiment of the present invention, guide rods are fixedly installed at both ends of the lifting frame, and the guide rods are slidably connected to the mounting box; A first electric push rod is fixedly installed on the bottom inner wall of the mounting box. The movable end of the first electric push rod is fixed to the lifting frame. The height of the lifting frame extending out of the mounting box is controlled by the extension and retraction of the first electric push rod.

[0008] As a further embodiment of the present invention, the welding module includes: The mounting bracket is fixedly installed at the end of the robotic arm, and the rotation angle and position of the mounting bracket are controlled by the robotic arm. The welding torch is fixedly mounted on the mounting bracket, with the welding head of the torch away from the mounting bracket.

[0009] As a further embodiment of the present invention, the welding module further includes: Both first distance sensors are fixedly installed on the bottom inner wall of the mounting frame, with the detection ends of the two first distance sensors facing the steel structure body and the cross plate respectively; The second distance sensor is fixedly installed on the bottom inner wall of the mounting bracket, and the second distance sensor is located between the two first distance sensors. The detection end of the second distance sensor faces the front of the welding point of the welding gun.

[0010] As a further embodiment of the present invention, the welding module further includes: The vision sensor is fixedly installed on one side of the top of the mounting bracket, with the detection end of the vision sensor facing the rear of the welding point of the welding gun.

[0011] As a further embodiment of the present invention, the clamping and correction module includes: A fixed base is fixedly installed on one side of the slide table. A second electric push rod is fixedly installed on one side of the fixed base. The movable end of the second electric push rod passes through the fixed base and is fixedly installed with a horizontal slide. The third electric push rod is fixedly installed on the top of the horizontal slide. The movable end of the third electric push rod passes through the horizontal slide and is fixedly installed with a connecting frame. A servo motor is fixedly installed on the bottom inner wall of the connecting frame. The output shaft of the servo motor passes through the connecting frame and is fixedly installed with a turntable, and the turntable is rotatably connected to the connecting frame. Two pneumatic grippers are fixedly installed at the bottom of the turntable, and clamps are fixedly installed at the movable ends of both pneumatic grippers.

[0012] As a further embodiment of the present invention, the clamping and correction module further includes: The fourth electric push rod is fixedly installed on one side of the connecting frame. A longitudinal slide is fixedly installed on the movable end of the fourth electric push rod. Two sixth distance sensors are fixedly installed on one side of the longitudinal slide, and the detection ends of the two sixth distance sensors face opposite directions. The fifth distance sensor is fixedly installed on one side of the connecting frame, with its detection end pointing vertically downwards.

[0013] As a further embodiment of the present invention, two protrusions are provided on opposite sides of the two clamps located on the same pneumatic gripper, with a gap between the two protrusions.

[0014] As a further embodiment of the present invention, the location identification system includes the following steps: Step 1: The slide table moves along the slide rail base, scans the end edge of the steel component, and reads the real-time coordinate value of the slide table; at the same time, the steel structure positioning module scans the other side edge of the steel component and reads the real-time coordinate value of the sensor in the steel structure positioning module. When the sensor beam sweeps across the edge of the steel component, the distance reading changes abruptly, and the system immediately records the trigger time and the corresponding coordinate value. Step 2: Combine the raw readings collected in Step 1 with the fixed mechanical zero-position offset constant during sensor installation to calculate the actual edge coordinates of the component within the grid. Step 3: Calculate the center coordinates of the tilt angle based on the corner point coordinates; Step 4: Compare the measured center (or centroid) with the preset target center to calculate the translational deviation, and at the same time calculate the rotational deviation; Step 5: Transmit the calculated translational deviation, rotational deviation, and complete contour position set to the control unit for subsequent welding path correction of the robotic arm and attitude adjustment of the clamping and correction module.

[0015] Compared with the prior art, the present invention provides a welding robot with adaptive adjustment function, which has the following beneficial effects: 1. This invention uses multiple modules and a robotic arm to form an intelligent welding system. After the steel components are hoisted to the loading station, the actual position of the steel components can be directly identified and calculated through the steel structure positioning module. The positional deviation of the steel components relative to the preset welding station is automatically obtained. There is no need for manual repeated adjustment of the placement of the steel components, which effectively reduces manpower consumption and improves the overall welding efficiency.

[0016] 2. The present invention, through the clamping and correction module, can work with the position deviation data obtained by the steel structure positioning module to clamp the horizontal plate to be welded and automatically adjust the tilt angle of the horizontal plate to complete the posture correction before welding, so that the position of the steel component to be welded can be aligned with the preset position, meeting the welding accuracy requirements, without the need for repeated manual adjustments.

[0017] 3. By integrating multiple sets of sensors into the welding module, this invention can detect the position and size of the gap to be welded in real time during the welding process, automatically correct the welding path, further improve the adaptive adjustment capability of welding, and ensure welding quality. Attached Figure Description

[0018] Figure 1 This is a schematic diagram of the working state structure of a welding robot with adaptive adjustment function proposed in this invention; Figure 2 This is a three-dimensional structural diagram of a welding robot with adaptive adjustment function proposed in this invention; Figure 3 This is an enlarged schematic diagram of the robotic arm structure of a welding robot with adaptive adjustment function proposed in this invention; Figure 4 This is a cross-sectional structural diagram of a steel positioning module for a welding robot with adaptive adjustment function proposed in this invention. Figure 5 This is an enlarged schematic diagram of the welding torch structure of a welding robot with adaptive adjustment function proposed in this invention. Figure 6 This is a schematic diagram of the working state structure of a welding torch of a welding robot with adaptive adjustment function proposed in this invention. Figure 7 This is a schematic diagram of a welding position detection structure for a welding robot with adaptive adjustment function proposed in this invention; Figure 8 This is an enlarged structural diagram of the clamping and straightening module of a welding robot with adaptive adjustment function proposed in this invention; Figure 9 This invention proposes a welding robot with adaptive adjustment function. Figure 8 A schematic diagram of the overall exploded structure; Figure 10 This is an enlarged schematic diagram of the connecting frame structure of a welding robot with adaptive adjustment function proposed in this invention.

[0019] In the diagram: 1. Slide rail base; 2. Slide table; 3. Robotic arm; 4. Welding module; 5. Steel structure positioning module; 6. Support platform; 7. Steel structure body; 701. Horizontal plate; 8. Clamping and straightening module; 401. Mounting bracket; 402. Welding torch; 403. Vision sensor; 404. First distance sensor; 405. Second distance sensor; 501. Mounting rod; 502. Third distance sensor; 503. Mounting box; 504. Lifting frame; 505. Linear motor; 506. Fixing frame; 507. Fourth distance sensor; 508. Guide rod; 509. First electric push rod; 801. Fixed base; 802. Second electric push rod; 803. Horizontal carriage; 804. Third electric push rod; 805. Connecting frame; 806. Servo motor; 807. Turntable; 808. Fourth electric push rod; 809. Longitudinal carriage; 810. Fifth distance sensor; 811. Sixth distance sensor; 812. Pneumatic gripper; 813. Clamping frame; 814. Protrusion. Detailed Implementation

[0020] To make the objectives, technical solutions, and advantages of this invention clearer, the invention will be further described in detail below through embodiments and in conjunction with the accompanying drawings. It should be understood that the specific embodiments described herein are merely illustrative of the invention and are not intended to limit the invention.

[0021] The component designations used in this document, such as "first" and "second," are merely for distinguishing the described objects and do not have any sequential or technical meaning. The terms "connection" and "linkage" used in this invention, unless otherwise specified, include both direct and indirect connections (linkages). It should be understood that the terms "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," "outer," "clockwise," and "counterclockwise," indicating orientations or positional relationships, are based on the orientations or positional relationships shown in the accompanying drawings and are used only for the convenience of describing the invention and simplifying the description. They do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as limiting the invention.

[0022] In this invention, unless otherwise explicitly specified and limited, "above" or "below" the second feature can mean that the first feature is in direct contact with the second feature, or that the first feature is in indirect contact with the second feature through an intermediate medium. Furthermore, "above," "over," and "on top" of the second feature can mean that the first feature is directly above or diagonally above the second feature, or simply that the first feature is at a higher horizontal level than the second feature. "Below," "below," and "under" the second feature can mean that the first feature is directly below or diagonally below the second feature, or simply that the first feature is at a lower horizontal level than the second feature.

[0023] Please see Figures 1-10 As shown, a welding robot with adaptive adjustment function mainly consists of a slide rail base 1, a slide table 2, a robotic arm 3, and multiple modules, as detailed below: A slide table 2 is provided above the slide rail base 1, and a robotic arm 3 is provided above the slide table 2. The above are all existing technologies. The slide table 2 slides on the slide rail base 1 and is provided with sliding power by an external drive device (such as a linear module), which can drive the robotic arm 3 to move along the slide rail direction. The robotic arm 3 can be a multi-axis serial robotic arm, which can flexibly adjust the position and angle of the end welding head to meet the operation requirements of different welding paths.

[0024] The end of the robotic arm 3 is equipped with a welding module 4, which can perform welding operations on the steel structure body 7 and the horizontal plate 701. At the same time, a weld detection system is also integrated on the side of the welding module 4. The weld detection system can monitor the weld position in real time, obtain the actual positional deviation information between the steel structure body 7 and the horizontal plate 701, and feed the information back to the robot's control unit. The control unit automatically adjusts the welding path of the robotic arm 3 according to the received positional deviation.

[0025] The slide rail base 1 also integrates a steel structure positioning module 5 and a support platform 6 on one side. When the steel structure body 7 is placed, it is located on the support platform 6. At the same time, the steel structure positioning module 5 and the slide rail base 1 cooperate to form a grid coordinate, which is the work position for placing the steel structure body 7. The coordinate deviation of the steel component position is collected in real time through the position recognition system. The collected deviation signal is transmitted to the control module, which generates corresponding adjustment commands to adjust the moving distance of the slide table 2 and the rotation angle of each joint of the robotic arm 3, and automatically completes the alignment correction of the welding position. There is no need for manual secondary movement and adjustment of the steel component, which simplifies the welding operation process and improves the positioning accuracy of the welding position.

[0026] The specific structure of welding module 4 is as follows: A mounting frame 401 is fixedly installed at the end of the robotic arm 3. The robotic arm 3 can control the rotation angle and position of the mounting frame 401. A welding torch 402 is fixedly installed on the mounting frame 401 (the welding torch 402 can be an automatic electric arc welding torch, or it can be a submerged arc welding torch or a gas shielded welding torch, and it is connected to external welding equipment to provide the electrical energy and shielding gas required for welding. Those skilled in the art can set it according to actual needs). The welding head of the welding torch 402 is away from the mounting frame 401. The high-temperature molten metal output by the welding torch 402 fills the splicing gap between the steel structure body 7 and the cross plate 701, and completes the welding and fixing of the two. The mounting bracket 401 is also equipped with a ranging sensor unit located below the welding torch 402. The ranging sensor unit is set facing the area to be welded and can collect the position signals of the steel structure body 7 and the cross plate 701 in real time. In conjunction with the weld detection system, it can obtain the position offset data of the weld and further correct the welding path to prevent the welding torch 402 from deviating from the predetermined welding trajectory, thus ensuring the uniformity and stability of the weld formation.

[0027] Furthermore, the ranging sensing unit consists of two first distance sensors 404 and one second distance sensor 405. The second distance sensor 405 is located between the two first distance sensors 404, and its detection end faces the front of the welding point of the welding torch 402. The detection ends of the two first distance sensors 404 face the steel structure body 7 and the horizontal plate 701, respectively. The two first distance sensors 404 can detect the distance values ​​from the steel structure body 7 and the horizontal plate 701, respectively, to determine the actual offset direction and offset of the splicing gap. The detection data is then transmitted to the control unit. The control unit combines the depth information in front of the welding point obtained by the second distance sensor 405 to comprehensively calculate the actual position of the current weld, matches the preset welding path to complete the correction and adjustment, and further improves the accuracy of the welding position.

[0028] Specific (e.g.) Figure 7 As shown), the values ​​detected by the two first distance sensors 404 during welding should be the same. If the distance detected by one of the first distance sensors 404 is less than the preset value, it means that the position of the workpiece plate corresponding to that sensor is biased towards the detection end, and the weld is shifted to that side. If the detected distance is greater than the preset value, it means that the workpiece plate on that side is far away from the detection end, and the weld is shifted to the other side. The control unit can quickly calculate the offset direction and offset amount based on the difference between the preset value and the detected value of the two first distance sensors 404. Combined with the depth information collected by the second distance sensor 405, the welding path is corrected in real time. This avoids the problem of skewed welding position and substandard forming quality caused by the horizontal deviation that exists when manually spot welding the horizontal plate 701. It can directly adapt to the splicing state of workpieces with small positional deviations and ensure the stability of welding quality.

[0029] In addition, such as Figure 6 As shown, a vision sensor 403 is fixedly installed on one side of the top of the mounting bracket 401. The detection end of the vision sensor 403 faces the rear of the welding point of the welding torch 402. It can immediately image the formed weld after the welding operation is completed. The image processing algorithm can quickly identify whether there are forming defects such as porosity, depression, and weld beads in the weld. If a defect is detected, it can be directly fed back to the control unit, which makes it easy for the robot to repair it in time. There is no need for subsequent manual re-inspection and rework adjustment, which reduces the operation steps and reduces the quality risks caused by missed inspections.

[0030] It should be noted that the vision sensor 403 uses an industrial CCD camera with a wide-angle lens and a resolution of no less than 10,000 pixels, which can clearly capture tiny surface defects of the weld. At the same time, the camera surface is covered with a transparent protective cover that is resistant to high temperature and dust, which can isolate the high temperature sputtering and fumes generated during welding operations, prevent the lens from being contaminated or blocked, and ensure the long-term stability of imaging and detection.

[0031] Furthermore, the specific structure of the steel positioning module 5 is as follows: Mounting rods 501 are fixedly installed at both ends on one side of the slide table 2, and a third distance sensor 502 is fixedly installed at the bottom of each of the two mounting rods 501. Meanwhile, mounting boxes 503 are fixedly installed at both ends on one side of the slide rail base 1. A lifting frame 504 is installed inside the mounting box 503. A linear motor 505 is fixedly installed on one side of the lifting frame 504. A fixing frame 506 is fixedly installed on the mover of the linear motor 505. A fourth distance sensor 507 is fixedly installed on one side of the fixing frame 506. The fourth distance sensor 507 works in conjunction with the third distance sensor 502 to detect the position coordinates of the steel structure body 7 placed on the support platform 6 from the x-axis and y-axis directions respectively. When the position of the steel structure body 7 deviates, the fourth distance sensor 507 and the third distance sensor 502 can quickly collect the deviation data, transmit it to the control unit, generate a correction command, and adjust the overall welding operation coordinates of the robotic arm 3.

[0032] It should be noted that the linear motor 505 is a model equipped with a high-precision displacement encoder, which can accurately feed back the movement position of the fourth distance sensor 507, ensuring the accuracy of position coordinate detection and avoiding the impact of displacement detection errors on the accuracy of steel component position deviation calculation.

[0033] During operation, the linear motor 505 drives the fourth distance sensor 507 to move along the slide rail to scan the side position of the steel structure body 7. Together with the third distance sensor 502, it scans the end position of the steel structure body 7, so that the actual position of the steel structure body 7 can be quickly obtained. After comparing it with the preset standard work position coordinates, the deviation value can be obtained, which is used by the control unit to adjust the welding path.

[0034] Specifically, the third distance sensor 502 is defined as a reference sensor for detecting the edge of the Y-axis (length or left-right direction), and the fourth distance sensor 507 is defined as a reference sensor for detecting the edge of the X-axis (width or front-back direction). The two work together to form a two-dimensional detection grid.

[0035] The intersection of the extended lines of the moving axis of the third distance sensor 502 and the moving axis of one of the fourth distance sensors 507 is set as the initial zero point; When the fourth distance sensor 507 scans the X edge, the system synchronously reads the real-time coordinate values ​​of the slide 2. This serves as the X-axis coordinate of that point; When the third distance sensor 502 scans the edge of the Y-axis, the system synchronously reads the real-time coordinate value of the linear motor 505. As the Y-axis coordinate of that point; The fixed mechanical zero-position offset constants during sensor installation are set as follows: After calibration, it becomes a known constant.

[0036] During the scanning process, the distance reading undergoes a step change when the sensor beam sweeps across the edge of the steel component. The coordinate values ​​at the four edge-triggered moments are recorded: The left edge in the X direction (detected by the fourth distance sensor 507) is:

[0037] The right edge in the X direction (detected by the fourth distance sensor 507) is:

[0038] The leading edge in the Y direction (detected by the third distance sensor 502) is:

[0039] The rear edge in the Y direction (detected by the third distance sensor 502) is:

[0040] in, , , , This is the timestamp when the corresponding edge triggers a step change.

[0041] The precise coordinates of the four corner points of the steel component within the grid are: Bottom left corner:

[0042] Bottom right corner:

[0043] Top left corner:

[0044] Top right corner:

[0045] Formula for the reference positioning center (position coordinates) of steel components:

[0046] Actual deviation formula (used to generate correction instructions): Let the system's preset target welding position center be:

[0047] The deviation is:

[0048]

[0049] The control unit is based on ( , Generate correction instructions for the welding operation position of robotic arm 3.

[0050] Based on the extracted edge extrema, the geometric dimensions of the steel components can be directly calculated: Total length in the X-axis direction:

[0051] Total width in the Y-axis direction:

[0052] When the steel component is not parallel to the grid edge (X-axis, Y-axis) (there is a rotation angle) When the sensor moves and the light beam sweeps across the edge of the steel structure, it records the actual grid coordinates of the trigger point: Let the first The actual coordinates of each sampling point are:

[0053] in:

[0054] Triggered by scanning along the X direction by the fourth distance sensor 507;

[0055] It is triggered by scanning along the Y direction by the third sensor.

[0056] All trigger points are clustered according to their spatial location, into point sets corresponding to four edges:

[0057] For each point set Fitting the linear equation:

[0058] slope With intercept The calculation formula is:

[0059]

[0060] Since opposite sides of a rectangle are parallel, theoretically: (The front and back are parallel) (The left and right sides are parallel, and the front and back sides are perpendicular.) In actual processing, to improve anti-interference performance, the average value is taken as the final slope: , Take the corresponding intercepts. , Take the corresponding intercepts. Take the slope of the front (or back) side Calculate the tilt angle:

[0061] that angle It is the rotation angle of the long side of the steel component relative to the positive direction of the X-axis (a positive value indicates counterclockwise tilt).

[0062] Find the intersection points of each pair of adjacent straight lines to obtain the four corner points of the rectangle. .

[0063] Two straight lines and The formula for the intersection point is:

[0064]

[0065] Among them, subscript and The numbers represent the intersection points of two adjacent edges. .

[0066] This gives us four corner points: Left front corner point (intersection of edge 1 and edge 3):

[0067] Right front corner point (intersection of edge 1 and edge 4):

[0068] Left rear corner point (intersection of edge 2 and edge 3):

[0069] Right rear corner point (intersection of edge 2 and edge 4):

[0070] The formula for the center position coordinates of a steel component (non-parallel state) is:

[0071] Similarly, the length of the steel member (long side, along the inclined direction) is:

[0072] The width of the steel member (short side, perpendicular to the direction of inclination) is:

[0073] Since the control unit not only needs to translate the robotic arm 3, but also needs to rotate the welding posture to fit the inclined component, the translational deviation and rotational deviation are calculated respectively. The translation deviation (compared to the preset target center) is as follows:

[0074]

[0075] The rotational deviation (usually with a preset target angle of 0°) is:

[0076] Based on this, the robotic arm 3 simultaneously adjusts the spatial position of the welding starting point and the attitude angle of the welding torch 402 to achieve precise tracking welding in an inclined state.

[0077] In addition, guide rods 508 are fixedly installed at both ends of the lifting frame 504, and the guide rods 508 are slidably connected to the mounting box 503. A first electric push rod 509 is fixedly installed on the bottom inner wall of the mounting box 503. The movable end of the first electric push rod 509 is fixed to the lifting frame 504. The height of the lifting frame 504 extending out of the mounting box 503 is controlled by the extension and retraction of the first electric push rod 509. During operation, the lifting frame 504 extends out of the mounting box 503. After the steel component position scanning is completed, the first electric push rod 509 can drive the lifting frame 504 to retract into the mounting box 503 as a whole, so as to avoid collision with the lifting frame 504 and the sensing component during the steel component loading process, thus protecting the detection mechanism and extending the service life of the sensor.

[0078] Furthermore, in order to adjust the tilt angle of the horizontal plate 701, a clamping and correction module 8 is also provided on one side of the slide table 2. The specific structure of the clamping and correction module 8 is as follows: A fixed base 801 is fixedly installed on one side of the slide table 2. A second electric push rod 802 is fixedly installed on one side of the fixed base 801. The movable end of the second electric push rod 802 passes through the fixed base 801 and is fixedly installed on a horizontal slide 803. A third electric push rod 804 is fixedly installed on the top of the horizontal slide 803. The movable end of the third electric push rod 804 passes through the horizontal slide 803 and is fixedly installed on a connecting frame 805. A servo motor 806 is fixedly installed on the bottom inner wall of the connecting frame 805. The output shaft of the servo motor 806 passes through... A turntable 807 is fixedly installed on the connecting frame 805, and the turntable 807 is rotatably connected to the connecting frame 805. Two pneumatic grippers 812 (model HFZ20-S, gripping stroke 20mm, clamping force can be adjusted by air pressure) are fixedly installed on the bottom of the turntable 807. The movable ends of the two pneumatic grippers 812 are fixedly installed with clamping brackets 813. Two protrusions 814 are opened on the opposite sides of the two clamping brackets 813 located on the same pneumatic gripper 812, and there is a gap between the two protrusions 814. When there is a slight tilt deviation between the horizontal plate 701 and the steel structure body 7, the second electric push rod 802 can be activated to extend, so that the pneumatic gripper 812 is positioned above the horizontal plate 701. Then, the servo motor 806 is activated to drive the turntable 807 to rotate, with the rotation angle being the same as the rotation deviation. After that, the third electric push rod 804 is activated to extend, causing the two pneumatic grippers 812 to fall, so that the protrusions 814 of the clamp 813 are respectively locked in the upper and lower positions on both sides of the horizontal plate 701 to clamp the horizontal plate 701. The horizontal plate 701 is adjusted by the pneumatic gripper 812 to correct the tilt deviation of the horizontal plate 701 to meet the requirements. Finally, precise welding can be carried out directly between the horizontal plate 701 and the steel structure body 7, further reducing the impact of splicing deviation on welding quality. There is no need to manually pry and adjust the position of the horizontal plate 701, which reduces the intensity of manual labor.

[0079] It should be noted that when the servo motor 806 is used in conjunction with the encoder, the number of rotations and the rotation angle of the output shaft are controllable, and those skilled in the art can set them according to actual needs.

[0080] Furthermore, a fourth electric push rod 808 is fixedly installed on one side of the connecting frame 805. A longitudinal slide 809 is fixedly installed on the movable end of the fourth electric push rod 808. Two sixth distance sensors 811 are fixedly installed on one side of the longitudinal slide 809, and the detection ends of the two sixth distance sensors 811 face opposite directions. When the connecting frame 805 moves to the side of the horizontal plate 701, the two sixth distance sensors 811 are located between the two horizontal plates 701. The distance between the two horizontal plates 701 can be determined by the difference in the detection distance on both sides. The detection data is directly fed back to the control unit. The control unit calculates the distance that the slide needs to move based on this data and automatically adjusts it according to the spacing between the two horizontal plates 701 to avoid weld deviation caused by different spacing between each horizontal plate 701 during manual spot welding.

[0081] In addition, a fifth distance sensor 810 is fixedly installed on one side of the connecting frame 805. The detection end of the fifth distance sensor 810 is vertically downward, which can detect the descent distance of the connecting frame 805. This prevents the third electric push rod 804 from driving the pneumatic gripper 812 to descend excessively and squeezing the horizontal plate 701, causing surface deformation damage, and ensuring the safety and accuracy of the clamping and correction process.

[0082] It should be noted that the distance sensors used in this article are all laser rangefinders. They can also be replaced with rangefinders based on different principles, such as ultrasonic rangefinders and infrared rangefinders, depending on the actual working environment. As long as they can stably output distance detection results, they can be adapted to this detection and correction system. They are highly adaptable and the components can be flexibly adjusted to meet the equipment configuration requirements of different workshops. Furthermore, the electric actuators used in this article are all linear motion power actuators that convert electrical energy into mechanical energy. They can be connected to an external power source and control switch, and drive the actuator to perform linear reciprocating motion by controlling the forward and reverse rotation of the motor. By cooperating with limit switches or Hall sensors, the safety protection and position control of the actuator's extension and retraction stroke can be achieved. Those skilled in the art can set them according to actual needs.

[0083] The following are the specific instructions for using this robot: The integral steel component to be welded is hoisted and placed on support platform 6, so that the steel component is roughly centered, and the material loading preparation is completed.

[0084] The first electric push rod 509 extends, driving the lifting frame 504 to lift the entire assembly box 503. The linear motor 505 drives the fourth distance sensor 507 to move along the Y-axis to scan the steel component. At the same time, the third distance sensor 502 moves along the X-axis with the slide table 2 to synchronously detect the contour edge of the steel component in another direction. The sensors in the two directions record the coordinates of all triggered edge points in sequence and transmit them to the control unit to complete the position information acquisition.

[0085] The control unit automatically obtains the actual contour, center position and tilt angle of the steel component according to the aforementioned fitting calculation method, compares it with the preset welding target parameters, and calculates the translational deviation and rotational deviation.

[0086] Subsequently, the first electric push rod 509 drives the lifting frame 504 to retract into the mounting box 503 to avoid collisions during subsequent clamping and correction operations.

[0087] Meanwhile, as the slide table 2 moves, the sixth distance sensor 811 is manually controlled to move between the two horizontal plates 701. The two sixth distance sensors 811 detect the side distance of the two horizontal plates 701 respectively, calculate the actual distance between the two horizontal plates 701, compare it with the preset distance to obtain the position deviation, and then the control unit drives the slide table 2 to adjust the position.

[0088] Based on the deviation data output by the control unit, the robotic arm 3 adjusts the welding starting point position and the posture of the welding torch 402. At the same time, the clamping and correction module 8 is activated. The second electric push rod 802 pushes the horizontal slide 803 to move, which in turn moves the clamp 813 above the horizontal plate 701. Subsequently, the servo motor 806 drives the turntable 807 to rotate at the corresponding angle according to the rotational deviation. Then, the third electric push rod 804 drives the pneumatic gripper 812 to fall. During the fall, the fifth distance sensor 810 detects the descent height in real time. After reaching the preset position, it stops. The pneumatic gripper 812 drives the clamp 813 to clamp the horizontal plate 701 to be corrected. After the angle correction is completed, precise welding can begin.

[0089] During the welding process, the first distance sensor 404 and the second distance sensor 405 detect the lateral distance between the end of the welding torch 402 and the two sides of the weld in real time. The lateral position of the welding torch 402 is adjusted by feedback to prevent the welding torch 402 from deviating during the welding process and to ensure that the weld is always in the correct working position of the welding torch 402. At the same time, the vision sensor 403 performs imaging and detection of the formed weld.

[0090] After welding is completed, the pneumatic gripper 812 releases the horizontal plate 701, all power components reset, and the welded steel component can be lifted out for the next operation.

[0091] The technical features of the above embodiments can be combined in any way. For the sake of brevity, not all possible combinations of the technical features in the above embodiments are described. However, as long as there is no contradiction in the combination of these technical features, they should be considered to be within the scope of this specification.

[0092] The embodiments described above are merely illustrative of several implementations of the present invention, and while the descriptions are specific and detailed, they should not be construed as limiting the scope of the invention. It should be noted that those skilled in the art can make various modifications and improvements without departing from the concept of the present invention, and these modifications and improvements all fall within the scope of protection of the present invention. Therefore, the scope of protection of the present invention should be determined by the appended claims.

Claims

1. A welding robot having a self-adapting function, characterized by, include: A slide rail base (1) is provided above the slide rail base (1), a slide table (2) is provided above the slide table (2), a robotic arm (3) is provided above the slide table (2), and a welding module (4) is provided at the end of the robotic arm (3). The welding module (4) is used to weld the connection between the steel structure body (7) and the horizontal plate (701), and will also make adaptive adjustments to the weld. The support platform (6) is fixedly installed on one side of the slide rail base (1), and the steel structure body (7) is placed on the support platform (6) when it is placed at the welding station; The steel structure positioning module (5) is set on one side of the slide rail base (1). The steel structure positioning module (5) simulates the work station where the steel structure body (7) is placed as a grid and identifies the position of the steel structure body (7) in the grid through the position recognition system. The clamping and correction module (8) is set on one side of the slide (2) and is used to adjust the tilt angle of the horizontal plate (701).

2. The welding robot with adaptive adjustment function according to claim 1, characterized in that, The steel structure positioning module (5) includes: Mounting rods (501) are fixedly installed at both ends on one side of the slide table (2), and a third distance sensor (502) is fixedly installed at the bottom of each of the two mounting rods (501). The mounting box (503) is fixedly installed at both ends of one side of the slide rail base (1). The mounting box (503) is equipped with a lifting frame (504). A linear motor (505) is fixedly installed on one side of the lifting frame (504). A fixed frame (506) is fixedly installed on the mover of the linear motor (505). A fourth distance sensor (507) is fixedly installed on one side of the fixed frame (506). The fourth distance sensor (507) is used in conjunction with the third distance sensor (502).

3. A welding robot with adaptive adjustment function according to claim 2, characterized in that, Guide rods (508) are fixedly installed at both ends of the lifting frame (504), and the guide rods (508) are slidably connected to the mounting box (503); The bottom inner wall of the mounting box (503) is fixedly installed with a first electric push rod (509). The movable end of the first electric push rod (509) is fixed to the lifting frame (504). The height of the lifting frame (504) extending out of the mounting box (503) is controlled by the extension and retraction of the first electric push rod (509).

4. A welding robot with adaptive adjustment function according to claim 1, characterized in that, The welding module (4) includes: Mounting bracket (401) is fixedly mounted on the end of robotic arm (3), and the rotation angle and position of mounting bracket (401) are controlled by robotic arm (3); The welding torch (402) is fixedly mounted on the mounting bracket (401), with the welding head of the welding torch (402) away from the mounting bracket (401).

5. A welding robot with adaptive adjustment function according to claim 4, characterized in that, The welding module (4) also includes: Two first distance sensors (404) are fixedly installed on the bottom inner wall of the mounting bracket (401), and the detection ends of the two first distance sensors (404) face the steel structure body (7) and the cross plate (701) respectively. The second distance sensor (405) is fixedly installed on the bottom inner wall of the mounting bracket (401), and the second distance sensor (405) is located between the two first distance sensors (404). The detection end of the second distance sensor (405) faces the front of the welding point of the welding torch (402).

6. A welding robot with adaptive adjustment function according to claim 4, characterized in that, The welding module (4) also includes: A vision sensor (403) is fixedly installed on one side of the top of the mounting bracket (401), with the detection end of the vision sensor (403) facing the rear of the welding point of the welding torch (402).

7. A welding robot with adaptive adjustment function according to claim 1, characterized in that, The clamping and correction module (8) includes: A fixed seat (801) is fixedly installed on one side of the slide table (2). A second electric push rod (802) is fixedly installed on one side of the fixed seat (801). The movable end of the second electric push rod (802) passes through the fixed seat (801) and is fixedly installed with a horizontal slide (803). The third electric push rod (804) is fixedly installed on the top of the horizontal slide (803). The movable end of the third electric push rod (804) passes through the horizontal slide (803) and is fixedly installed with a connecting frame (805). A servo motor (806) is fixedly installed on the bottom inner wall of the connecting frame (805). The output shaft of the servo motor (806) passes through the connecting frame (805) and is fixedly installed with a turntable (807). The turntable (807) is rotatably connected to the connecting frame (805). Two pneumatic grippers (812) are fixedly installed at the bottom of the turntable (807), and the movable ends of the two pneumatic grippers (812) are fixedly installed with clamps (813).

8. A welding robot with adaptive adjustment function according to claim 7, characterized in that, The clamping and correction module (8) also includes: The fourth electric push rod (808) is fixedly installed on one side of the connecting frame (805). The movable end of the fourth electric push rod (808) is fixedly installed with a longitudinal slide (809). Two sixth distance sensors (811) are fixedly installed on one side of the longitudinal slide (809). The detection ends of the two sixth distance sensors (811) face opposite directions. The fifth distance sensor (810) is fixedly installed on one side of the connecting frame (805), with the detection end of the fifth distance sensor (810) pointing vertically downward.

9. A welding robot with adaptive adjustment function according to claim 7, characterized in that, Two protrusions (814) are provided on opposite sides of the two clamps (813) located on the same pneumatic gripper (812), and there is a gap between the two protrusions (814).

10. A welding robot with adaptive adjustment function according to claim 1, characterized in that, The location identification system includes the following steps: Step 1: The slide table (2) moves along the slide rail base (1), scans the end edge of the steel component, and reads the real-time coordinate value of the slide table (2); at the same time, the steel structure positioning module (5) scans the other side edge of the steel component, and reads the real-time coordinate value of the sensor in the steel structure positioning module (5). When the sensor beam sweeps across the edge of the steel component, the distance reading changes abruptly, and the system immediately records the trigger time and the corresponding coordinate value. Step 2: Combine the raw readings collected in Step 1 with the fixed mechanical zero-position offset constant during sensor installation to calculate the actual edge coordinates of the component within the grid. Step 3: Calculate the center coordinates of the tilt angle based on the corner point coordinates; Step 4: Compare the measured center (or centroid) with the preset target center to calculate the translational deviation, and at the same time calculate the rotational deviation; Step 5: Transmit the calculated translational deviation, rotational deviation, and complete contour position set to the control unit for subsequent welding path correction of the robotic arm (3) and posture adjustment of the clamping and correction module (8).

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