Anchoring cable machine shaft welding tool

Abstract

The application relates to an anchor cable machine shaft welding tool, which comprises two bases arranged at intervals left and right, linear slide table assemblies and driving mechanisms arranged at intervals front and back on the top of the bases, roller support assemblies arranged on the top of the linear slide table assemblies, and the driving mechanisms are in transmission connection with the roller support assemblies. Since the length of the anchor cable machine shaft is usually long and the weight is large, multiple welding tools are needed to support the anchor cable machine shaft according to the length of the anchor cable machine shaft, so that the axial line of the anchor cable machine shaft cannot be guaranteed to be in a horizontal state when hoisting and placing. The linear slide table assemblies can adjust the axial position of the anchor cable machine shaft, so that the axial line of the anchor cable machine shaft tends to be horizontal. The driving mechanisms drive the roller support assemblies to rotate, and the welding gun is held by an operator to perform welding at a fixed position. The outer circumferential surface is continuously and uniformly welded, welding errors caused by frequent manual turning are avoided, the thickness consistency of the welding layer is guaranteed, and the machining precision after repair and the equipment operation stability are improved.

Description

Technical Field

[0001] This invention relates to the field of welding fixture technology, and in particular to a welding fixture for an anchor cable machine shaft. Background Technology

[0002] The anchor winch is a key piece of equipment on a ship used for deploying and retrieving anchor cables. During long-term operation, the anchor cable shaft is prone to severe wear due to repeated friction, compression, and impact loads. After wear, the shaft diameter decreases, leading to increased clearance and affecting transmission accuracy and equipment stability. When the wear exceeds the allowable limit, the shaft usually needs to be repaired. In the repair process, welding is often used to restore the shaft diameter, followed by machining to the standard tolerance range. However, anchor winch shafts typically have a long axial length and a large self-weight. In the current technology, the anchor winch shaft is lifted onto a simple support for welding during welding repair. Welding on a simple support requires operators to adjust the welding position to weld different parts of the shaft, which can lead to excessive coaxiality after welding and make it difficult to guarantee the machining accuracy after repair. Summary of the Invention

[0003] The purpose of this invention is to provide a welding fixture for anchor cable machine shafts to solve the problems existing in the prior art.

[0004] The above-mentioned technical objective of the present invention is achieved through the following technical solution: A welding fixture for anchor cable winch shafts includes a base with two units spaced apart on the left and right sides. A linear slide assembly and a drive mechanism are arranged at the top of the base, with the linear slide assembly extending longitudinally. The linear slide assembly is used to adjust the axial position of the anchor cable winch shaft to be welded. Each linear slide assembly has a roller support assembly at its top, which supports the anchor cable winch shaft to be welded. The drive mechanism is connected to the roller support assembly and drives the roller support assembly to rotate, thereby causing the anchor cable winch shaft to rotate around its axis, facilitating omnidirectional welding of the outer circumference of the anchor cable winch shaft.

[0005] By adopting the above technical solution, since the anchor cable machine shaft is usually long and heavy, multiple welding fixtures are needed to support it according to its length. Therefore, it is impossible to ensure that the axis of the anchor cable machine shaft is in a horizontal state during hoisting and placement. The linear slide assembly can adjust the axial position of the anchor cable machine shaft to be welded, so that the axis of the anchor cable machine shaft tends to be horizontal, ensuring that the support points are reasonably distributed. At the same time, the drive mechanism drives the roller support assembly to rotate, so that the anchor cable machine shaft can rotate at a constant speed around its own axis during the welding process. With the operator holding the welding gun in a fixed position, continuous and uniform welding of the outer circumference of the anchor cable machine shaft can be achieved. This effectively avoids welding errors caused by frequent manual flipping or adjustment of the workpiece position, ensures the consistency of the weld layer thickness and the coaxiality of the axis, and thus improves the processing accuracy and equipment operation stability after repair.

[0006] In a further embodiment, the roller support assembly includes a support base, a first rotating shaft, a support wheel, a bushing, a worm gear, and a worm. The length direction of the support base is the front-to-back direction. The interior of the support base is a hollow structure. The bottom end of the support base is provided with a second through hole that extends from front to back. A bushing is fixedly installed in the second through hole. A worm gear passes through the bushing and is movably connected to the bushing. The axial direction of the worm gear is the front-to-back direction. The top end of the support base is symmetrically provided with third through holes that extend from left to right. A first rotating shaft is rotatably installed in each of the third through holes. The axis of the first rotating shaft is collinear with the axis of the third through hole. A worm gear is fixedly installed on each of the first rotating shafts. The worm gear is installed in conjunction with the worm gear. Support wheels are fixedly installed at both ends of the first rotating shaft.

[0007] By adopting the above technical solution, the cooperation between the worm and the worm wheel realizes the transmission of power and the reduction and torque increase. When the drive mechanism drives the worm to rotate, the worm wheel rotates accordingly and drives the first shaft to rotate, which in turn drives the support wheel to rotate and drive the anchor cable machine shaft to rotate. The support wheel is installed on the support seat through the first shaft, which can stably support the anchor cable machine shaft. Moreover, the contact friction between the support wheel and the surface of the anchor cable machine shaft is moderate, which can effectively drive the shaft to rotate and prevent slippage, thus ensuring the smoothness and synchronization of the shaft rotation during the welding process, thereby ensuring the welding quality.

[0008] In a further embodiment, the linear slide assembly includes a frame, a lead screw, a movable seat, a guide rail, and a slider. The frame is fixedly installed at the top front end of the base, and the length direction of the frame is the front-to-back direction. Guide rails are fixedly installed at both the left and right ends of the top of the frame. A first through hole is provided at the front end of the frame, and a lead screw is rotatably installed in the first through hole. The axis of the lead screw is in the front-to-back direction, and the rear end of the lead screw extends rearward and is rotatably connected to the frame. A movable seat is screwed onto the lead screw, and a slider is fixedly installed on the top of the movable seat. The bottom of the slider is slidably connected to the guide rail, and the top of the slider is fixedly connected to the bottom of the support base.

[0009] By adopting the above technical solution, the operator can drive the moving seat to move back and forth along the screw by rotating the lead screw, which in turn drives the slider to move back and forth along the guide rail, and finally drives the support seat and the anchor cable machine shaft to be welded to move back and forth, thereby adjusting the axial position of the anchor cable machine shaft. The guide rail guides and supports the movement of the slider, ensuring the smoothness and straightness of the movement process, and avoiding deviation or jamming caused by uneven force. By precisely adjusting the axial position of the anchor cable machine shaft, the axis of the anchor cable machine shaft can be made horizontal between multiple support points, providing an accurate reference for subsequent rotary welding, and avoiding radial runout or axial movement of the anchor cable machine shaft during rotation due to axis tilt, thereby ensuring the stability of the welding trajectory.

[0010] In a further embodiment, the drive mechanism includes a motor, a reducer, a mounting plate, and a coupling. The mounting plate is fixedly mounted on the top rear end of the base, and the reducer is fixedly mounted on the rear end of the mounting plate. The input end of the reducer is connected to the output shaft of the motor, and the output end of the reducer extends forward to the front end of the mounting plate and is fixedly connected to a lead screw.

[0011] By adopting the above technical solution, the motor provides the power source, which is then reduced and increased in torque by the reducer and output to the worm gear. This ensures that the anchor cable machine shaft obtains a suitable and stable rotation speed during the welding process, avoiding poor weld formation due to excessive speed and preventing local overheating and deformation due to excessively slow speed. The output end of the reducer is fixedly connected to the worm gear, realizing efficient power transmission. The mounting plate provides a stable mounting foundation for the motor and reducer.

[0012] In a further embodiment, the front end of the lead screw extends forward to the outside of the frame, and an adjusting handwheel is fixedly installed at the front end of the lead screw.

[0013] By adopting the above technical solution, the handwheel can be adjusted so that the operator can manually rotate the screw, thereby accurately controlling the displacement of the moving seat and thus achieving fine adjustment of the axial position of the anchor cable machine shaft. The structure is simple and reliable, easy to operate, and can achieve precise positioning without an additional power source, reducing equipment cost and maintenance difficulty.

[0014] In a further embodiment, the base has integrally formed fixing plates on both the left and right sides of its bottom end.

[0015] By adopting the above technical solution, the fixing plate is used to firmly install the base on the ground, which enhances the structural rigidity and vibration resistance of the entire tooling, and prevents the tooling from shifting or shaking due to changes in the center of gravity or external forces during the rotation of the anchor cable machine shaft and welding process, thereby further ensuring the accuracy and safety of the welding operation.

[0016] In summary, the present invention has the following beneficial effects: 1. This invention, by setting up a linear slide assembly and a roller support assembly, can flexibly adjust the axial position of the anchor cable machine shaft to be welded, making its axis tend to be horizontal. The drive mechanism drives the shaft to rotate at a uniform speed, achieving continuous and uniform welding of the outer circumference. This effectively solves the problem of large welding errors caused by manual position adjustment in existing technologies, significantly improving welding quality and repair accuracy. By using a worm gear transmission structure to drive the support wheel rotation, it has advantages such as good self-locking performance, smooth transmission, and strong load-bearing capacity, ensuring the stability and synchronization of the anchor cable machine shaft rotation under heavy load conditions, avoiding slippage, ensuring the continuity of the welding process, and further improving the overall stability and applicability of the tooling. Attached Figure Description

[0017] Figure 1 This is a schematic diagram of the overall structure of the present invention; Figure 2 This is a structural schematic diagram illustrating the roller support assembly of the present invention; Figure 3 This is a structural schematic diagram illustrating the linear slide assembly of the present invention; Figure 4 This is a structural schematic diagram illustrating the drive mechanism of the present invention; Figure 5 This is a schematic diagram illustrating the structural connection between the auxiliary support component and the welding fixture used to demonstrate the present invention; Figure 6 This is a structural schematic diagram illustrating the auxiliary support component of the present invention; Figure 7 This is a schematic diagram illustrating the structural connection between the support component and the worm gear in Embodiment 3 of the present invention; Figure 8 This is a schematic diagram illustrating the worm gear structure of Embodiment 3 of the present invention; Figure 9 This is an internal sectional view illustrating the worm gear structure of Embodiment 3 of the present invention; Figure 10 This is a cross-sectional view illustrating the connection between the support base and the slider in Embodiment 3 of the present invention; Figure 11 This is a partially enlarged schematic diagram illustrating the connection between the support assembly, slider, and guide block in Embodiment 3 of the present invention; Figure 12 This is a flowchart illustrating the synchronous control of the motor in this invention.

[0018] In the diagram, 1. Base; 2. Linear slide assembly; 21. Frame; 22. Lead screw; 23. Moving seat; 24. Guide rail; 25. Slider; 3. Roller support assembly; 31. Support seat; 32. First rotating shaft; 33. Support wheel; 34. Bushing; 35. Worm gear; 36. Worm; 4. Drive mechanism; 41. Motor; 42. Reducer; 43. Mounting plate; 44. Coupling; 5. Auxiliary support assembly; 51. Fixed seat; 52. Support column; 53. Second rotating shaft; 54. Turntable; 55. Support rod; 6. Adjusting handwheel; 7. Fixed plate; 8. Cross shaft; 9. Guide block; 10. Limit block; 361. First worm; 362. Second worm. Detailed Implementation

[0019] The present invention will be further described in detail below with reference to the accompanying drawings.

[0020] Identical parts are indicated by the same reference numerals. It should be noted that the terms "front," "rear," "left," "right," "upper," and "lower" used in the following description refer to the attached figures. Figure 1 In this specification, the terms "bottom surface" and "top surface," "inner" and "outer" refer to the direction towards / away from the geometry of a specific component, respectively. Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating / implying relative importance / or implicitly specifying the number of technical features indicated. Thus, a feature defined as "first" or "second" may explicitly / implicitly include one or more of that feature. In the description of this specification, "multiple" means two or more, unless otherwise explicitly and specifically defined by the direction of the center.

[0021] Example 1: like Figure 1 - Figure 4As shown, a welding fixture for anchor cable winch shafts includes a base 1, with two bases 1 spaced apart on the left and right sides. The bases 1 are fixedly installed on the ground. On both sides of the bottom of each base 1, an integrally formed fixing plate 7 is provided. The fixing plates 7 are bolted to the ground, ensuring the two bases 1 are parallel to each other during installation. The top of each base 1 has a linear slide assembly 2 positioned front to back and a drive mechanism 4 spaced apart. The linear slide assembly 2 extends longitudinally and is used to adjust the axial position of the anchor cable winch shaft to be welded. Each linear slide assembly 2 has a roller support assembly 3 on its top, supporting the anchor cable winch shaft to be welded. The drive mechanism 4 is connected to the roller support assembly 3 and drives the roller support assembly 3 to rotate, thereby causing the anchor cable winch shaft to rotate around its axis, facilitating the welding of the anchor cable winch shaft. The outer circumference surface is welded in all directions. Since the anchor cable machine shaft is usually long and heavy, multiple welding fixtures are required to support it according to its length. Therefore, it is impossible to ensure that the axis of the anchor cable machine shaft is in a horizontal state during hoisting and placement. The linear slide assembly 2 can adjust the axial position of the anchor cable machine shaft to be welded, so that the axis of the anchor cable machine shaft tends to be horizontal and ensures that the support points are reasonably distributed. At the same time, the drive mechanism 4 drives the roller support assembly 3 to rotate, so that the anchor cable machine shaft can rotate at a constant speed around its own axis during the welding process. With the operator holding the welding gun in a fixed position, continuous and uniform welding of the outer circumference surface can be achieved. This effectively avoids welding errors caused by frequent manual flipping or adjustment of the workpiece position, ensures the consistency of the weld layer thickness and the coaxiality of the axis, and thus improves the processing accuracy and equipment operation stability after repair.

[0022] The roller support assembly 3 includes a support base 31, a first rotating shaft 32, a support wheel 33, a bushing 34, a worm gear 35, and a worm 36. The length direction of the support base 31 is the front-to-back direction. The interior of the support base 31 is a hollow structure. The bottom end of the support base 31 is provided with a second through hole that extends from front to back. The bushing 34 is fixedly installed in the second through hole, and the worm 36 passes through the bushing 34. The bushing 34 and the worm 36 are movably connected. The axial direction of the worm 36 is the front-to-back direction. The top end of the support base 31 is symmetrically provided with third through holes that extend from left to right. The first rotating shaft 32 is rotatably installed in each of the third through holes. The axis of the first rotating shaft 32 is collinear with the axis of the third through hole. The first rotating shaft 32 is fixedly mounted on each of the third through holes. A worm gear 35 is installed in conjunction with a worm 36. Support wheels 33 are fixedly installed at both ends of the first rotating shaft 32. The cooperation between the worm 36 and the worm gear 35 realizes the transmission of power and the reduction and torque increase. When the drive mechanism 4 drives the worm 36 to rotate, the worm gear 35 rotates accordingly and drives the first rotating shaft 32 to rotate, which in turn drives the support wheels 33 to rotate and drive the anchor cable machine shaft to rotate. The support wheels 33 are installed on the support seat 31 through the first rotating shaft 32, which can stably support the anchor cable machine shaft. The contact friction between the support wheels 33 and the surface of the anchor cable machine shaft is moderate, which can effectively drive the shaft to rotate and prevent slippage, ensuring the smoothness and synchronization of the shaft rotation during the welding process, thereby ensuring the welding quality.

[0023] The linear slide assembly 2 includes a frame 21, a lead screw 22, a movable seat 23, a guide rail 24, and a slider 25. The frame 21 is fixedly mounted on the top front end of the base 1. The length direction of the frame 21 is the front-to-back direction. Guide rails 24 are fixedly mounted on both the left and right ends of the top of the frame 21. A first through hole is provided at the front end of the frame 21, and a lead screw 22 is rotatably mounted in the first through hole. The axis of the lead screw 22 is in the front-to-back direction. The rear end of the lead screw 22 extends rearward and is rotatably connected to the frame 21. A movable seat 23 is screwed onto the lead screw 22. The front end of the lead screw 22 extends forward to the outside of the frame 21, and an adjusting handwheel 6 is fixedly mounted on the front end of the lead screw 22. A slider 25 is fixedly mounted on the top of the movable seat 23. The bottom of the slider 25 is slidably connected to the guide rail 24, and the top of the slider 25 is connected to... The bottom of the support base 31 is fixedly connected. The operator can drive the moving base 23 to move back and forth along the screw 22 by rotating the screw 22, which in turn drives the slider 25 to move back and forth along the guide rail 24. Finally, the support base 31 and the anchor cable machine shaft to be welded are moved back and forth to adjust the axial position of the anchor cable machine shaft. The guide rail 24 guides and supports the movement of the slider 25, ensuring the smoothness and straightness of the movement process and avoiding deviation or jamming caused by uneven force. By precisely adjusting the axial position of the anchor cable machine shaft, the axis of the anchor cable machine shaft can be kept horizontal between multiple support points, providing an accurate reference for subsequent rotary welding and avoiding radial runout or axial movement of the anchor cable machine shaft during rotation due to axis tilt, thereby ensuring the stability of the welding trajectory.

[0024] The drive mechanism 4 includes a motor 41, a reducer 42, a mounting plate 43, and a coupling 44. The mounting plate 43 is fixedly installed at the top rear end of the base 1, and the reducer 42 is fixedly installed at the rear end of the mounting plate 43. The input end of the reducer 42 is connected to the output shaft of the motor 41. The output end of the reducer 42 extends forward to the front end of the mounting plate 43. The output shaft of the reducer 42 is fixedly installed with the coupling 44, and the other end of the coupling 44 is fixedly connected to the worm gear 36. The motor 41 provides the power source, which is reduced and increased in torque by the reducer 42 and then output to the worm gear 36. This ensures that the anchor cable machine shaft obtains a suitable and stable rotation speed during the welding process, avoiding poor weld formation due to excessive speed and preventing local overheating and deformation due to excessively slow speed. The output end of the reducer 42 is fixedly connected to the worm gear 36, realizing efficient power transmission. The mounting plate 43 provides a stable mounting foundation for the motor 41 and the reducer 42.

[0025] Example 2: like Figures 5-6 As shown, it also includes an auxiliary support assembly 5, which is located on the left side of the left base 1. The auxiliary support assembly 5 is used to support the left end of the anchor cable machine shaft to be welded. The auxiliary support assembly 5 includes a fixed seat 51, a support column 52, a second rotating shaft 53, a turntable 54, and a support rod 55. The fixed seat 51 is fixedly installed on the left side of the left base 1. The support column 52 is fixedly installed on the top of the fixed seat 51. The second rotating shaft 53 is rotatably installed on the right top end of the support column 52. The length direction of the second rotating shaft 53 is left and right. The turntable 54 is fixedly installed on the right end of the second rotating shaft 53. Multiple support rods 55 are uniformly fixedly installed on the right end face along the axis. The axis of the support rods 55 is in the left-right direction. Since there is a connecting rod inside the gear, the support rods 55 fixedly installed on the turntable 54 are inserted into the gear. The support rods 55 support the connecting rods. As the anchor cable machine shaft rotates, the turntable 54 rotates synchronously. At the same time, the turntable 54 is rotatably installed on the support column 52 through the second rotating shaft 53. It can adapt to the small radial swing or axial displacement that may occur during the rotation of the anchor cable machine shaft, play a flexible buffering role, and prevent workpiece damage or support failure caused by rigid contact.

[0026] Example 3: like Figures 7-11As shown, to better adapt to anchor cable winch shafts of different diameters, the worm 36 can be divided into a first worm 361 and a second worm 362. The first worm 361 is fixedly connected to the motor 41, and its length direction is the front-to-back direction. A cross shaft 8 is fixedly installed at the front end of the first worm 361, and the second worm 362 is slidably installed outside the cross shaft 8. Multiple round holes are provided at both ends of the cross shaft 8, and limit blocks 10 are detachably installed in the round holes. The limit blocks 10 have countersunk holes, and countersunk bolts are used to fix them in the countersunk holes to limit the second worm 362. The axial movement of the two worm gears 362 enables the fixed connection or separation adjustment of the first worm gear 361 and the second worm gear 362. The support seat 31 at the rear end is fixedly connected to the slider 25, and the support seat 31 at the front end is slidably connected to the slider 25. The slider 25 is provided with a positioning mounting hole, and a guide block 9 is fixedly installed at the top front end of the slider 25. The guide block 9 is used to limit the forward and backward movement direction of the support seat 31 at the front end. The bottom of the support seat 31 at the front end is provided with a mounting hole, and a fastening bolt passes through the mounting hole. Position the mounting hole and thread it onto the slider 25. When welding anchor cable machine shafts of different diameters, loosen the fastening bolts between the slider 25 and the support seat 31 and between the cross shaft 8 and the second worm 362, releasing the lock on the support seat 31. The operator can manually push the support seat 31 at the front end in the front-back direction to change the distance between the two roller support components 3. Since the first worm 361 and the second worm 362 are slidably connected through the cross shaft 8, the second worm 362 can undergo axial displacement relative to the first worm 361 during the distance adjustment process, while the cross shaft 8 can still maintain effective torque transmission, ensuring that power can be continuously transmitted to the worm wheel 35 after the adjustment position. After the distance between the two support seats 31 is adjusted to the optimal support position that matches the length and diameter of the anchor cable machine shaft to be welded, tighten the fastening bolts again to fix the support seat 31 on the slider 25, thereby ensuring the rigidity of the support structure and the stability of the transmission during the welding process. This breaks through the limitations of traditional fixed-distance tooling, significantly improves the compatibility and versatility of the tooling for anchor cable machine shafts of different specifications, and reduces the development cost of special tooling.

[0027] Example 4: like Figure 12As shown, a dual AC motor speed synchronization control system is added to synchronize the speed of the AC motors 41 in the two sets of drive mechanisms 4 and perform power supply voltage stabilization and filtering. In actual welding conditions, rotational power is provided by independent AC motors 41. However, due to factors such as grid voltage fluctuations, deviations in motor characteristics, and differences in contact resistance between the rollers and the shaft on both sides, the actual output speeds of the two AC motors 41 are prone to deviation, which in turn leads to relative torsional stress at both ends of the anchor cable machine shaft. This can cause uneven weld thickness and weld offset, or even radial runout of the shaft, roller slippage, or tooling jamming in severe cases. A collaborative control scheme is constructed from two dimensions: power supply voltage stabilization and filtering and closed-loop speed synchronization control. This suppresses the causes of speed fluctuations at the root and eliminates dynamic speed differences through real-time feedback adjustment, ensuring that the dual motors maintain high-precision synchronous operation under all working conditions.

[0028] The electrical control system includes a control cabinet, a main controller, a first frequency converter, a second frequency converter, a speed detection unit, a power supply voltage regulation and filtering unit, an operation unit, and a protection unit. The main controller is preferably a programmable logic controller (PLC). The first frequency converter is electrically connected to an AC motor 41 located on one of the bases 1, and the second frequency converter is electrically connected to an AC motor 41 located on the other base 1. The main controller is communicatively connected to both the first and second frequency converters to control the start / stop status, rotation direction, and output speed of the two AC motors 41. The two AC motors 41 are three-phase AC asynchronous motors. The first and second frequency converters use vector control to adjust the speed of the corresponding AC motors 41. By changing the power supply frequency and the corresponding output voltage of the AC motors 41 through the frequency converters, the AC motors 41 can maintain a relatively stable output torque within a low speed range, thus meeting the requirements of low-speed, continuous, and stable rotation during the anchor cable shaft welding process. Due to the large mass of the anchor cable winch shaft, when both roller support assemblies 3 bear the load, if the two AC motors 41 are simply connected in parallel or operate at the same given frequency, the actual rotational speeds of the two roller support assemblies 3 may still deviate due to differences in the slip rate of the two AC motors 41, the transmission efficiency of the reducer 42, the meshing resistance of the worm gear 35 and worm 36, the contact pressure between the support wheel 33 and the anchor cable winch shaft, and the coefficient of friction. Even if the first and second frequency converters are set to the same output frequency, the actual rotational speeds of the two roller support assemblies 3 may still deviate. When the rotational speed deviation persists, one roller support assembly 3 may generate active traction, while the other roller support assembly 3 may generate relative resistance, thereby generating additional torque on the anchor cable winch shaft and potentially causing local sliding, axial movement, and changes in the welding position of the support wheel 33. Therefore, a closed-loop synchronous control method based on actual rotational speed feedback is adopted, rather than relying solely on setting the two frequency converters to the same frequency to achieve open-loop synchronization.

[0029] Speed ​​detection units are respectively installed on the rotating components connecting the two AC motors 41. The speed detection units are preferably rotary encoders. The first rotary encoder is used to detect the actual speed of the first AC motor, and the second rotary encoder is used to detect the actual speed of the second AC motor. The rotary encoders are mounted on the output shaft of the reducer 42. The detected speed signals can further reflect the actual mechanical transmission state after the reducer 42, reducing the possibility of failing to identify transmission abnormalities in the reducer 42 by only detecting the motor shaft speed. The first and second rotary encoders respectively send pulse signals to the main controller. The main controller calculates the actual speeds corresponding to the two roller support components 3 based on the number of pulses received per unit time, and obtains the first actual speed. Second actual speed The main controller generates the target rotation speed based on preset welding process parameters. One AC motor is set as the master drive motor, and the other AC motor is set as the slave drive motor. The master drive motor is set according to the target speed. The drive motor operates simultaneously according to the target speed. The main controller dynamically compensates for the actual speed difference between the master and slave drive motors according to... Calculate the speed deviation between the two drive mechanisms 4, when the speed deviation When the speed is within the preset allowable range, the first and second frequency converters maintain the current output state. When the speed deviation exceeds the preset allowable range, the main controller corrects the output frequency of the frequency converter corresponding to the slave drive motor according to the positive or negative direction of the speed deviation. When the actual speed of the slave drive motor is lower than that of the main drive motor, the output frequency of the slave drive motor is increased; when the actual speed of the slave drive motor is higher than that of the main drive motor, the output frequency of the slave drive motor is decreased, so that the two AC motors 41 are brought back to a state of synchronization. The speed compensation adopts a proportional-integral control method, based on the speed difference. The compensation amount is calculated based on the duration of the error, reducing instantaneous speed deviation while eliminating long-term steady-state deviation. This prevents the drive motor from operating at a slightly higher or lower speed than the main drive motor for extended periods after load changes. To avoid frequent inverter adjustments caused by pulse fluctuations due to electromagnetic interference from the rotary encoder, the main controller calculates the compensation amount based on the first actual speed. Second actual speed Digital filtering is performed, which can be done using a moving average filtering method. After obtaining multiple speed sampling values ​​continuously, the average value is calculated and used as the effective speed value for the current control cycle. This filters out abnormal sampling values ​​caused by transient interference, making the frequency correction process of the two frequency converters smoother. The two AC motors 41 adopt a low-speed start and slow acceleration mode. After the operator inputs the target rotation speed through the operation unit, the main controller first controls the first and second frequency converters to start simultaneously and gradually increases the output frequency according to the preset acceleration curve, so that the two AC motors 41 can accelerate smoothly from a stationary state to the target running speed. This can prevent the AC motors 41 from generating a large impact torque when starting instantaneously, thereby avoiding instantaneous slippage between the support wheel 33 and the anchor cable machine shaft.

[0030] During the startup phase, the main controller also performs synchronous judgment on the startup process of the two AC motors 41, and continuously compares the first actual speed. Second actual speed When the speed difference between the two exceeds the preset start-up allowable value and continues for more than the preset time, it is determined that the two drive mechanisms 4 have a starting asynchronous phenomenon. At this time, the side with the higher speed is restricted from continuing to accelerate, while the acceleration rate of the side with the lower speed is increased. After the actual speed of the two AC motors 41 returns to the allowable deviation range, they accelerate together to the target speed. Therefore, it can prevent a large mechanical drag effect when one AC motor 41 has already driven the anchor cable machine shaft to rotate, while the other AC motor 41 has not yet established an effective driving force. After the anchor cable machine shaft enters a stable rotation state, the main controller continuously collects the feedback signals of the two rotary encoders and performs real-time speed synchronization correction on the two AC motors 41. The allowable error of the speed synchronization of the two AC motors 41 can be set within ±0.5% of the target speed.

[0031] To improve the power supply quality of the entire electrical control system, a power supply voltage regulation and filtering unit is installed. This unit is positioned between the external AC power supply and the first, second, and main controller frequency converters. It suppresses voltage fluctuations, transient pulses, high-frequency interference, and electromagnetic interference generated by the welding equipment in the input power supply. The external three-phase AC power supply first passes through a circuit breaker and an AC input filter before supplying power to the first and second frequency converters. The AC input filter can employ a surge absorber to attenuate high-frequency common-mode interference, differential-mode interference, and transient surges in the power grid. Since the welding equipment may generate strong transient interference to the power grid during arc initiation, arc termination, or rapid current changes, installing a filter and surge suppression structure at the frequency converter input reduces the probability of such interference entering the frequency converter power circuit and causing frequency converter malfunctions or abnormal encoder feedback signals. In environments with significant external power supply voltage fluctuations, an automatic voltage regulator is installed on the AC input side. When a certain fluctuation in the input voltage is detected, the automatic voltage regulator compensates for the input voltage, ensuring that the power supplied to the first and second frequency converters remains within the allowable operating range. This prevents insufficient output torque of the AC motor 41 due to a continuously low input voltage, and also prevents the frequency converter from triggering overvoltage protection due to excessively high input voltage. Both the first and second frequency converters have internal rectifier circuits and DC bus filter circuits. After rectification, the AC power is converted to DC power. The filter capacitor on the DC bus smooths the rectified DC power, which is then converted back to an adjustable frequency by the inverter module according to the frequency and voltage given by the main controller. The three-phase AC power supply provides power to the corresponding AC motors 41. Through rectification, DC filtering, and inverter modulation, the direct impact of small fluctuations in external AC voltage on the actual speed of the motors can be reduced, enabling the two AC motors 41 to obtain a relatively stable drive power supply. The main controller, rotary encoder, and operating unit are preferably powered by an independent low-voltage DC control power supply. The low-voltage DC control power supply is output from the AC power supply after isolation transformation, rectification, filtering, and voltage regulation, and can provide a stable 24V DC power supply to the main controller and sensors. The output of the control power supply can also be equipped with capacitor filtering, common-mode filtering, and transient voltage suppressors to reduce electromagnetic interference generated by the AC motors 41, frequency converters, and welding equipment from entering the control loop. The encoder signal line preferably adopts... Shielded twisted-pair cable is used, and power lines are laid separately from low-voltage signal lines to further improve the anti-interference capability of the speed feedback signal. The main controller can also collect the output current or torque signals fed back by the first and second frequency converters and use them as auxiliary judgment criteria for the load status of the two drive mechanisms 4. Under normal conditions, since the two roller support assemblies 3 share the rotational driving force of the anchor cable machine shaft, the loads of the two AC motors 41 should be in a relatively close state. When the current of one AC motor 41 is significantly higher than that of the other AC motor 41, it may indicate that the contact pressure between the corresponding support wheel 33 and the anchor cable machine shaft is too large, there is abnormal resistance between the worm gear 35 and the worm 36, or the other support wheel 33 is malfunctioning. If slippage occurs, the main controller can first reduce the overall system speed without immediately stopping the machine, and redistribute the output of the two AC motors 41. When the current difference or speed difference continues to exceed the set safety range, the main controller will then control both frequency converters to stop output simultaneously. To prevent one AC motor 41 from failing while the other continues to drive the anchor cable machine shaft, a dual-motor interlocking protection method is adopted. When the first or second frequency converter experiences overcurrent, overvoltage, undervoltage, overheating, phase loss, encoder malfunction, or communication failure, the corresponding fault signal is sent to the main controller. The main controller simultaneously sends a deceleration and stop command to both frequency converters, causing the two AC motors 41 to stop synchronously according to the set deceleration curve.The system is only allowed to restart when both frequency converters are in normal operating condition and both speed detection units provide valid feedback signals.

[0032] An emergency stop switch is installed in the control cabinet or operating position. When the operator finds that the anchor cable machine shaft moves abnormally, the support wheel 33 slips, the welding torch comes into abnormal contact with the workpiece, or other dangerous situations, the main controller or safety control circuit will immediately cut off the drive output of the two AC motors 41 by pressing the emergency stop switch. Before the emergency stop is released, the two AC motors 41 remain in a prohibited start state to improve the safety of the welding operation.

[0033] In the embodiments disclosed in this invention, the terms "installation," "connection," "linking," and "fixing" should be interpreted broadly. For example, "connection" can be a fixed connection, a detachable connection, or an integral connection; "linking" can be a direct connection or an indirect connection through an intermediate medium. Those skilled in the art can understand the specific meaning of the above terms in the embodiments disclosed in this invention according to the specific circumstances.

[0034] This specific embodiment is merely an explanation of the present invention and is not intended to limit the invention. After reading this specification, those skilled in the art can make modifications to this embodiment without contributing any inventive step, but such modifications are protected by patent law as long as they are within the scope of the claims of the present invention.

Claims

1. A welding fixture for anchor cable winch shafts, comprising a base (1), characterized in that: The base (1) has two spaced left and right. The top of the base (1) is provided with a linear slide assembly (2) and a drive mechanism (4) arranged in front and back. The length direction of the linear slide assembly (2) is the front and back direction. The linear slide assembly (2) is used to adjust the axial position of the anchor cable machine shaft to be welded. The top of the linear slide assembly (2) is provided with a roller support assembly (3). The roller support assembly (3) is used to support the anchor cable machine shaft to be welded. The drive mechanism (4) is connected to the roller support assembly (3) for transmission. The drive mechanism (4) is used to drive the roller support assembly (3) to rotate, thereby driving the anchor cable machine shaft to be welded to rotate around its axis, which facilitates the all-round welding operation on the outer circumference of the anchor cable machine shaft.

2. The anchor cable winch shaft welding fixture according to claim 1, characterized in that: The roller support assembly (3) includes a support base (31), a first rotating shaft (32), a support wheel (33), a bushing (34), a worm gear (35), and a worm (36). The length direction of the support base (31) is the front-to-back direction. The interior of the support base (31) is a hollow structure. The bottom end of the support base (31) is provided with a second through hole that extends from front to back. The bushing (34) is fixedly installed in the second through hole. The worm (36) passes through the bushing (34), and the bushing (34) and the worm (36) are connected. The worm (36) is movably connected to the worm (36), and the axial direction of the worm is the front-to-back direction. The top of the support base (31) is symmetrically provided with a third through hole that runs through the left and right sides. A first rotating shaft (32) is rotatably installed in each of the third through holes. The axis of the first rotating shaft (32) is collinear with the axis of the third through hole. A worm wheel (35) is fixedly installed on each of the first rotating shafts (32). The worm wheel (35) is installed in conjunction with the worm (36). Support wheels (33) are fixedly installed at both ends of the first rotating shaft (32).

3. The anchor cable machine shaft welding fixture according to claim 2, characterized in that: The linear slide assembly (2) includes a frame (21), a lead screw (22), a movable seat (23), a guide rail (24), and a slider (25). The frame (21) is fixedly installed at the top front end of the base (1). The length direction of the frame (21) is the front-back direction. The left and right ends of the top of the frame (21) are fixedly installed with guide rails (24). The front end of the frame (21) is provided with a first through hole. The lead screw (22) is rotatably installed in the first through hole. The axis direction of the lead screw (22) is the front-back direction. The rear end of the lead screw (22) extends backward and is rotatably connected to the frame (21). The movable seat (23) is screwed onto the lead screw (22). The top of the movable seat (23) is fixedly installed with a slider (25). The bottom of the slider (25) is slidably connected to the guide rail (24). The top of the slider (25) is fixedly connected to the bottom of the support seat (31).

4. The anchor cable winch shaft welding fixture according to claim 1, characterized in that: The drive mechanism (4) includes a motor (41), a reducer (42), a mounting plate (43), and a coupling (44). The mounting plate (43) is fixedly installed at the top rear end of the base (1). The reducer (42) is fixedly installed at the rear end of the mounting plate (43). The input end of the reducer (42) is connected to the output shaft of the motor (41). The output end of the reducer (42) extends forward to the front end of the mounting plate (43). The output shaft of the reducer (42) is fixedly installed with a coupling (44). The other end of the coupling (44) is fixedly connected to a worm gear (36).

5. The anchor cable winch shaft welding fixture according to claim 3, characterized in that: The front end of the lead screw (22) extends forward to the outside of the frame (21), and an adjusting handwheel (6) is fixedly installed at the front end of the lead screw (22).

6. The anchor cable winch shaft welding fixture according to claim 1, characterized in that: The base (1) has integrally formed fixing plates (7) on both the left and right sides of its bottom end.

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