Semi-automatic turnout base plate welding production line

Abstract

The semi-automatic turnout base plate welding production line comprises an upper computer, a robot controller, a PLC, a welding power source and a carrying robot. The transfer robot is arranged in the center of the production line layout; two parallel chain plate conveying lines are symmetrically arranged on the two sides of the carrying robot, and the carrying robot is arranged on the symmetric center line of the chain plate conveying lines. Manual grouping platforms are arranged at the starting ends of the two chain plate conveying lines correspondingly, welding platforms are arranged at the tail ends of the two chain plate conveying lines correspondingly, and the welding platforms are provided with welding robots; a feeding frame is arranged at the symmetrical center line position of the two manual team forming platforms. And a finished product pad is arranged at the symmetrical center line position of the two welding platforms. A semi-automatic production scheme combining manual assembly and automatic welding is adopted, semi-automatic welding production of turnout base plate products of various types, full specifications and complex structures is achieved, the turnout base plate welding production efficiency and the product quality are improved, and a new thought is provided for the industrial intelligent and automatic manufacturing technology.

Description

Technical Field

[0001] The utility model belongs to the technical field of welding production of operating transportation turnout pads, and in particular relates to a semi-automatic turnout pad welding production line. Background Art

[0002] Turnout pads are key components of railway turnouts, supporting the track and positioning the rails, requiring high precision. The basic structure of a turnout pad consists of a base plate and small fasteners, connected together by welding. Therefore, the quality of the welds directly affects the pad's quality and is closely linked to the safety of railway line operations.

[0003] Railway turnouts have complex structures and require a wide variety of pad types and specifications, including flat pads, slide bed pads, switch pads, frog pads, and guardrail pads. Furthermore, high dimensional accuracy requirements are required for products, resulting in heavy production tasks for factories and great difficulty in processing and manufacturing.

[0004] At present, the assembly and welding process of turnout pad components mainly rely on two methods: manual or automated welding. The manual production method is labor-intensive and requires a high level of skill from welders. The welding quality is greatly affected by human factors, resulting in low production efficiency and unstable product quality of pad products. The fully automated welding production method of turnout pads can only cover a small number of pad products with simple structures and uniform specifications. In addition, the excessive pursuit of automation of the entire production process can easily lead to unreasonable production process settings. Specifically, the loading and unloading of pad components and the positioning and assembly of components are cumbersome and time-consuming, resulting in poor continuity of production steps, unstable time rhythm, and the inability to improve production efficiency. In this regard, the following improved technical solutions are proposed. Utility Model Content

[0005] The technical problem solved by the utility model is to provide a semi-automatic turnout pad welding production line, which adopts a semi-automatic production solution combining manual assembly and automatic welding to realize the semi-automatic welding production of complex structure turnout pad products of various types and full specifications, thereby improving the turnout pad welding production efficiency and product quality.

[0006] The technical solution adopted by the utility model is a semi-automatic turnout pad welding production line, which includes a host computer, a robot controller, a PLC controller and a welding power supply.

[0007] It also includes a handling robot; the handling robot is arranged at the center of the production line layout; two parallel chain conveyor lines are symmetrically arranged on both sides of the handling robot, and the handling robot is arranged on the symmetrical center line of the chain conveyor line; manual teaming platforms are respectively set at the starting ends of the two chain conveyor lines, and welding platforms are respectively set at the ends of the two chain conveyor lines, and the welding platforms are equipped with welding robots; loading racks are set at the symmetrical center lines of the two manual teaming platforms; finished product material pads are set at the symmetrical center lines of the two welding platforms.

[0008] Among the above technical solutions, as the preferred technical solution of the present invention, an electromagnetic adsorption extension clamp is provided at the handling end of the handling robot; the electromagnetic adsorption extension clamp controls the clamp change through the PLC controller, which is used to grab the pad bottom plate and complete the pad bottom plate loading and pad finished product unloading.

[0009] In the above technical solution, as a further improvement of the present invention, a position sensor Ⅰ and a character recognition sensor are arranged on the chain conveyor line; the position sensor Ⅰ is used to detect whether the position of the pad to be welded reaches the pad character recognition detection position; the character recognition sensor is used to identify the characters of the pad to be welded, and is used to determine the type and specifications of the pad to be welded, and upload the character recognition results to the host computer. The host computer processes the character recognition results, and sends instructions to the welding robot and the handling robot through the robot controller 1 to execute the automatic welding program and the automatic unloading program corresponding to the pad characters.

[0010] In the above technical solution, as a further improvement of the present invention, the manual teaming platform is provided with a control button I and a status indicator light I; the control button I is used to manually control the loading process of the handling robot and the material transfer process of the chain conveyor line; the manual teaming platform is provided with a guide bar; the guide bar is used to accurately fix the position of the pad to be welded near the center axis of the chain conveyor line.

[0011] In the above technical solution, as a further improvement of the present invention, a semi-enclosed protective cover is provided on the outside of the welding robot; the host computer, robot controller, PLC controller, and welding power supply are arranged outside the protective cover and close to the manual teaming platform.

[0012] In the above technical solution, as a further improvement of the present invention, the welding position of the welding platform is provided with rollers, a position sensor II, a lifting device and a clamping device; the rollers are used to continuously and smoothly transport the pad to be welded to the welding position of the welding robot; after the position sensor II detects that the pad to be welded has reached the specified position, the lifting device lifts and fixes the position of the pad through the hole position of the pad bottom plate, and the clamping device clamps the pad bottom plate to complete the fixation of the welding operation position of the pad to be welded.

[0013] Among the above technical solutions, as the preferred technical solution of the present invention, the execution end of the welding robot is provided with a welding assembly; the welding assembly is connected to the welding power supply, the welding cooling water tank and the shielding gas delivery pipeline; the welding method of the welding robot is metal electrode gas shielded welding.

[0014] Among the above technical solutions, as the preferred technical solution of the present invention, both the welding robot and the handling robot are programmed through a teaching pendant.

[0015] In the above technical solution, as a further improvement of the present invention, a control button II and a status indicator light II are provided on the robot controller; the control button II is used by the operator to shut down the equipment in time in an emergency.

[0016] In the above technical solution, as a further improvement of the present invention, the manual teaming platform is equipped with a pad base plate pairing and positioning template, which is used for manually performing the pairing, spot welding, positioning and fixing operations of the pad base plate and parts.

[0017] The advantages of this utility model compared with the prior art are:

[0018] 1. The utility model combines the flexibility of manual operation with the high efficiency of the automated welding production line to realize the automated welding production of complex structure turnout pad products of various types and full specifications, thereby improving the welding production efficiency and product quality of turnout pads.

[0019] 2. This utility model can solve the problem of robotic automated industrial production of complex product categories through semi-automated production methods, and provides new ideas for industrial intelligence and automated manufacturing technology. BRIEF DESCRIPTION OF THE DRAWINGS

[0020] Figure 1 This is a schematic diagram of the layout structure of the semi-automatic turnout pad welding production line of the utility model;

[0021] Figure 2 For this utility model Figure 1 A schematic diagram of the enlarged structure of the welding platform;

[0022] Figure 3 This is a flow chart of the semi-automatic turnout pad welding production method related to the present utility model;

[0023] In the figure: 1-robot controller, 2-PLC controller, 3-welding power supply, 4-handling robot 4, 5-chain conveyor line, 6-manual team platform, 61-guide bar, 7-welding robot, 71-roller, 72-position sensor II, 73-lifting device, 74-clamping device, 8-loading rack, 9-finished product pad, 10-protective cover, 11-welding platform. DETAILED DESCRIPTION

[0024] The following is a combination of the appended examples of the present invention. Figure 1-3 The technical solutions in the embodiments of the present invention are clearly and completely described. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of them. All other embodiments derived by persons of ordinary skill in the art based on the embodiments of the present invention without creative effort shall fall within the scope of protection of the present invention.

[0025] A semi-automatic turnout pad welding production line, (such as Figure 1 The system (shown in FIG. 1 ) includes a host computer, a robot controller 1, a PLC controller 2, and a welding power source 3; it also includes a handling robot 4, a chain conveyor line 5, a manual teaming platform 6, a welding robot 7, a loading rack 8, and a finished product pad 9. Specifically, the welding power source is connected to the welding robot 7; the host computer is connected to the input of the PLC controller 2, the output of the PLC controller 2 is connected to the input of the robot controller 1, and the output of the robot controller 1 is connected to the welding robot 7 and the handling robot 4.

[0026] The operating principle is as follows: The host computer establishes a connection with the PLC controller 2 via Ethernet, serial communication, or wireless communication. As the monitoring and control center, the host computer is responsible for sending control instructions to the PLC controller 2 and receiving data and status information from it. The PLC controller 2 is connected to the robot controller 1 via an I / O interface, serial communication, or Ethernet communication. Based on the host computer's instructions and program logic, the PLC controller 2 sends control signals to the robot controller 1, achieving precise control of the welding robot 7 and the handling robot 4. The robot controller 1 is the core component of the welding robot 7 and the handling robot 4. It is responsible for receiving control signals from the PLC controller 2 and converting them into specific movement instructions for the welding robot 7 and the handling robot 4. The welding robot 7 and the handling robot 4 are connected to the robot controller 1 via cables or buses to transmit signals and execute control instructions. This connection method realizes a complete control chain from upper-level monitoring to lower-level execution, improving the overall performance and reliability of the system. The host computer provides a user-friendly human-machine interface, making it easy for operators to monitor and operate the welding robot 7 and the handling robot 4. As an intermediary, the PLC controller 2 enables precise control and data exchange with the robot controller 1, ensuring system stability and real-time performance. The robot controller 1 then focuses on controlling the specific actions of the welding robot 7 and the handling robot 4, improving control accuracy and efficiency.

[0027] (like Figure 1(as shown) also includes a handling robot 4; the handling robot 4 is located at the center of the production line layout; placing the handling robot 4 at the center of the production line can make the distance between it and each production station or processing area relatively balanced and short, thereby shortening the time and distance of material handling and improving the material flow efficiency of the entire production line. The central layout helps to achieve more efficient material scheduling and distribution, reduce waiting time during the production process, and improve the overall output rate of the production line. The handling robot 4 in the central position can maximize the use of production space through reasonable path planning and motion control, reduce the additional space occupied by material handling, and improve the space utilization rate of the production workshop. Placing the handling robot 4 at the center of the production line facilitates centralized monitoring and maintenance by operators and managers, allowing them to identify and resolve problems in a timely manner.

[0028] Two straight and parallel chain conveyor lines 5 are symmetrically arranged on both sides of the handling robot 4, and the handling robot 4 is set on the symmetrical center line of the chain conveyor lines 5. The chain conveyor lines 5 serve as the main channel for material transportation. Their parallel and symmetrical layout enables the materials to be smoothly and efficiently transported to the working area of ​​the handling robot. The handling robot 4 works between the two chain conveyor lines 5 and can complete the material handling task without moving long distances, thereby reducing idle time and energy consumption. This layout improves the parallel processing capability of the production line and greatly increases the material processing volume per unit time. The chain conveyor lines 5 are symmetrically arranged on both sides of the handling robot 4, making the layout of the entire production line more compact and reasonable, which not only saves production space, but also makes the overall appearance of the production line more neat and beautiful.

[0029] A manual assembly platform 6 is located at the starting end of each of the two chain conveyor lines 5, and a welding platform 11 is located at the end of each of the two chain conveyor lines 5. Each welding platform 11 is equipped with a welding robot 7. Loading racks 8 are located symmetrically at the midline of the two manual assembly platforms 6, and finished material pads 9 are located symmetrically at the midline of the two welding platforms 11. The installation of the manual assembly platforms 6 allows materials to be organized and placed onto the chain conveyor lines in an orderly and rapid manner during the loading phase. Operators can perform preliminary inspections and sorting of materials on the manual assembly platforms 6 to ensure they enter the production line in the correct direction and order. Because the loading racks 8 are located symmetrically at the midline of the two manual assembly platforms 6, operators can conveniently supply materials to both chain conveyor lines 5 simultaneously, reducing waiting time for loading and improving production efficiency. The chain conveyor lines 5 serve as a bridge for material transfer, tightly connecting the manual assembly platforms 6 and the welding robot 7. Driven by the chain conveyor lines 5, materials are automatically transferred to the welding robot 7 for welding, achieving a seamless transition in the production process. The flexibility and adaptability of the chain conveyor line 5 allow the production process to be adjusted according to actual needs: for example, when the welding robot 7 on one side fails or requires maintenance, the operator can quickly adjust the running direction or speed of the chain conveyor line to ensure that the welding robot 7 on the other side can continue to work and maintain the continuity and stability of the production line. Handing over the welding work to the welding robot 7 can reduce manual intervention and human errors. At the same time, the welding robot 7 can work in harsh environments, reducing the labor intensity and risks of workers. The setting of the finished material pad 9 allows the welded switch pads to be stored and stacked in an orderly manner. This not only facilitates the management and inventory of finished products, but also provides convenience for subsequent packaging, transportation and other processing links. The finished material pad 9 is located at the symmetrical midline position of the two welding robots 7, so that the finished products can be stored in a centralized manner and maximize the use of space resources. This layout method also helps to reduce the distance and time cost of material handling.

[0030] In the above embodiment, as a preferred embodiment of the present invention, the handling end of the handling robot 4 is provided with an electromagnetic adsorption extension clamp; the electromagnetic adsorption extension clamp controls the clamp change through the PLC controller 2, and is used to grab the pad bottom plate and complete the pad bottom plate loading and pad finished product unloading.

[0031] The electromagnetic adsorption extension clamp utilizes electromagnetic principles to rapidly adsorb and release the pad base. This non-contact gripping method not only improves gripping efficiency but also avoids material damage that can be caused by traditional mechanical clamps. Through precise control by the PLC controller 2, the electromagnetic adsorption extension clamp accurately identifies and grasps the pad base, ensuring accurate and stable material handling. The PLC controller 2 supports automated control of fixture changes, enabling the handling robot to quickly change fixture types to accommodate pad bases of varying sizes, shapes, and weights based on varying production requirements. Automated handling and fixture changes reduce manual intervention and labor costs, lowering the company's operating costs. The electromagnetic adsorption extension clamp and PLC controller 2 typically utilize a modular design for easy maintenance and replacement. Furthermore, programming and maintenance of the PLC controller 2 are relatively simple, reducing technical barriers and maintenance costs. The electromagnetic adsorption extension clamp can adapt to pad bases of varying materials, sizes, and shapes, demonstrating its high adaptability.

[0032] In the above embodiment, as a further improved embodiment of the present invention, a position sensor I and a character recognition sensor are provided on the chain conveyor line 5; the position sensor I is used to detect whether the position of the pad to be welded reaches the pad character recognition detection position; the character recognition sensor is used to identify the characters of the pad to be welded, to determine the type and specifications of the pad to be welded, and to upload the character recognition results to the host computer, the host computer processes the character recognition results, and sends instructions to the welding robot 7 and the handling robot 4 through the robot controller 1 to execute the automatic welding program and automatic unloading program corresponding to the pad characters.

[0033] Position Sensor I detects the position of the underlay plate to be welded in real time, ensuring that it triggers the character recognition sensor to perform character recognition when it reaches the designated position. This fully automated process requires no human intervention, significantly improving production efficiency. After the character recognition sensor identifies the characters on the underlay plate to be welded, it transmits the results to the host computer. Based on the recognition results, the host computer sends instructions to the welding robot and handling robot via the robot controller to execute the automatic welding and unloading procedures corresponding to the underlay plate characters. This process is fully automated from detection to execution. The character recognition sensor accurately identifies the characters on the underlay plate to be welded, thereby determining the type and specifications of the underlay plate. This precise recognition capability eliminates potential errors caused by human judgment and ensures accurate and consistent production. Based on the character recognition results, the welding robot and handling robot execute the corresponding welding and unloading procedures, enabling customized production of underlay plates of different types and specifications. Through real-time monitoring and recognition, underlay plates to be welded can be quickly transferred to the next production stage, reducing time wasted waiting for recognition or sorting. Automated detection and recognition reduce the level of human intervention and the reliance on skilled labor.

[0034] In the above embodiment, as a further improved embodiment of the present utility model, the manual teaming platform 6 is provided with a control button I and a status indicator light I; the control button I is used to manually control the loading process of the handling robot 4 and the material transfer process of the chain conveyor line 5; the manual teaming platform 6 is provided with a guide bar 61; the guide bar 61 is used to accurately fix the position of the pad to be welded near the central axis of the chain conveyor line 5.

[0035] The operator can conveniently control the loading process of the handling robot 4 and the material transfer process of the chain conveyor line 5 using the manual control button I. This direct control method makes operation more intuitive and convenient, while also improving control precision and accuracy. The status indicator I provides real-time information on the operating status of the handling robot and chain conveyor line, helping the operator to promptly understand production status and make appropriate adjustments. This visual feedback mechanism improves the controllability and safety of the production process. The guide bar 61 is designed to accurately fix the backing plate to be welded near the center axis of the chain conveyor line 5. This design ensures that the backing plate maintains a stable posture and position during transportation, avoiding welding errors or quality issues caused by positional deviation. It also simplifies the handling robot's grasping and positioning process, improving production efficiency and accuracy. The control button I and status indicator I on the manual teaming platform 6 combine manual control with automated production, retaining the flexibility and accuracy of manual intervention while leveraging the efficiency and stability of automated production. This combination makes the production line more flexible and reliable, able to adapt to changing production needs. The control button I and status indicator light I are also designed with production line safety in mind. Operators can use control button I to stop the transport robot 4 and chain conveyor line 5 at any time to avoid unexpected situations. Furthermore, the real-time feedback from status indicator I helps operators identify potential safety hazards and take appropriate measures.

[0036] In the above embodiment, as a further improved embodiment of the present invention, a semi-enclosed protective cover 10 is provided on the outside of the welding robot 7; the host computer, the robot controller 1, the PLC controller 2, and the welding power supply 3 are arranged on the outside of the protective cover 10 and close to the manual team platform 6.

[0037] The semi-enclosed protective housing 10 provides a physical barrier for the welding robot 7, effectively preventing spatter, high-temperature sparks, and other materials generated during the welding process from directly harming operators or other equipment, significantly reducing safety risks at the production site. Key equipment, including the host computer, robot controller 1, PLC controller 2, and welding power supply 3, is located outside the protective housing 10, close to the manual teaming platform 6. This not only facilitates operator monitoring and maintenance, but also prevents these precision devices from being directly exposed to the harsh welding environment, reducing equipment failure and damage caused by environmental factors. Pollutants such as smoke and harmful gases generated during the welding process are partially isolated by the protective housing, reducing their impact on the production environment and helping to maintain a clean and tidy production site. The noise generated by the welding robot 7 during operation is also partially absorbed and isolated by the protective housing 10, reducing the noise level at the production site and providing a more comfortable working environment for the operator. The design of the protective housing 10 reduces interference from external factors, such as dust and moisture, on the welding robot 7 and its control equipment, thereby improving the reliability and stability of the equipment. Placing key equipment outside the protective housing 10 allows operators to quickly access and operate these devices during routine maintenance and overhaul, improving maintenance convenience and efficiency. If an abnormality occurs on the production line, operators can quickly intervene and make adjustments through the host computer or robot controller 1, ensuring continuous and stable production.

[0038] In the above embodiment, as a further improved embodiment of the present invention, the welding position of the welding platform 11 is provided with a roller 71, a position sensor II 72, a lifting device 73 and a clamping device 74; the roller 71 is used to continuously and smoothly transport the pad to be welded to the welding position of the welding robot 7; after the position sensor II 72 detects that the pad to be welded has reached the specified position, the lifting device 73 lifts and fixes the pad position through the position of the pad bottom plate hole, and the clamping device 74 clamps the pad bottom plate to complete the fixation of the welding operation position of the pad to be welded.

[0039] The continuous and smooth transport of rollers 71 ensures that the backing plate to be welded reaches the welding position of the welding robot 7 accurately and precisely. This transport method not only improves production efficiency but also ensures the stability and consistency of the backing plate during transport, laying a good foundation for subsequent welding operations. Position sensor II 72 detects the position of the backing plate to be welded in real time and issues a signal when it reaches the designated position. This precise position detection capability ensures the accuracy and reliability of the welding operation and avoids welding quality issues caused by position deviation. Upon receiving the signal from position sensor II 72, the lifting device 73 quickly activates, lifting the backing plate to a certain height and securing it through the holes in the backing plate base. This securing method is not only stable and reliable, but also adapts to backing plates of different specifications and sizes, improving the flexibility and adaptability of the welding operation. After the backing plate is lifted to the designated position and secured, the clamping device 74 immediately clamps the backing plate base, further ensuring its stability and position during the welding process. This dual securing method significantly improves the accuracy and reliability of the welding operation. The coordinated operation of roller 71, position sensor II 72, lifting device 73, and clamping device 74 enables the welding robot to quickly and accurately transport, position, and secure the backing plate to be welded, improving the efficiency of the welding operation while ensuring the stability and consistency of the welding quality. The entire welding process is highly automated, reducing the need for manual intervention and the possibility of error, which not only reduces labor intensity but also improves production efficiency and product quality. By adjusting the operating parameters of lifting device 73 and clamping device 74, the system can adapt to welding operations on backing plates of different specifications and sizes. This flexibility allows the production line to easily respond to changes in production requirements for different products. Because the entire welding process is highly automated and standardized, the production line can quickly respond to changes in market demand and adjust production plans and product specifications to meet customer needs.

[0040] In the above embodiment, as a preferred embodiment of the present utility model, the execution end of the welding robot 7 is provided with a welding assembly; the welding assembly is connected to the welding power supply 3, the welding cooling water tank and the shielding gas delivery pipeline; the welding method of the welding robot 7 is metal arc welding.

[0041] The use of MIG / MAG welding creates smooth, uniform welds with an aesthetically pleasing appearance, reducing the workload of subsequent grinding and finishing. Welding robot 7 can operate continuously without interruption, unconstrained by fatigue or rest periods, significantly improving production efficiency. MIG / MAG welding boasts a high welding speed, enabling the completion of numerous welding tasks in a short period of time. Using built-in programs and sensors, welding robot 7 automatically identifies welding positions and adjusts welding parameters, achieving fully automated welding. Automated welding reduces the need for manual operation and reduces the impact of human factors on welding quality. MIG / MAG welding uses an inert gas (such as argon and helium) as a shielding gas, effectively preventing harmful reactions such as oxidation and nitridation during the welding process and protecting welding quality. Automated welding reduces the generation of pollutants such as welding fume and spatter, improving the working environment and reducing health hazards to operators. The modular design of the welding assembly facilitates installation, maintenance, and replacement. The welding cooling water tank promptly cools the welding gun tip, maintaining the stability of the welding process and extending the service life of the equipment. The shielding gas delivery pipeline ensures a stable supply of shielding gas and avoids gas interruption problems during welding.

[0042] In the above-described embodiment, as a preferred embodiment of the present invention, both the welding robot 7 and the handling robot 4 are programmed using a teach pendant. Teach pendant programming allows operators to intuitively create instructions and work paths by physically moving the robot or using a control device. This eliminates the need for in-depth programming knowledge, lowering the skill threshold and enabling even non-professionals to quickly master operating techniques. Due to the intuitiveness and ease of use of teach pendant programming, operators can quickly become familiar with and master programming methods, shortening training cycles and improving production efficiency. Teach pendant programming allows operators to instantly modify and optimize programs after field trial and error. This flexibility enables the robots to quickly adapt to changes in production lines or new product production requirements, reducing downtime and production delays. Whether for simple assembly tasks or complex operations such as welding and handling, teach pendant programming provides an effective solution. Compared to traditional manual or text-based programming, teach pendant programming significantly increases programming speed. Operators can quickly get the equipment running and conduct field trial and error and debugging, thereby shortening the programming cycle. Because teach pendant programming reduces the skill requirements for operators, companies can reduce their reliance on professional programmers and lower labor costs. At the same time, efficient programming methods also help improve production efficiency and product quality, further reducing production costs. Teach-in programming provides a safe and effective solution. Through pre-set programs and paths, robots can accurately and stably complete tasks, avoiding casualties and property damage. Teach-in programming ensures the robot's precision and stability when performing tasks. Through repeated teaching and optimization, the robot can perform operations according to predetermined paths and parameters, improving work quality and consistency. Teach-in programming is often closely integrated with the robot's control system, facilitating integration with other equipment and systems. Teach-in programming programs are easy to copy, edit, and transfer. When equipment malfunctions or requires adjustment, technicians can quickly locate the problem and modify the program to ensure normal operation and production efficiency.

[0043] In the above embodiment, as a further improvement of the present invention, the robot controller 1 is provided with a control button II and a status indicator light II. The control button II is used by the operator to promptly shut down the equipment in an emergency, thereby improving operational safety. The control button II and status indicator light II provided on the robot controller 1 provide a means for the operator to promptly shut down the equipment in an emergency, providing significant technical advantages such as improved safety, enhanced emergency response capabilities, enhanced operator confidence, and facilitated troubleshooting and maintenance.

[0044] In the above technical solution, as a further improvement of the present invention, the manual teaming platform 6 is equipped with a pad bottom plate pairing and positioning template, and the pad bottom plate pairing and positioning template is used for manually performing the pairing, spot welding, positioning and fixing operations of the pad bottom plate and parts.

[0045] (like Figure 3 The present invention relates to a semi-automatic turnout pad welding production method, which is a production method of any of the semi-automatic turnout pad welding production lines, and the production method comprises the following steps:

[0046] Step 1: Check the power supply;

[0047] Step 2: Manually control automatic loading;

[0048] Step 3: Manual pairing;

[0049] Step 4: Manually control the conveying;

[0050] Step 5: Character recognition;

[0051] Step 6: Automatically transport to the welding position;

[0052] Step 7: Automatically position and fix the pad;

[0053] Step 8: Automatically weld the backing plate;

[0054] Step 9: After welding is completed, the clamping device and the lifting device are released;

[0055] Step 10: Automatic unloading;

[0056] Repeat steps 1 to 10 to achieve continuous semi-automatic welding production of pad products.

[0057] Complex pad products have many weld positions and a large total weld length. The semi-automatic turnout pad welding production method of the utility model is adopted. During the automatic welding process of the robot, the subsequent pads are manually assembled and spot-welded to ensure continuous feeding of the pads to be welded, eliminating the problems of long idle periods of the welding robot and discontinuous work processes caused by the fully automatic loading operation mode; the production rhythm is stable and the efficiency is improved.

[0058] In step 1: Check to ensure that the equipment, fixtures and various status indicators are working properly, place neatly stacked pad bottom plates on the loading rack 8, prepare the pad group to position the template and pad small parts, and power on the equipment when ready.

[0059] The preliminary inspection and preparation in step 1 ensure that the production process is in optimal condition at startup, reducing downtime caused by equipment failure or insufficient material preparation. Neatly stacked pallet bases can be quickly identified and grasped by the equipment, speeding up the production process. The accuracy of tooling fixtures and positioning templates is crucial to ensuring the accuracy of pallet assembly. Advance inspection and preparation ensure that these tools are in good condition, thereby avoiding errors during the assembly process and improving product quality. The normal operation of the status indicator light provides real-time feedback on the equipment status, allowing timely identification and resolution of problems and preventing defective products caused by equipment anomalies. A comprehensive inspection before equipment startup can promptly identify and eliminate potential safety hazards, such as aging electrical circuits and loose mechanical components, to ensure the safety of personnel and equipment during the production process.

[0060] In step 2: manually press the loading control button I, the handling robot 4 starts to move, and after scanning the stacked pallet base plate through 3D vision, it automatically grabs the pallet base plate and places it on the manual teaming platform 6.

[0061] The introduction of the handling robot 4 in step 2 significantly improves the degree of automation of the production line. Through preset programs and advanced sensor technology, the robot can independently complete the entire process from identification to grasping to placement, reducing the need for human intervention. 3D visual scanning technology provides the handling robot with high-precision recognition capabilities. By quickly capturing and analyzing information such as the shape, size, and position of the base plate, the robot can accurately select the target and grasp it, improving the accuracy and efficiency of the operation. The automated grasping and placement process avoids the errors and delays that may be caused by manual operation, ensuring the smooth progress of the production process. Automated operation reduces the chance of direct contact between personnel and heavy materials, and reduces the risk of accidental injury that may occur during the handling process. The use of handling robots reduces the demand for human resources, especially in the handling of heavy objects and repetitive labor, which helps companies reduce labor costs.

[0062] In step 3: with the help of the pad base plate assembly positioning template, the pad base plate and parts are manually assembled and spot welded.

[0063] Step 3: Using a positioning template for alignment ensures that each base plate and component assembly adheres to the same standards and requirements, ensuring consistent and stable assembly results. The positioning template simplifies tedious assembly steps, enabling operators to complete the alignment process more quickly. Furthermore, the markings and instructions on the template reduce operational complexity and improve operator efficiency. Due to the improved assembly precision, using a positioning template for alignment significantly reduces rework due to assembly errors, saving time and labor costs while also improving overall production efficiency. Precise alignment and spot welding ensure a secure and reliable connection between the base plate and components, enhancing the stability of the entire structure and playing a significant role in improving product lifespan and safety. The use of a positioning template ensures that the assembly results meet design requirements and regulatory standards, avoiding quality issues caused by improper assembly. The markings and positioning holes on the positioning template make quality control and inspection during the assembly process more intuitive and convenient, allowing operators to easily check that the assembly meets requirements and promptly identify and correct any issues. Using positioning templates for group operations helps to achieve standardized management of the production process. By establishing unified assembly standards and processes, companies can better control product quality and production efficiency.

[0064] In step 4: manually press the chain plate conveyor line start control button I, the chain plate conveyor line 5 starts to run, and the side of the base plate to be welded is close to the guide baffle 61, and the base plate to be welded is manually transferred to the chain plate conveyor line 5.

[0065] By manually pressing the start control button, the chain conveyor line 5 can respond quickly and start running. This process realizes the initial triggering of automation. While the chain conveyor line 5 is running, the bottom plate of the pad to be welded is manually placed accurately on the conveyor line. This human-machine collaborative working mode gives full play to the stability of the automated equipment and the flexibility of manual operation, and improves the overall working efficiency. The side of the bottom plate of the pad to be welded is placed close to the guide baffle 61. This design helps to achieve accurate positioning and guiding of the bottom plate of the pad, reducing the risk of offset and misalignment. Accurate positioning and guiding provide a good foundation for subsequent operations such as spot welding and fixation, which helps to improve the assembly accuracy and product quality of the entire production process. Through the conveying process of the chain conveyor line 5, the need for manual handling of heavy objects is reduced, thereby reducing the risk of personal injury caused by improper handling. As a mature conveying equipment, the chain conveyor line 5 has high stability and reliability, and can operate stably for a long time without failure or shutdown.

[0066] In step 5: when the position sensor I detects that the bottom plate of the pad to be welded reaches the detection position of the character recognition sensor, the chain plate conveyor line 5 stops conveying, and the character recognition sensor starts to recognize the character mark of the bottom plate of the pad.

[0067] The precise detection of position sensor I in step 5 ensures that the pad base is recognized only when it reaches a specific position, avoiding recognition errors caused by unstable position during movement. The pause in conveying on chain conveyor line 5 provides a stable recognition environment for the character recognition sensor, reducing vibration and interference caused by material movement, thereby improving recognition accuracy and reliability. Once position sensor I detects that the pad base has reached the specified position, the chain conveyor line can quickly respond and pause conveying. This efficient connection of the process reduces waiting time and improves overall production efficiency. The automatic recognition function of the character recognition sensor replaces traditional manual inspection methods, realizing the automation and intelligence of the production process, reducing labor costs and error rates. The character recognition sensor can recognize the character markings on different pad bases, which enables the production line to flexibly respond to the production needs of products of different models and specifications. By identifying the character markings on the pad base, the product can be uniquely identified and traced, helping to quickly locate the cause and take appropriate measures when problems arise.

[0068] In step 6: the character recognition sensor sends the character recognition result to the host computer and the robot controller 1. After the processing is completed, the chain plate conveyor line 5 starts to run and conveys the base plate to be welded to the working position of the welding robot 7.

[0069] In step 6, the information transmission between the character recognition sensor and the host computer and robot controller 1 is carried out in real time, ensuring the immediacy and accuracy of the recognition results. The host computer and robot controller 1 have powerful data processing capabilities and can quickly analyze and process the received character recognition results to provide accurate guidance for subsequent welding operations. The entire process achieves a high degree of automated control. From character recognition to the start and stop of the conveyor line, to the operation preparation of the welding robot, all are automatically completed through preset programs and algorithms, reducing the need for manual intervention. Through the coordinated work of the character recognition sensor and the chain conveyor line 5, the precise positioning of the bottom plate of the pad to be welded before welding can be ensured, providing a stable working environment for the welding robot. After receiving the signal that the processing is completed, the chain conveyor line 5 can start quickly and continue to transport materials, realizing the continuity and efficiency of the production process.

[0070] In step 7: after the position sensor II 72 of the welding robot 7 detects that the pad bottom plate has reached the designated welding operation position, the lifting device 73 fixes the pad bottom plate position through the pad bottom plate holes, and the clamping device 74 clamps the pad bottom plate to complete the fixation of the welding operation position of the pad to be welded.

[0071] The high-precision detection capability of the position sensor II 72 in step 7 ensures that the welding robot 7 can accurately identify the welding operation position reached by the pad bottom plate, providing a solid foundation for subsequent fixation and welding operations. The lifting device 73 is fixed through the holes on the pad bottom plate. This design not only improves the stability of the fixation, but also reduces the risk of displacement due to external forces. At the same time, the clamping action of the clamping device 74 further enhances the fixing effect of the pad bottom plate, ensuring that the position remains unchanged during the welding process. High-precision positioning and fixation reduce errors and deviations in the welding process. The entire process from the detection of the pad bottom plate to fixation to the welding operation has been automated, reducing the need for manual intervention, improving the level of automation in the production process, and reducing the risk of safety accidents caused by human factors.

[0072] In step 8, welding robot 7 automatically executes the welding program corresponding to the character markings on the backing plate, performing backing plate welding. Leveraging advanced control systems and sensor technology, welding robot 7 precisely controls various welding parameters, such as welding current, voltage, speed, and angle, ensuring welding accuracy. Compared to manual welding, welding robot 7 maintains highly consistent welding quality, avoiding deviations and defects caused by human factors, thereby improving overall product quality. Welding robot 7 can perform welding operations continuously and stably without the need for breaks or shifts, significantly improving production efficiency. Welding robot 7 can operate in harsh environments such as high temperatures and high smoke levels, reducing safety risks for workers. Utilizing high-quality mechanical structures and electrical components, welding robot 7 boasts high reliability and stability, enabling long-term, trouble-free operation. Through teach-in programming, welding robot 7 can precisely control a variety of complex movements and automatically select the corresponding welding program based on the character markings on the backing plate, enhancing production flexibility and adaptability. The automated production of welding robot 7 reduces reliance on manual labor and reduces labor costs.

[0073] In step 9: After welding is completed, the clamping device 74 and lifting device 73 are released. Automatic release of the clamping device 74 and lifting device 73 after welding is complete is a crucial step in the automated welding process. This seamless integration reduces the need for manual intervention and enhances the overall automation of the production process. Automated release enables rapid response, reduces wait time, and enables the next production step to proceed immediately, thereby improving overall production efficiency. The clamping device 74 and lifting device 73 were designed with precise control in mind. After welding is completed, they accurately release the clamping and securing mechanism on the backing plate, avoiding damage to the product caused by incomplete or excessive release. Automated release reduces workers' direct exposure to hazardous factors such as high temperature and high pressure, reducing the risk of industrial accidents. Timely release of the clamping device 74 and lifting device 73 also helps protect welding robots and other related equipment, preventing damage from prolonged stress or jamming. Automated release reduces the uncertainty and error associated with manual operation, reduces wear on the clamping and lifting devices, and thus extends the life of the equipment. Since the possibility of manual intervention and misoperation is reduced, the maintenance process of the automated release operation is also simplified accordingly, reducing maintenance costs and difficulty.

[0074] In step 10, handling robot 4 grabs the finished pad, automatically unloads it, and places it on the dedicated finished pad 9. Steps 1 through 10 are repeated to achieve continuous semi-automated welding production of pad products. The automated grabbing and unloading by handling robot 4, combined with the continuous welding operations by welding robot 7, enables continuous semi-automated production of pad products. This production method significantly improves production efficiency and reduces manual intervention and waiting time. Combined with automated unloading, it reduces workers' direct exposure to hazardous factors such as high temperatures and high pressures, reducing the risk of industrial accidents.

[0075] The above description demonstrates that this utility model combines the flexibility of manual labor with the efficiency of automated welding production lines to achieve automated welding production of a wide variety of complex turnout pads across a full range of specifications, improving both production efficiency and product quality. This utility model's design, through its semi-automated production approach, addresses the robotically automated industrial production of complex products, providing new insights into intelligent and automated industrial manufacturing.

[0076] It should be understood that although this specification is described according to one embodiment, this embodiment does not only include one independent technical solution. This narrative method of the specification is only for the sake of clarity. Those skilled in the art should regard the specification as a whole. The technical solutions in this embodiment can also be appropriately arranged and combined to form other embodiments that can be understood by those skilled in the art.

Claims

1. A semi-automatic turnout pad welding production line, characterized by: It includes a host computer, a robot controller (1), a PLC controller (2), and a welding power source (3); The invention also includes a handling robot (4); the handling robot (4) is arranged at the center of the production line layout; two parallel chain plate conveyor lines (5) are symmetrically arranged on both sides of the handling robot (4), and the handling robot (4) is arranged on the symmetrical center line of the chain plate conveyor line (5); a manual teaming platform (6) is respectively arranged at the starting end of the two chain plate conveyor lines (5), and a welding platform (11) is respectively arranged at the end of the two chain plate conveyor lines (5), and the welding platform (11) is equipped with a welding robot (7); a loading rack (8) is arranged at the symmetrical center line position of the two manual teaming platforms (6); and a finished material pad (9) is arranged at the symmetrical center line position of the two welding platforms (11).

2. The semi-automatic turnout pad welding production line according to claim 1 is characterized in that: The handling end of the handling robot (4) is provided with an electromagnetic adsorption extension clamp; the electromagnetic adsorption extension clamp controls the clamp change through a PLC controller (2) and is used to grasp the pad bottom plate and complete the pad bottom plate loading and pad finished product unloading.

3. The semi-automatic turnout pad welding production line according to claim 1 is characterized in that: A position sensor I and a character recognition sensor are provided on the chain plate conveyor line (5); the position sensor I is used to detect whether the position of the pad to be welded reaches the pad character recognition detection position; the character recognition sensor is used to identify the characters of the pad to be welded, to determine the type and specification of the pad to be welded, and to upload the character recognition results to the host computer, the host computer processes the character recognition results, and sends instructions to the welding robot (7) and the handling robot (4) through the robot controller (1) to execute the automatic welding program and the automatic unloading program corresponding to the pad characters.

4. The semi-automatic turnout pad welding production line according to claim 1 is characterized in that: The manual teaming platform (6) is provided with a control button I and a status indicator light I; the control button I is used to manually control the loading process of the handling robot (4) and the material transfer process of the chain plate conveyor line (5); the manual teaming platform (6) is provided with a guide bar (61); the guide bar (61) is used to accurately fix the position of the backing plate to be welded near the central axis of the chain plate conveyor line (5).

5. The semi-automatic turnout pad welding production line according to claim 1 is characterized in that: A semi-enclosed protective cover (10) is provided outside the welding robot (7); the host computer, the robot controller (1), the PLC controller (2), and the welding power supply (3) are arranged outside the protective cover (10) and close to the manual teaming platform (6).

6. The semi-automatic turnout pad welding production line according to claim 1 is characterized in that: The welding position of the welding platform (11) is provided with a roller (71), a position sensor II (72), a lifting device (73) and a clamping device (74); the roller (71) is used to continuously and smoothly transport the pad to be welded to the welding position of the welding robot (7); after the position sensor II (72) detects that the pad to be welded has reached the specified position, the lifting device (73) lifts and fixes the pad position through the pad bottom plate hole position, and the clamping device (74) clamps the pad bottom plate to complete the fixing of the pad to be welded welding operation position.

7. The semi-automatic turnout pad welding production line according to claim 1 is characterized in that: The execution end of the welding robot (7) is provided with a welding assembly; the welding assembly is connected to a welding power source (3), a welding cooling water tank and a shielding gas delivery pipeline; the welding method of the welding robot (7) is metal arc welding.

8. The semi-automatic turnout pad welding production line according to claim 1 is characterized in that: The welding robot (7) and the handling robot (4) are both programmed via a teaching pendant.

9. The semi-automatic turnout pad welding production line according to claim 1 is characterized in that: The robot controller (1) is provided with a control button II and a status indicator light II; the control button II is used by operators to shut down the equipment in time in an emergency.

10. The semi-automatic turnout pad welding production line according to claim 1, characterized in that: The manual teaming platform (6) is equipped with a pad base plate pairing and positioning template, and the pad base plate pairing and positioning template is used for manually performing pairing, spot welding, positioning and fixing operations between the pad base plate and parts.

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