Wire reel wire feeding monitoring device of welding robot

Abstract

The utility model relates to the technical field of welding, in particular to a welding wire reel wire feeding monitoring device of a welding robot, which comprises a welding wire reel, a wire feeding device for reducing scattering of tin beads, a wire shortage monitoring device and a controller, a welding wire is wound on a rotating shaft of the welding wire reel, and the wire shortage monitoring device comprises a detection shell and a photoelectric sensor. A wire lacking monitoring penetrating through hole is formed in the detection shell in a penetrating mode, the photoelectric sensor is of a U-shaped structure, the inner wall of one end of the top of the photoelectric sensor is a laser emitting end, the inner wall of the other end of the top of the photoelectric sensor is a laser receiving end, and the photoelectric sensor is electrically connected with the controller through a wire. According to the welding wire conveying device, welding wires are crushed while being evenly conveyed, welding defects caused by scattering of tin beads are reduced, in the conveying process, the welding wires are subjected to wire missing detection through cooperation of a wire missing monitoring penetrating through hole of the detection shell and a photoelectric sensor, and the welding quality defect caused by the wire missing problem is prevented; and potential damage to other parts of the welding robot is reduced.

Description

Technical Field

[0001] The utility model relates to the technical field of welding, in particular to a wire feeding monitoring device for a welding wire reel of a welding robot. Background Art

[0002] Welding robots are industrial robots specifically designed for welding operations, increasing productivity and improving working conditions. They are multi-purpose, reprogrammable, automatically controlled manipulators with three or more programmable axes, typically with a welding gun or welding (cutting) torch attached to the last axis. With technological advancements, modern welding robots have significantly improved stability and weld quality, while also reducing the risk of workers working in hazardous environments.

[0003] In the welding robot system, the wire reel is an important component. It is responsible for storing and transporting the welding wire to the welding area. It is used to store the coiled welding wire. During the welding process, the wire reel rotates to release the welding wire, ensuring continuous and uniform delivery of the welding wire to the wire feeding mechanism of the welding robot.

[0004] During soldering operations, since the tin wire contains flux, the flux will vaporize due to the rapid rise in temperature, and the tin beads will fly and adhere to the surrounding solder joints. During the wire reel feeding process of the welding robot, if the welding wire breaks, it will lead to subsequent weld defects, insufficient penetration, undercuts, etc., affecting the mechanical properties of the weld and reducing the appearance and intrinsic quality of the weld. When the welding wire is missing or broken, it will cause jamming in the wire feeding device. In severe cases, it may cause mechanical failure or even damage to components such as the wire feeding wheel. Sudden wire breakage or inconsistent wire feeding will lead to unstable welding arc, thereby causing unexpected burns or deformation to the workpiece surface, resulting in reduced production efficiency. Utility Model Content

[0005] The purpose of the utility model is to provide a wire feeding monitoring device for a welding robot to solve the problems raised in the above background technology.

[0006] To achieve the above objectives, the present invention provides the following technical solutions:

[0007] A wire feeding monitoring device for a welding robot comprises a wire reel, a wire feeding device for reducing tin ball scattering, a wire shortage monitoring device, and a controller. Welding wire is wound around a rotating shaft of the wire reel. The wire shortage monitoring device comprises a detection housing and a photoelectric sensor. The detection housing is arranged in a conical structure. A wire shortage monitoring through hole is formed in the detection housing. The photoelectric sensor is arranged in a U-shaped structure. The inner wall of one end of the top of the photoelectric sensor is a laser emitting end, and the inner wall of the other end is a laser receiving end. The photoelectric sensor is electrically connected to the controller via a wire.

[0008] The controller is provided with an audible and visual alarm via a wire connection.

[0009] As an optimal solution of the present invention, the wire reel is located on one side of the wire feeding device, and the wire feeding device includes a wire breaking component for reducing the scattering of tin balls and breaking the outer wall of the welding wire and a conveying component for conveying the welding wire, and the wire breaking component includes a first wire breaking driving gear, a second wire breaking driving gear, a wire breaking gear disc and a conveying wheel, the first wire breaking driving gear is fixedly connected with a first fixed shaft inside, the wire breaking gear disc is connected with the first fixed shaft away from the outer circumferential wall of one end of the first wire breaking driving gear, the second wire breaking driving gear is meshed and located directly below the first wire breaking driving gear, the second fixed shaft is fixedly connected inside the second wire breaking driving gear, the conveying wheel is connected with the second fixed shaft away from the outer circumferential wall of one end of the second wire breaking driving gear, and a wire breaking conveying groove is provided on the outer circumferential wall of the conveying wheel directly below the bottom of the wire breaking gear disc.

[0010] As a preferred solution of the present invention, the conveying assembly includes a first pushing wheel, a second pushing wheel, a first driving gear and a second driving gear, a third driving shaft is fixedly connected and penetrated inside the first driving gear, the first pushing wheel is located on the outer circumferential wall of the third driving shaft away from the first driving gear, the second pushing wheel is engaged and located at the bottom of the first pushing wheel, a fourth driving shaft is fixedly connected and penetrated inside the second pushing wheel, the second driving gear is located directly below the first driving gear and is connected to the outer circumferential wall of the fourth driving shaft away from the second driving gear, and a pushing channel for the welding wire to be pushed through is formed between the first driving gear and the second driving gear.

[0011] As a preferred solution of the present invention, the end of the first fixed shaft away from the wire breaking gear plate passes through the first wire breaking drive gear and is connected to the outside of the first fixed shaft. The first fixed shaft passes through the driving wheel and is connected to the driving motor through a coupling.

[0012] As a preferred solution of the present invention, the third drive shaft is away from the first pushing wheel and passes through the outside of the first driving gear and is connected to a driven wheel, and the driven wheel is connected to the driving wheel through a drive belt.

[0013] As a preferred solution of the present invention, the welding wire sequentially passes through the broken wire conveying groove, the pushing channel and the wire-missing monitoring through hole and extends to the outside thereof.

[0014] As a preferred solution of the present invention, the laser emitting end and the laser receiving end on the inner wall of one end of the top of the photoelectric sensor are located on both sides of the welding wire.

[0015] Compared with the prior art, the beneficial effects of the present invention are:

[0016] In response to the problems raised in the background technology, the present invention uses a wire reel in conjunction with a conveying assembly to uniformly convey the welding wire. During the conveying process, the wire breaking assembly breaks the welding wire to reduce and minimize the tin ball flying caused by flux vaporization, thereby improving welding quality and working environment, improving weld quality, and reducing welding defects caused by tin ball flying.

[0017] The first push wheel, second push wheel, first drive gear and second drive gear of the conveying assembly work together with the wire reel to evenly and continuously convey the welding wire to the welding area, ensuring that the welding wire travels in a straight line without bending or entanglement;

[0018] During the conveying process, the wire missing monitoring through-hole of the shell is detected and the photoelectric sensor is used to detect the wire missing. The inner wall of one end of the top of the photoelectric sensor is the laser emitting end, and the inner wall of the other end is the laser receiving end. The laser is emitted by the laser emitting end. Under normal circumstances, the laser receiving end receives the laser signal blocked by the welding wire. When the welding wire is missing or interrupted, the laser receiving end will receive the complete laser signal. The controller processes the signal of the photoelectric sensor and responds accordingly based on whether the missing welding wire is detected. The controller controls the sound and light alarm on it to alarm. Real-time monitoring can timely detect abnormal conditions of the welding wire, prevent welding quality defects caused by welding wire problems, improve production efficiency, reduce machine downtime caused by welding wire problems, improve overall production continuity, reduce maintenance costs, detect welding wire problems in advance, reduce potential damage to other components of the welding robot, save long-term maintenance costs, and has high compatibility and flexibility. The monitoring device can adapt to different types and specifications of welding wires, as well as different models of welding robots. BRIEF DESCRIPTION OF THE DRAWINGS

[0019] Figure 1 This is a three-dimensional diagram of the overall structure of the utility model;

[0020] Figure 2 This is a side view of the utility model wire shortage monitoring device;

[0021] Figure 3 This is the axonometric drawing of the photoelectric sensor of the utility model;

[0022] Figure 4 This is a top view of the wire breaking assembly of the utility model;

[0023] Figure 5 This is a top view of the conveying component of the present invention.

[0024] In the figure: 1. welding wire reel; 11. welding wire; 2. wire feeding device; 21. wire breaking assembly; 211. first wire breaking drive gear; 2111. first fixed shaft; 212. second wire breaking drive gear; 2121. second fixed shaft; 213. wire breaking gear disc; 214. conveying wheel; 2141. broken wire passing through conveying trough; 22. conveying assembly; 221. first pushing wheel; 222. second pushing wheel; 2221. fourth driving shaft; 223. first driving gear; 2231. third driving shaft; 224. second driving gear; 23. driving wheel; 24. driving motor; 25. driven wheel; 26. driving belt; 3. wire missing monitoring device; 31. detection shell; 311. wire missing monitoring through-hole; 32. photoelectric sensor. DETAILED DESCRIPTION

[0025] The technical solutions in the embodiments of the present invention will be described clearly and completely below in conjunction with the embodiments of the present invention.

[0026] Example

[0027] See also Figure 1-5 The utility model provides a technical solution: a wire feeding monitoring device for a welding robot, comprising a wire reel 1, a wire feeding device 2 for reducing tin ball scattering, a wire shortage monitoring device 3 and a controller. A welding wire 11 is wound on the rotating shaft of the wire reel 1, and the wire shortage monitoring device 3 comprises a detection shell 31 and a photoelectric sensor 32. The detection shell 31 is arranged in a conical structure, and a wire shortage monitoring through hole 311 is opened through the inside of the detection shell 31. The photoelectric sensor 32 comprises a U-shaped structure. The inner wall of one end of the top of the photoelectric sensor 32 is a laser emitting end, and the inner wall of the other end is a laser receiving end. The photoelectric sensor 32 is electrically connected to the controller through a wire; the laser emitting end and the laser receiving end on the inner wall of one end of the top of the photoelectric sensor 32 are located on both sides of the welding wire 11; an audible and visual alarm is provided on the controller through a wire connection.

[0028] It should be noted that, in this embodiment, the photoelectric sensor 32 is located at the exit of the wire-missing monitoring through-hole 311 of the detection housing 31. The wire-missing monitoring through-hole 311 of the detection housing 31 ensures that the welding wire runs in a straight line to avoid bending or entanglement. When the welding wire 11 passes through the wire-missing monitoring through-hole 311 of the detection housing 31 and passes between the laser emitting end and the laser receiving end, the signal emitted by the laser emitting end is blocked by the welding wire 11, and the laser receiving end receives the laser signal blocked by the welding wire 11.

[0029] When the welding wire 11 is missing or interrupted, the laser receiving end will receive the complete laser signal, the controller processes the signal of the photoelectric sensor 32, and responds accordingly based on whether the missing welding wire 11 is detected. The controller controls the sound and light alarm on it to sound an alarm, and real-time monitoring can promptly detect abnormal conditions of the welding wire 11;

[0030] Prevent welding quality defects caused by welding wire 11 problems, improve production efficiency, reduce machine downtime caused by welding wire 11 problems, improve overall production continuity, reduce maintenance costs, detect welding wire 11 problems in advance, reduce potential damage to other parts of the welding robot, save long-term maintenance costs, high compatibility and flexibility, the monitoring device can adapt to different types and specifications of welding wire, as well as different models of welding robots.

[0031] See also Figure 1 and 4 The wire reel 1 is located on one side of the wire feeding device 2. The wire feeding device 2 includes a wire breaking component 21 for breaking the outer wall of the welding wire 11 to reduce the scattering of tin beads and a conveying component 22 for conveying the welding wire 11. The wire breaking component 21 includes a first wire breaking driving gear 211, a second wire breaking driving gear 212, a wire breaking gear plate 213 and a conveying wheel 214. The first wire breaking driving gear 211 is fixedly connected with a first fixed shaft 2111 inside. The wire breaking gear plate 213 is connected to the outer circumferential wall of the first fixed shaft 2111 away from the first wire breaking driving gear 211, and the second wire breaking driving gear 212 is meshed with the first wire breaking driving gear 211. Located directly below the first wire-breaking drive gear 211, a second fixed shaft 2121 is fixedly penetrated inside the second wire-breaking drive gear 212, and the conveying wheel 214 is connected to the outer circumferential wall of the second fixed shaft 2121 away from the second wire-breaking drive gear 212. A wire-breaking conveying groove 2141 is provided on the outer circumferential wall of the conveying wheel 214 directly below the bottom of the wire-breaking gear disc 213; the first fixed shaft 2111 penetrates the first wire-breaking drive gear 211 at one end away from the wire-breaking gear disc 213 and is connected to the outside of the driving wheel 23. The first fixed shaft 2111 penetrates the driving wheel 23 and is connected to the driving motor 24 through a coupling.

[0032] It should be noted that, in this embodiment, the welding wire reel 1 cooperates with the conveying assembly 22 to uniformly convey the welding wire 11. During the conveying process, the welding wire 11 is broken by the wire breaking assembly 21 to reduce and minimize the scattering of tin beads caused by the vaporization of the flux, thereby improving the welding quality and working environment, improving the weld quality, and reducing welding defects caused by scattering of tin beads.

[0033] Furthermore, when the welding wire 11 passes through the wire-breaking conveying trough 2141, the wire-breaking gear plate 213 on the top thereof evenly breaks the top of the welding wire 11, and the driving motor 24 drives the first fixed shaft 2111 to rotate. When the first fixed shaft 2111 rotates, the first wire-breaking driving gear 211 and the wire-breaking gear plate 213 on it rotate. Since the first wire-breaking driving gear 211 is meshed with the second wire-breaking driving gear 212 on the second fixed shaft 2121, the first wire-breaking driving gear 211 is further driven to be connected to the second wire-breaking driving gear 212. The conveying wheel 214 on the second fixed shaft 2121 rotates. When the welding wire 11 passes through the wire breaking and conveying trough 2141, the wire breaking gear plate 213 on the top thereof evenly breaks the top of the welding wire 11. By uniformly breaking the welding wire 11, the scattering of tin beads is reduced, and the appearance and internal quality of the weld are improved. The systematic pretreatment 11 of the welding wire 11 reduces machine downtime caused by welding wire problems, improves production efficiency, and pretreatment reduces potential damage to welding equipment, saving long-term maintenance costs.

[0034] See also Figure 1 and 5 The conveying assembly 22 includes a first pushing wheel 221, a second pushing wheel 222, a first driving gear 223 and a second driving gear 224. The first driving gear 223 is fixedly connected with a third driving shaft 2231 inside. The first pushing wheel 221 is located on the outer circumferential wall of the third driving shaft 2231 away from the first driving gear 223. The second pushing wheel 222 is meshed and located at the bottom of the first pushing wheel 221. The second pushing wheel 222 is fixedly connected with a fourth driving shaft 2221 inside. The second driving gear 224 is located on the first driving gear The wheel 223 is directly below the outer circumferential wall of the fourth drive shaft 2221 away from the second drive gear 224, and a pushing channel for the welding wire 11 to be pushed through is formed between the first drive gear 223 and the second drive gear 224; the third drive shaft 2231 is away from the first pushing wheel 221 and passes through the outside of the first drive gear 223 and is connected to the driven wheel 25, and the driven wheel 25 is connected to the driving wheel 23 through the driving belt 26; the welding wire 11 passes through the broken wire through-conveying groove 2141, the pushing channel and the wire shortage monitoring through-hole 311 in sequence and extends to the outside thereof.

[0035] It should be noted that, in this embodiment, the first pushing wheel 221, the second pushing wheel 222, the first driving gear 223 and the second driving gear 224 of the conveying assembly 22 cooperate with the wire reel 1 to uniformly and continuously convey the welding wire 11 to the welding area, ensuring that the welding wire 11 travels in a straight line and avoids bending or entanglement.

[0036] Furthermore, one end of the first fixed shaft 2111 away from the wire breaking gear plate 213 passes through the first wire breaking driving gear 211 and is connected to the outside of the driving wheel 23. The first fixed shaft 2111 passes through the driving wheel 23 and is connected to the driving motor 24 through a coupling. A section of the third driving shaft 2231 away from the first pushing wheel 221 passes through the outside of the first driving gear 223 and is connected to the driven wheel 25. The driven wheel 25 is connected to the driving wheel 23 through a driving belt 26.

[0037] While the driving motor 24 drives the first fixed shaft 2111 to rotate, it drives the driven wheel 25 on the fourth driving shaft 2221 to rotate through the driving wheel 23 and the driving belt 26. When the driven wheel 25 rotates, it drives the second driving gear 224 to rotate. The second driving gear 224 is meshed and connected with the first driving gear 223, further driving the first pushing wheel 221 and the second pushing wheel 222 to rotate to evenly and continuously deliver the welding wire 11 to the welding area, ensuring that the welding wire 11 travels in a straight line to avoid bending or entanglement.

[0038] The working process of this utility model:

[0039] When in use, the controller starts the drive motor 24, and the drive motor 24 drives the first fixed shaft 2111 to rotate. When the first fixed shaft 2111 rotates, the first wire breaking drive gear 211 and the wire breaking gear plate 213 thereon rotate. Since the first wire breaking drive gear 211 is meshed and connected with the second wire breaking drive gear 212 on the second fixed shaft 2121, the first wire breaking drive gear 211 is further driven to rotate the conveying wheel 214 on the second fixed shaft 2121 connected to the second wire breaking drive gear 212. When the welding wire 11 passes through the wire breaking conveying trough 2141, the wire breaking gear plate 213 at the top thereof evenly breaks the top of the welding wire 11;

[0040] The driving motor 24 drives the first fixed shaft 2111 to rotate, and at the same time, drives the driven wheel 25 on the fourth driving shaft 2221 to rotate through the driving wheel 23 and the driving belt 26. When the driven wheel 25 rotates, it drives the second driving gear 224 to rotate. The second driving gear 224 is meshed and connected with the first driving gear 223, and further drives the first pushing wheel 221 and the second pushing wheel 222 to rotate, so as to uniformly and continuously deliver the welding wire 11 to the welding area, ensuring that the welding wire 11 travels in a straight line and avoids bending or entanglement.

[0041] The photoelectric sensor 32 is located at the exit of the wire-missing monitoring through-hole 311 of the detection shell 31. The wire-missing monitoring through-hole 311 of the detection shell 31 ensures that the welding wire travels in a straight line to avoid bending or entanglement. When the welding wire 11 passes through the wire-missing monitoring through-hole 311 of the detection shell 31 and passes between the laser emitting end and the laser receiving end, the signal emitted by the laser emitting end is blocked by the welding wire 11, and the laser receiving end receives the laser signal blocked by the welding wire 11; when the welding wire 11 is missing or interrupted, the laser receiving end will receive a complete laser signal, and the controller processes the signal of the photoelectric sensor 32 and responds accordingly based on whether the missing welding wire 11 is detected. The controller controls the sound and light alarm thereon to sound an alarm, and real-time monitoring can promptly detect abnormal conditions of the welding wire 11.

[0042] Although the embodiments of the present invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and variations may be made to these embodiments without departing from the principles and spirit of the present invention, and the scope of the present invention is defined by the appended claims and their equivalents.

Claims

1. A wire feeding monitoring device for a welding robot, comprising a wire reel (1), a wire feeding device (2) for reducing tin ball scattering, a wire shortage monitoring device (3) and a controller, characterized in that: A welding wire (11) is wound around the rotating shaft of the welding wire reel (1), and the wire shortage monitoring device (3) includes a detection shell (31) and a photoelectric sensor (32), wherein the detection shell (31) is arranged in a conical structure, and a wire shortage monitoring through hole (311) is opened through the inside of the detection shell (31), and the photoelectric sensor (32) includes a U-shaped structure, the inner wall of one end of the top of the photoelectric sensor (32) is a laser emitting end, and the inner wall of the other end is a laser receiving end, and the photoelectric sensor (32) is electrically connected to the controller through a wire; The controller is provided with an audible and visual alarm via a wire connection.

2. The wire feeding monitoring device for a welding robot according to claim 1, characterized in that: The welding wire reel (1) is located on one side of the wire feeding device (2), and the wire feeding device (2) includes a wire breaking assembly (21) for breaking the outer wall of the welding wire (11) to reduce the scattering of tin beads and a conveying assembly (22) for conveying the welding wire (11), the wire breaking assembly (21) includes a first wire breaking driving gear (211), a second wire breaking driving gear (212), a wire breaking gear plate (213) and a conveying wheel (214), the first wire breaking driving gear (211) is fixedly connected with a first fixed shaft (2111) inside, and the wire breaking gear plate (213) is connected to the first fixed shaft ( 2111) is connected to the outer circumferential wall of one end of the first wire-breaking driving gear (211), the second wire-breaking driving gear (212) is engaged and located directly below the first wire-breaking driving gear (211), and a second fixed shaft (2121) is fixedly connected and penetrated inside the second wire-breaking driving gear (212), and the conveying wheel (214) is connected to the outer circumferential wall of one end of the second fixed shaft (2121) away from the second wire-breaking driving gear (212), and a wire-breaking conveying groove (2141) is provided on the outer circumferential wall of the conveying wheel (214) directly below the bottom of the wire-breaking gear disc (213).

3. The wire feeding monitoring device for a welding robot according to claim 2, characterized in that: The conveying assembly (22) includes a first pushing wheel (221), a second pushing wheel (222), a first driving gear (223) and a second driving gear (224); the first driving gear (223) is internally fixedly connected with a third driving shaft (2231); the first pushing wheel (221) is located on the outer circumferential wall of the third driving shaft (2231) away from the first driving gear (223); the second pushing wheel (222) is engaged and located at the bottom of the first pushing wheel (221); the second pushing wheel (222) is internally fixedly connected with a fourth driving shaft (2221); the second driving gear (224) is located directly below the first driving gear (223) and is connected to the outer circumferential wall of the fourth driving shaft (2221) away from the second driving gear (224); a pushing channel for the welding wire (11) to be pushed through is formed between the first driving gear (223) and the second driving gear (224).

4. The wire feeding monitoring device for a welding robot according to claim 2, characterized in that: The end of the first fixed shaft (2111) away from the wire breaking gear plate (213) passes through the first wire breaking driving gear (211) and is externally connected to a driving wheel (23). The first fixed shaft (2111) passes through the driving wheel (23) and is connected to a driving motor (24) via a coupling.

5. The wire feeding monitoring device for a welding robot according to claim 3, characterized in that: The third driving shaft (2231) is separated from the first pushing wheel (221) and passes through the first driving gear (223). The outside of the third driving shaft (223) is connected to a driven wheel (25). The driven wheel (25) is connected to the driving wheel (23) via a driving belt (26).

6. The wire feeding monitoring device for a welding robot according to claim 2, characterized in that: The welding wire (11) sequentially passes through the broken wire through-conveying groove (2141), the pushing channel and the wire-missing monitoring through-hole (311) and extends outside thereof.

7. The wire feeding monitoring device for a welding robot according to claim 1, characterized in that: The laser emitting end and the laser receiving end on the inner wall of one end of the top of the photoelectric sensor (32) are located on both sides of the welding wire (11).

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