Semi-automatic welding repair device for frog

Abstract

The utility model provides a frog semi-automatic welding repair device which comprises a welding robot and a welding robot control cabinet. The welding robot comprises a robot body and a frame structure for fixing the robot body. A portable fixing clamp is arranged at the bottom of the frame structure; the welding robot control cabinet integrates a robot controller, a robot demonstrator and a welding power source. Wherein the robot controller is in communication connection with the robot demonstrator. The device is compact and light in overall structure and good in safety, and the convenience and flexibility of the device are effectively improved; the lightweight design of the control cabinet is realized, and the safety and stability of the control cabinet are enhanced; by setting parameters or directly selecting storage parameters in a welding process software package, welding path planning is completed, the welding path planning time is effectively saved, and the online frog repair welding efficiency is improved; the adaptability and flexibility of manual operation are high, and the requirements for recognition of complex defect positions of different types and different sizes and welding path planning can be met.

Description

Technical Field

[0001] This utility model belongs to the field of welding technology for transportation operations, and specifically relates to a semi-automatic welding and repair device for turnouts. Background Technology

[0002] The frog is a crucial piece of equipment on railway lines and a vulnerable component of the railway structure. During service, it endures the immense pressure, impact, and vibration from train wheels, resulting in wear, spalling, cracks, and other damage. This can lead to contact fatigue, preventing it from reaching its designed lifespan and causing it to fail and be taken off the tracks. Even cast high-manganese steel frogs can develop defects such as porosity and cracks during factory manufacturing. To address these issues, manual arc welding is typically used to repair damaged frogs in service and those with defects in the factory. However, the primary method for in-service and factory repair of frogs is manual arc welding. The quality of repairs heavily relies on the welder's skill level and sense of responsibility, resulting in inconsistent quality. The high labor intensity also significantly impacts repair quality, efficiency, and the post-repair service life.

[0003] Automated welding technology is already widespread in the industrial field, and automated welding for repairing damaged frogs is imperative. In the prior art, a steel frog repair device disclosed in CN218695356U and a repair method and system for high-manganese steel frogs disclosed in CN115722846A both use visual sensors to identify the location of defects.

[0004] However, the ability of visual sensors to identify defect locations is easily affected by complex ambient lighting, impacting recognition accuracy. Furthermore, the complex process of visual sensors identifying defect locations, visual software building spatial defect models, and computer extraction of feature points and weld placement results in lengthy welding path planning times, affecting the efficiency of on-line fork repair welding. Moreover, limitations in post-visual recognition modeling restrict adaptability and flexibility, failing to fully meet the requirements for accurate identification and welding path planning of complex defect locations of various types and sizes. To address these issues, the following technical solution is proposed. Utility Model Content

[0005] The technical problem solved by this utility model is to provide a semi-automatic welding and repair device for turnouts, which solves the technical drawbacks of the fully automatic visual recognition described in the background art and ensures the welding and repair effect.

[0006] The technical solution adopted in this utility model is: a semi-automatic welding and repair device for turnouts, including a welding robot and a welding robot control cabinet.

[0007] The welding robot consists of a robot body and a frame structure that holds the robot body in place; a portable fixing clamp is provided at the bottom of the frame structure.

[0008] The welding robot control cabinet integrates a robot controller, a robot teach pendant, and a welding power supply; the robot controller is connected to the robot teach pendant for communication.

[0009] As a further improvement of the present invention, the welding robot control cabinet also includes a robot body wiring port, a teach pendant wiring port, and a main power switch; it also includes a welding torch interface and a power cord interface.

[0010] In the above technical solution, as a preferred technical solution of this utility model: the portable fixing fixture has two convenient locking structures; wherein the first convenient locking structure is used to adjust and fix the position of the portable fixing fixture as a whole on the frame structure; the second convenient locking structure is located at the bottom of the first convenient locking structure; the second convenient locking structure is tightened by pressing against the fixing surface inside the frog wheel flange groove, thereby constraining and fixing the second convenient locking structure inside the frog wheel flange groove, thereby fixing the welding robot as a whole above the frog to be welded.

[0011] In the above technical solution, the preferred technical solution of this utility model is as follows: the frame structure has a horizontal frame, a vertical frame, and an X-axis track; wherein, a portable fixing clamp is installed on the horizontal frame; the vertical frame is vertically connected to the horizontal frame; the top of the vertical frame is vertically fixed and supported to the X-axis track; the X-axis track is equipped with a robot body that moves linearly along its X-axis; the robot body also includes a Y-axis mechanism; the execution end of the Y-axis mechanism is equipped with a Z-axis mechanism; the execution end of the Z-axis mechanism is equipped with a vertically downward welding torch.

[0012] In the above technical solutions, the preferred technical solution of this utility model is: a robot controller or robot teach pendant integrating a control board, a human-machine interface, a power switch, an indicator button, and an emergency stop button.

[0013] In the above technical solutions, the preferred technical solution of this utility model is: the human-machine interface includes a central touch screen display.

[0014] The touch screen has a customizable button area, a "lock" button, a "maintenance mode" button, an "automatic mode" button, and a "teach mode" button on the left side outside the screen, from top to bottom.

[0015] The custom button area includes the F1 button and the F2 button.

[0016] The F1 button is used to continue executing the next welding instruction.

[0017] The F2 button is used to execute the command to insert a weld layer.

[0018] The right side of the touch screen features, from top to bottom, a speed percentage adjustment button area, a "Continue" button, a "Pause" button, and a "End" button.

[0019] The speed percentage adjustment button area includes a "+" button, an "F%" button, and a "-" button.

[0020] The bottom outer edge of the touch screen has a speed multiplier button area and a movement control button area.

[0021] The speed multiplier button area includes: a "×1" button, a "×10" button, and a "×100" button; the movement control button area includes: multiple "A+ Correction" buttons, multiple "A- Correction" buttons; one "A+" button, one "A-" button; one "X+" button, one "X-" button; one "Y+" button, one "Y-" button; one "Z+" button, and one "Z-" button.

[0022] The bottom of the touch screen also features buttons for "Gas Inspection", "Welding Process", "Wire Feed", "Wire Retraction", "Arc Start", "Arc Extinguish", "IO", "Main Menu", "Handwheel", and "Continuous".

[0023] The touchscreen display has a USB port and a "handwheel" button on the top outer side.

[0024] In the above technical solutions, the preferred technical solution of this utility model is as follows: the robot controller or robot teach pendant includes a "multi-layer multi-channel point acquisition" module and a "multi-layer multi-channel instruction" module.

[0025] The "Multi-layer Multi-channel Point Acquisition" module is used to acquire the location points of the area to be welded.

[0026] The "Multi-layer Multi-pass Instruction" module is used to set specific welding parameters.

[0027] The “Multi-layer Multi-pass Point Taking” module takes eight points to determine the weld size; the eight points are in sequence: inner bottom start point I (P1), inner bottom end point I (P2), inner top start point (P3), inner top end point (P4), inner bottom start point II (P5), inner bottom end point II (P6), outer top start point (P7), and outer top end point (P8).

[0028] The outer top starting point (P7) and outer top ending point (P8) can be determined automatically based on the direction and spacing from P1 to P6.

[0029] The touch screen under the "Multi-layer Multi-channel Instruction" module includes the following operation units: "Zeroing Welding Pass Count", "Clearing Point Content", "Setting Parameters", "Check Completed", "To Start Point", "To End Point", "Increase Count by 1", "Setting Voltage and Current", "Setting Posture", and "Setting Left and Right Swing Welding".

[0030] In the above technical solutions, the preferred technical solution of this utility model is: in the "multi-layer multi-channel sampling" module or the "multi-layer multi-channel instruction" module, welding defects are divided into three types according to the different boundary characteristics of welding defects: Type I defects, Type II defects, and Type III defects.

[0031] Type I defects are characterized by a fully closed boundary structure.

[0032] Type II defects are characterized by a one-sided open structure.

[0033] Type III defects are open structures on both sides.

[0034] Among them, special markings are made for weld defects in open structures, and the welding parameters of the welds are adjusted adaptively.

[0035] In the above technical solution, as a further improvement of this utility model, the touch screen (301) under the "multi-layer multi-channel point acquisition" module and the "multi-layer multi-channel instruction" module also includes a "welding gun output" operation unit, an "arc start" operation unit, a "continuation arc start" operation unit, an "arc end" operation unit, a "circular arc welding" operation unit, a "front and back swing welding" operation unit, a "left and right swing welding" operation unit, a "fish scale welding" operation unit, and a "path end" operation unit.

[0036] As a further improvement of the present invention, the "setting parameters" operation unit includes a "layer number" setting submodule, a "molten pool height" setting submodule, a "molten pool left width" setting submodule, and a "molten pool right width" setting submodule.

[0037] As a further improvement of the present invention, the sub-interface of the touch screen also includes a welding setting interface.

[0038] The welding settings interface includes a "Run Instructions" display and a "Welding Interruption Control" unit.

[0039] The welding settings interface also includes "Welding Layer Number Display" information, which includes a "Total Number of Layers" setting unit, a "Current Number of Layers" setting unit, and an "Obstacle Avoidance Distance" setting unit.

[0040] The welding settings interface also includes "Current Welding Position Display" information, which includes the current number of welding layers and the current number of welding passes.

[0041] The welding settings interface also includes "Insert Welding Layer Number Settings" display information, and below the "Insert Welding Layer Number Settings" display information are the Insert Welding Layer Number Setting Unit and the Insert Welding Pass Number Setting Unit.

[0042] The welding settings interface also includes a "Setup Complete" operation unit.

[0043] As a further improvement of the present invention, the above technical solution is as follows: the welding torch is a special gas shielded welding machine, which has a low current welding function, a light spatter short-circuit transition function, and a standard root welding function.

[0044] As a further improvement of the present invention, the robot controller or robot teach pendant also includes a "boundary weld bead welding program" module; the "boundary weld bead welding program" module is used to automatically execute the boundary weld bead welding program for welding on the open boundary side.

[0045] The "Boundary Welding Procedure" module includes the "Create New Welding Procedure" operation unit.

[0046] The "Create New Welding Program" operation unit includes a storage medium; the storage medium stores a number of data; the data comes from previous in-plant tests and on-site welding repair parameter records, and the data provides welding parameters corresponding to defects of different shapes and sizes; the welding parameters include welding wire specifications, defect length, defect width, defect height, welding current, welding voltage, welding speed, left swing pair, and right swing pair parameters.

[0047] Advantages of this utility model compared to the prior art:

[0048] 1. This utility model solves the technical drawbacks of the fully automatic visual recognition described in the background technology, ensuring the welding repair effect; it relatively improves the welding repair efficiency, welding repair flexibility and adaptability, and meets the needs of accurate identification and welding path planning for complex defect locations of various types and sizes.

[0049] 2. The welding robot in this utility model consists of a robot body and a frame structure for fixing the robot body. The frame structure is equipped with a welding robot X-axis track and a portable fixing fixture. The X-axis track provides the robot with movement conditions in the X-axis direction. The fixing fixture uses the wheel flange groove of the fork to clamp and fix the welding robot as a whole. It is easy to operate and highly adaptable. The overall structure of the device is compact, lightweight and safe, which greatly improves the convenience and flexibility of the equipment.

[0050] 3. This utility model welding robot control cabinet integrates a robot controller and a welding power supply, and connects to a robot teach pendant. The welding robot control cabinet is also equipped with a robot body wiring port, a teach pendant wiring port, and a main power switch. It also includes a welding torch interface and a power cord interface. All connecting cables are detachable to achieve a lightweight design of the welding robot control cabinet, which can enhance the safety and stability of the welding robot control cabinet.

[0051] 4. In this invention, the defect locations P1 to P8 are manually picked up, and the welding robot controller automatically establishes the shape and size of the defect space based on the location points. By setting parameters or directly selecting stored parameters in the welding process software package, the welding path planning is completed.

[0052] 5. The weld at the defect boundary marked as an open location point in this utility model is welded using the boundary weld welding program parameters in the "Boundary Welding Program" module. As for manually extracting the defect location point, it avoids the disadvantage of visual sensor identification of defect location being easily affected by complex ambient light, and eliminates the complex process of visual sensor identification of defect location, visual software to build spatial defect model, computer extraction of feature location points and layout of weld. Therefore, it can effectively save welding path planning time, improve the efficiency of on-line fork repair welding, and the manual operation has strong adaptability and flexibility, which can meet the identification and welding path planning needs of complex defect locations of different types and sizes. Attached Figure Description

[0053] Figure 1 This is a schematic diagram of the overall structure of the device of this utility model;

[0054] Figure 2 This is a schematic diagram of the structure of the welding robot of this utility model;

[0055] Figure 3 This is a schematic diagram of the structure of the welding robot control cabinet of this utility model;

[0056] Figure 4 This is a schematic diagram of the human-machine interface of this utility model;

[0057] Figure 5 This utility model Figure 4 A schematic diagram of the operation interface under the "Multi-layer Multi-channel Point Acquisition" module in the human-machine interface;

[0058] Figure 6 This is a schematic diagram of the locations P1 to P8 for manually picking up defects according to this utility model;

[0059] Figure 7 This is a schematic diagram of a defective structure of the turnout of this utility model;

[0060] Figure 8 This is a schematic diagram of the type II defect structure of the turnout of this utility model;

[0061] Figure 9 This is a schematic diagram of the three types of defect structures of the frog of this utility model;

[0062] Figure 10 This utility model Figure 4 A schematic diagram of the operation interface under the "Multi-level Multi-channel Instruction" module in the human-machine interface;

[0063] Figure 11 This is a schematic diagram of the operation interface under the "Set Parameters" operation unit of this utility model;

[0064] Figure 12 This diagram illustrates the distribution of the multi-layered, multi-pass weld layers and weld beads of this utility model.

[0065] Figure 13 This is a schematic diagram of the touch display screen under the "welding settings interface" of this utility model;

[0066] Figure 14 This is a schematic diagram of the touch screen display of the welding process software package under the "Boundary Welding Procedure" module of this utility model;

[0067] In the diagram: 1-Welding robot, 2-Welding robot control cabinet; 1-1 Robot body, 1-2 Frame structure, 1-3 Fixture, 1-4 Welding torch; 2-1 Robot body wiring port, 2-2 Teach pendant wiring port, 2-3 Main power switch; 1-301 First convenient locking structure; 1-302 Second convenient locking structure; 1-201 Horizontal frame, 1-202 Vertical frame, 1-203 X-direction track, 3-Human machine operation interface, 301-Touch display screen, 4-Emergency stop button, 5-Welding settings interface, 6-Tube; 7-Type I defect, 8-Type II defect, 9-Type III defect. Detailed Implementation

[0068] The following will refer to the appendix in the embodiments of this utility model. Figure 1-14 The technical solutions in the embodiments of this utility model are clearly and completely described herein. Obviously, the described embodiments are only some embodiments of this utility model, and not all embodiments. Based on the embodiments of this utility model, all other embodiments obtained by those skilled in the art without creative effort are within the protection scope of this utility model.

[0069] A semi-automatic welding and repair device for turnouts includes a welding robot 1 and a welding robot control cabinet (e.g., Figure 1 (As shown).

[0070] The welding robot 1 includes a robot body 1-1 and a frame structure 1-2 for fixing the robot body 1-1 (e.g., ...). Figure 2 (As shown).

[0071] This utility model provides a portable clamping function: the bottom of the frame structure 1-2 is equipped with a portable fixing clamp 1-3. Literally, any structure with a "convenient fixing" function is applicable to this invention.

[0072] The above embodiments are preferred embodiments of this utility model: (in conjunction with...) Figure 2The portable fixing clamp 1-3 has two convenient locking structures. The first convenient locking structure 1-301 is used to adjust and fix the position of the portable fixing clamp 1-3 as a whole on the frame structure 1-2. The second convenient locking structure 1-302 is located at the bottom of the first convenient locking structure 1-301; the second convenient locking structure 1-302 is pressed against the fixing surface inside the wheel flange groove of the fork 6, constraining and fixing the second convenient locking structure 1-302 inside the wheel flange groove of the fork 6, thereby fixing the welding robot 1 as a whole above the fork 6 to be welded.

[0073] The specific embodiments of the first convenient locking structure 1-301 and the second convenient locking structure 1-302 described above can be implemented using the following conventional structure: The first convenient locking structure 1-301 consists of a fixed frame and a set screw. The position of the portable fixing clamp 1-3 relative to the frame structure 1-2 is adjusted by the "fixed frame"; the position of the "fixed frame" is locked by tightening the set screw. As for the second convenient locking structure 1-302, it can consist of a connecting block and a screw with a set screw; wherein, the top of the connecting block is used to vertically fix the bottom of the fixed frame of the first convenient locking structure 1-301, and the bottom of the connecting block has sufficient thickness, and an adjustable screw with adjustable left and right extension lengths is vertically rotated and installed within the thickness of the bottom block of the connecting block, and a set screw is installed at the extended end of the screw. By adjusting the screw's extension length, the top block at the outer end of the screw presses against the fixing surface inside the wheel flange groove of the fork 6, thus constraining and fixing the second portable locking structure 1-302 within the wheel flange groove of the fork 6, thereby fixing the welding robot 1 entirely above the fork 6 to be welded. It is evident that this portable fixing fixture 1-3 is more compact, space-saving, lightweight, and easily portable than other structures.

[0074] To achieve semi-automatic welding and repair operations on the turnout using a robot teach pendant, the welding robot control cabinet 2 integrates a robot controller, a robot teach pendant, and a welding power supply. The robot controller is communicatively connected to the robot teach pendant and is used to control the orderly operation of the welding robot and other related components, thus laying the foundation for further integration, miniaturization, and semi-automatic teaching functions of the device.

[0075] The above embodiments are further improved embodiments of the present invention: (e.g.) Figure 3 As shown, the welding robot control cabinet 2 also includes a robot body wiring port 2-1, a teach pendant wiring port 2-2, and a main power switch 2-3; it also includes a welding torch interface and a power cord interface.

[0076] This invention integrates multiple wiring ports into the welding robot control cabinet 2, enabling it to connect to and control more external devices, thus achieving automated control of the equipment. This multi-line linkage control method effectively improves the stability and production efficiency of the device. Furthermore, multiple wiring ports make coordinated linkage between different devices possible, improving the overall control accuracy and operational efficiency of the system. Finally, the integration of multiple wiring ports also allows the control cabinet to receive electrical signals from different devices. By analyzing and processing these signals, fault monitoring and troubleshooting can be achieved, which helps improve the operational safety of the equipment and reduce the impact of faults on production. Finally, the integration of multiple wiring ports supports the linkage control of various devices, exhibiting strong compatibility and versatility. This allows the control cabinet to adapt to different application scenarios and needs, improving its applicability and practicality.

[0077] The above-described embodiments of frame structures 1-2 are preferred embodiments of this utility model: (see again) Figure 1 , Figure 2 The frame structure 1-2 comprises a horizontal frame 1-201, a vertical frame 1-202, and an X-axis track 1-203. The portable fixing fixture 1-3 is mounted on the horizontal frame 1-201. The bottom of the vertical frame 1-202 is vertically fixed to the outer end of the horizontal frame 1-201; the top of the vertical frame 1-202 is vertically fixed to the X-axis track 1-203. This integrates a portion of the X-axis actuator of the robot body 1-1 (i.e., the X-axis track 1-203) with the frame structure 1-2, resulting in a compact and lightweight design of the welding robot 1. Based on this design concept: the robot body 1-1, which moves linearly along its X-axis, is mounted on the X-axis track 1-203; the robot body 1-1 also includes a Y-axis mechanism; the execution end of the Y-axis mechanism is equipped with a Z-axis mechanism; and the execution end of the Z-axis mechanism is equipped with a vertically downward-facing welding torch 1-4. This enables the three-degree-of-freedom (movement along the X, Y, and Z axes) welding displacement adjustment function of welding torches 1-4.

[0078] In the above embodiments, as a preferred embodiment of the present invention, the robot controller or the robot teach pendant integrates a control board, a human-machine interface 3, a power on / off switch, an indicator button, and an emergency stop button 4. It should be understood that both the robot controller and the robot teach pendant can adopt an integrated design. However, as a preferred embodiment, the robot controller integrates a control board, a human-machine interface 3, a power on / off switch, an indicator button, and an emergency stop button 4.

[0079] (like Figure 3As shown in the above embodiments, as a preferred embodiment of the present invention, the human-machine interface 3 includes a central touch screen display 301.

[0080] The touch display screen 301 has a custom button area, a "lock" button, a "maintenance mode" button, an "automatic mode" button, and a "teach mode" button on the left side outside the screen, from top to bottom.

[0081] The custom button area includes the F1 button and the F2 button.

[0082] The F1 button is used to continue executing the next welding command.

[0083] The F2 button is used to execute the command to insert a weld layer.

[0084] The touch display screen 301 has a speed percentage adjustment button area, a "Continue" button, a "Pause" button, and an "End" button on the right side outside the screen, from top to bottom.

[0085] The speed percentage adjustment button area includes a "+" button, an "F%" button, and a "-" button.

[0086] The touch display screen 301 has a speed multiplier button area and a movement control button area on the bottom outer side.

[0087] The speed multiplier button area includes a "×1" button, a "×10" button, and a "×100" button; the movement control button area includes multiple "A+ Correction" buttons, multiple "A- Correction" buttons; one "A+" button, one "A-" button; one "X+" button, one "X-" button; one "Y+" button, one "Y-" button; one "Z+" button, and one "Z-" button.

[0088] The bottom of the touch display screen 301 is also equipped with a "Gas Inspection" button, a "Welding Process" button, a "Wire Feed" button, a "Wire Retraction" button, a "Start Arc" button, a "Stop Arc" button, an "IO" button, a "Main Menu" button, a "Handwheel" button, and a "Continuous" button.

[0089] The touch display screen 301 has a USB port and a "handwheel" button on the top outer side.

[0090] In practical implementation: For example, the USB interface allows the device to transfer data with other external devices (such as computers, programmers, etc.). This allows users to easily import welding parameters, programs, etc., from the computer into the welding equipment, or export data from the equipment to the computer for further analysis and processing. This data exchange capability greatly improves the flexibility and efficiency of the equipment. Through the USB interface, users can easily update the device's firmware or software to adapt to new welding requirements or fix potential problems. Furthermore, technicians can use the USB interface for equipment fault diagnosis and repair, thereby reducing equipment downtime.

[0091] Generally speaking, the "handwheel" button can be used to adjust welding parameters (such as current, voltage, welding speed, etc.), control the movement of the equipment (such as moving the welding head, adjusting the welding angle, etc.), or perform other specific operations.

[0092] In the above embodiments, as a preferred technical solution of this utility model: the robot controller or the robot teach pendant includes a "multi-layer multi-channel point acquisition" module and a "multi-layer multi-channel instruction" module (e.g. Figure 5 , Figure 10 (As shown).

[0093] The "multi-layer multi-channel point acquisition" module is used to acquire the location points of the area to be welded.

[0094] The "multi-layer multi-pass instruction" module is used to set specific welding parameters.

[0095] The "multi-layer, multi-pass sampling" module selects eight points to determine the weld bead size; the eight points sequentially include: (e.g.) Figure 6 (As shown) Inner bottom starting point I (P1), inner bottom ending point I (P2), inner top starting point (P3), inner top ending point (P4), inner bottom starting point II (P5), inner bottom ending point II (P6), outer top starting point (P7), outer top ending point (P8).

[0096] The outer top starting point (P7) and outer top ending point (P8) can also be determined automatically based on the direction and spacing from P1 to P6.

[0097] (like Figure 10 As shown, the touch display screen 301 under the "Multi-layer Multi-channel Instruction" module includes an operation unit for "Zeroing Welding Brace Count", an operation unit for "Clearing Point Content", an operation unit for "Setting Parameters", an operation unit for "Check Completed", an operation unit for "To Start Point", an operation unit for "To End Point", an operation unit for "Increase Count by 1", an operation unit for "Setting Voltage and Current", an operation unit for "Setting Posture", and an operation unit for "Setting Left and Right Swing Welding".

[0098] In the above embodiments, as a preferred embodiment of the present invention: in the "multi-layer multi-channel sampling" module or "multi-layer multi-channel instruction" module, welding defects are classified into three types according to the different boundary characteristics of the welding defects: Type I defect 7, Type II defect 8, and Type III defect 9 (e.g., Figures 7 to 9 (As shown).

[0099] The type 7 defect is a fully closed-boundary structure;

[0100] The type II defect 8 is a one-sided open structure;

[0101] The type 3 defect 9 is an open structure on both sides.

[0102] Among them, special markings are made for weld defects in open structures, and the welding parameters of the welds are adjusted adaptively.

[0103] (See again) Figure 5 , Figure 10 In the above embodiments, as a further improved embodiment of the present invention: the touch display screen 301 under the "multi-layer multi-channel point acquisition" module and the "multi-layer multi-channel instruction" module also includes a "welding gun output" operation unit, an "arc start" operation unit, a "continuation arc start" operation unit, an "arc end" operation unit, a "circular arc welding" operation unit, a "front and back swing welding" operation unit, a "left and right swing welding" operation unit, a "fish scale welding" operation unit, and a "path end" operation unit.

[0104] (like Figure 11 As shown in the above embodiment, as a further improved embodiment of the present utility model: the "setting parameters" operation unit includes a "layer number" setting submodule, a "melt pool height" setting submodule, a "melt pool left width" setting submodule, and a "melt pool right width" setting submodule.

[0105] (like Figure 13 As shown in the above embodiment, as a further improved embodiment of the present invention: the sub-interface of the touch display screen 301 further includes a welding setting interface 5.

[0106] The welding settings interface 5 includes "running instruction" display information and a "welding interruption control" unit.

[0107] The welding settings interface 5 also includes "welding layer number display" information, which includes a "total number of layers" setting unit, a "current number of layers" setting unit, and an "obstacle avoidance running distance" setting unit.

[0108] The welding settings interface 5 also includes "current welding position display" information, which includes the current number of welding layers and the current number of welding passes.

[0109] The welding settings interface 5 also includes "Insert Welding Layer Number Setting" display information, and below the "Insert Welding Layer Number Setting" display information are an Insert Welding Layer Number Setting Unit and an Insert Welding Pass Number Setting Unit.

[0110] The welding settings interface 5 also includes a "Settings Complete" operation unit.

[0111] In the above embodiments, as a further improved embodiment of the present utility model: the welding guns 1-4 are dedicated gas shielded welding machines, which have low current welding function, light spatter short-circuit transition function, and are equipped with root welding function as standard.

[0112] Among its features, the low-current welding function allows the welding machine to weld at low currents, meaning a stable welding process can be achieved even under low current conditions. The minimal spatter short-circuit transition function significantly reduces spatter during welding, making the process cleaner and more efficient. The standard root welding function enables the welding machine to easily perform root pass welding and all-position welding, improving welding flexibility and adaptability. In summary, the low-current welding function, minimal spatter short-circuit transition function, and standard root welding function of this dedicated gas-shielded welding machine constitute its significant technical advantages. These advantages enable the welding machine to perform excellently in various welding tasks, achieving efficient, stable, and reliable welding processes.

[0113] In the above embodiments, as a further improved embodiment of the present invention: the robot controller or the robot teach pendant further includes a "boundary weld bead welding program" module (in conjunction with...). Figure 14 (A schematic diagram of the touch screen display of the welding process software package under the "Boundary Welding Procedure" module is shown). The "Boundary Welding Procedure" module is used to automatically execute the boundary welding procedure for welding on the open boundary side.

[0114] The “Boundary Welding Procedure” module includes a “Create New Welding Procedure” operation unit.

[0115] The “New Welding Program” operation unit includes a storage medium; the storage medium stores a number of data; the data comes from previous in-plant tests and on-site welding repair parameter records, and the data provides welding parameters corresponding to defects of different shapes and sizes; the welding parameters include welding wire specifications, defect length, defect width, defect height, welding current, welding voltage, welding speed, left swing pair, and right swing pair parameters.

[0116] In specific implementation, this utility model is carried out according to the following embodiments: the defect location of the fork welding repair is usually wide and deep, and multiple layers and multiple welding procedures are required for welding.

[0117] The "multi-layer multi-pass welding program" adopts a modular design, which includes two operation modules: the "multi-layer multi-pass point acquisition" module and the "multi-layer multi-pass instruction" module.

[0118] The first step is to use the "multi-layer multi-channel point acquisition" module to acquire the location points of the area to be welded; the second step is to use the "multi-layer multi-channel instruction" module to set specific welding parameters.

[0119] (like Figure 5 (As shown) The "Multi-layer Multi-pass Point Taking" command requires taking 8 points to determine the weld bead size. The point positions are as follows: Figure 6 As shown, P7 and P8 can be omitted, and the system will automatically determine them based on the direction and spacing from P1 to P6.

[0120] Defect boundaries can be either open or closed, resulting in three types of defects:

[0121] Type I defects: all boundaries are closed ( Figure 7 );

[0122] Type II defect: One side is open ( Figure 8 );

[0123] Type III defect: Open on both sides ( Figure 9 ).

[0124] Among them, "open" defect boundaries are prone to weld collapse during repair, which can easily lead to incomplete repair, excessively large weld beads, and poor weld bead formation quality. Therefore, weld beads at "open" defect boundaries need to be specially marked, and welding parameters need to be adjusted accordingly. Specifically, during the in-plant testing phase, welding parameters with good open boundary weld bead formation performance are tested, stored as a "boundary weld bead welding program," and stored in the robot controller. During the "multi-layer, multi-pass point sampling" operation, the location points at the open boundary are marked. The location point markings corresponding to the three defect types are shown in Table 1.

[0125] Table 1: Location markers for the three defect types

[0126]

[0127] Subsequently, the weld bead marked as the open boundary side is automatically welded using the boundary weld bead welding procedure.

[0128] (like Figure 10 As shown, the "Multi-layer Multi-pass Instruction" module includes sub-instructions such as zeroing the number of weld passes, clearing the sampling points, setting parameters, checking completion, returning to the starting point, returning to the ending point, incrementing the number of passes by 1, setting voltage and current, setting posture, and setting left and right sway welding.

[0129] The meanings of each step instruction are as follows: Clear weld pass count: This is usually written in the first line of the "multi-layer multi-pass program instruction" to clear the previously accumulated weld pass count in the system so as not to affect the current multi-layer multi-pass welding by the previously accumulated weld pass count.

[0130] Clear the data points: This is usually written on the second line of a multi-level, multi-program instruction to prevent the current parameter settings from being affected by the data points previously captured.

[0131] Mark location point type ( Figure 10 (Not shown in the text): Used to determine the type of defect boundary.

[0132] Setting parameters: (e.g.) Figure 11 As shown, the parameters that need to be set are the number of layers, the height of the molten pool, the left width of the molten pool, and the right width of the molten pool. It should be noted that: if seven points have already been taken using the "Multi-layer Multi-track Point Taking" command, the settings for the three parameters of molten pool height, left width of the molten pool, and right width of the molten pool are invalid, and only the number of layers needs to be entered; if only the first three points have been taken using the "Multi-layer Multi-track Point Taking" command, all four parameters on this parameter page are valid.

[0133] Check complete: When the execution reaches this step, it will check the number of layers to determine whether multiple layers and multiple channels have been completed, and then jump to the set label according to the status of A24.

[0134] To start point: Set the speed to reach the calculated start point of each weld bead, in mm / min.

[0135] To the endpoint: Set the speed to reach the calculated endpoint of each weld bead, in mm / min.

[0136] Increment by 1: When this instruction is executed, the number of weld passes is incremented by 1 to determine the position of the next weld pass and whether the processing is complete.

[0137] Voltage and current settings: The current and voltage for welding a specific weld pass in a specific layer can be set individually.

[0138] Setting posture: The posture of a specific weld bead on a specific layer can be set individually.

[0139] Set left and right oscillating welding: You can set a specific layer and a specific weld pass to use left and right oscillating welding. For the parameter settings of left and right oscillating welding, please refer to the

Left and Right Oscillating Welding

[0140] The distribution of weld layers and weld beads in a multi-layer, multi-pass welding process is as follows: Figure 12 As shown.

[0141] Table 2 shows a program example for multi-layer, multi-pass welding:

[0142] Table 2

[0143]

[0144] Because the robot teach pendant has physical buttons F1 and F2, each with different indication functions:

[0145] Once the program is set to complete one weld pass, the robot will pause its work to allow time for manual inspection of the welding effect, water cooling of the weld pass, and hammering of the weld pass. After the above operations are completed and the manual inspection is satisfactory, pressing the F1 button will continue to execute the next weld pass welding instruction.

[0146] During the welding repair process, if issues such as incomplete weld beading, weld bead misalignment, or weld bead interruption occur, it is necessary to re-perform the welding of that particular weld bead. This requires entering the "Welding Settings Interface" (e.g., ...). Figure 13 (As shown). This interface displays the welding layer status, including the total number of layers and the current number of layers; it also shows the current welding position; and it allows you to insert welding layers and number of passes. After clicking "Setting Complete", press the F2 button to execute the welding command to insert the welding layer and pass.

[0147] This invention can also be customized to develop a dedicated "welding process software package".

[0148] The parameters in the "welding process software package" (such as...) Figure 14 (As shown) This includes the length, width, and height of the weld defect, welding current, welding voltage, welding speed, left swing amplitude, and right swing amplitude. The data mainly comes from previous in-plant tests and field welding parameter records. These data provide recommended welding parameters for defects of different shapes and sizes, aiming to improve the efficiency of field welding strategy development and welding effect.

[0149] It should be noted that when using the welding parameters in the "Welding Process Software Package", the parameter setting steps in the multi-layer, multi-pass instruction operation can be canceled.

[0150] Regarding welding robot 1, it should be noted that this utility model, developed based on the on-site construction environment, is a three-axis portable welding robot characterized by easy transport, installation, and operation. The three-axis portable welding robot is connected to a welding robot controller, which in turn is connected to a teach pendant. By executing a manually taught welding trajectory program, it performs automatic welding repair of the turnout.

[0151] This utility model relates to a semi-automatic welding and repair method for a forklift, the method being based on any of the aforementioned semi-automatic welding and repair devices for forks; the method includes the following steps:

[0152] Example 1:

[0153] S1. Based on the location, shape, and size of the damage, after grinding and removing the damaged area, a type 7 defect is formed (e.g., ...). Figure 7 (As shown).

[0154] S2. Using the portable fixing clamp 1-3 at the bottom of the frame structure 1-2 of the welding robot 1, fix the welding robot 1 at a suitable position above the welding area of ​​the turnout 6. Check whether the various mechanisms of the robot body 1-1 and the welding torch 1-4 of the welding robot 1 are operating normally. After confirming that they are operating normally, start the device.

[0155] S3. Wait for the welding robot body 1-1 to move to the set origin point, and the status will be ready;

[0156] S4. Operate the robot teaching pendant and enter the operation interface of the "multi-layer multi-channel sampling" module. Manually observe the shape of type 1 defect 7. Move the welding robot 1 so that the front end of the welding gun 1-4 is close to the sampling position. Extract the position points P1 to P8 of type 1 defect 7 one by one in sequence.

[0157] S5. Operate the robot teach pendant and enter the operation interface of the "multi-layer multi-path point acquisition" module. Set the position point types of P1~P4 and P5~P8 according to the boundary type of type 1 defect 7.

[0158] S6. Operate the robot teach pendant and enter the operation interface of the "Set Parameters" operation unit. Based on the shape and size of the type, manually determine and set the parameters of the number of layers, molten pool height, left width of the molten pool, and right width of the molten pool.

[0159] S7. Operate the robot teach pendant and enter ( Figure 14 The "Boundary Welding Procedure" module allows users to select a similar welding procedure based on the actual type I defect length, width, and height; or, according to process requirements, modify or create a new welding procedure in the "Create Welding Procedure" unit and apply it to the upcoming welding repair operation.

[0160] S8. After completing the pre-welding preparations, operate the robot teach pendant and enter the operation interface of the "Multi-layer Multi-pass Instruction" module on the touch screen 301. Click the "Automatic Mode" button on the robot teach pendant touch screen 301 to start the multi-layer multi-pass welding program from the first step of the program.

[0161] S9. Welding robot 1 starts and automatically performs welding repair work according to the set welding path.

[0162] S10. After each weld pass is completed, welding robot 1 retreats to the welding transition point and waits for manual removal of oxide scale, water cooling of the weld pass, and hammering of the weld pass.

[0163] If steps S11 and S10 are successful, click the F1 button on the human-machine interface 3 of the robot teach pendant to continue the welding repair operation.

[0164] S12. During the welding repair process, if the weld bead is not fully welded, the weld bead is offset, or the weld bead is interrupted, the welding of a certain weld bead shall be re-implemented. That is, enter the welding settings interface 5, insert the welding layer and number of passes as required, click "Setting Complete", press the F2 button, and execute the welding command of the newly inserted layer and number of passes.

[0165] S13. After the welding instructions for the newly inserted welding layer and number of passes are completed, press the F1 button to continue executing the instructions in the multi-layer multi-pass welding program of the previous stage, i.e., step S8.

[0166] S14. After welding is completed, check the welding effect, remove the equipment, and clean up the site.

[0167] Example 2:

[0168] S1. Based on the location, shape, and size of the damage, after grinding and removing the damaged area, a type II defect 8 is formed (e.g., Figure 8 (As shown).

[0169] S2. Using the portable fixing clamp 1-3 at the bottom of the frame structure 1-2 of the welding robot 1, fix the welding robot 1 at a suitable position above the welding area of ​​the turnout 6. Check whether the various mechanisms of the robot body 1-1 and the welding torch 1-4 of the welding robot 1 are operating normally. After confirming that they are operating normally, start the device.

[0170] S3. Wait for the welding robot body 1-1 to move to the set origin point, and the status will be ready;

[0171] S4. Operate the robot teaching pendant and enter the operation interface of the "multi-layer multi-channel sampling" module. Manually observe the shape of type II defect 8. Move the welding robot 1 so that the front end of the welding gun 1-4 is close to the sampling position. Extract the position points P1 to P8 of type II defect 8 one by one in sequence.

[0172] S5. Operate the robot teach pendant and enter the operation interface of the "multi-layer multi-path point acquisition" module. Set the position point types of P1~P4 and P5~P8 according to the boundary type of type II defect 8.

[0173] S6. Operate the robot teach pendant and enter the operation interface of the "Set Parameters" operation unit. Based on the shape and size of Type II defect 8, manually determine and set the parameters of number of layers, molten pool height, left width of molten pool and right width of molten pool.

[0174] S7. Operate the robot teach pendant to enter the operation interface of the "Boundary Welding Program" module. Select a similar welding program based on the actual Type II defect length, Type II defect width, and Type II defect height. Alternatively, modify or create a new welding program in the operation interface of the "Create Welding Program" unit according to process requirements and apply it to the upcoming welding repair operation.

[0175] S8. After completing the pre-welding preparations, operate the robot teach pendant and enter the operation interface of the "Multi-layer Multi-pass Instruction" module on the touch screen 301. Click the "Automatic Mode" button on the robot teach pendant touch screen 301 to start the multi-layer multi-pass welding program from the first step of the program.

[0176] S9. Welding robot 1 starts and automatically performs welding repair work according to the set welding path.

[0177] S10. After each weld pass is completed, welding robot 1 retreats to the welding transition point and waits for manual removal of oxide scale, water cooling of the weld pass, and hammering of the weld pass.

[0178] If steps S11 and S10 are successful, click the F1 button on the human-machine interface 3 of the robot teach pendant to continue the welding repair operation.

[0179] S12. During the welding repair process, if the weld bead is not fully welded, the weld bead is offset, or the weld bead is interrupted, the welding of a certain weld bead shall be re-implemented. That is, enter the welding settings interface 5, insert the welding layer and number of passes as required, click "Setting Complete", press the F2 button, and execute the welding command of the newly inserted layer and number of passes.

[0180] S13. After the welding instructions for the newly inserted welding layer and number of passes are completed, press the F1 button to continue executing the instructions in the multi-layer multi-pass welding program of the previous stage, i.e., step S8.

[0181] S14. After welding is completed, check the welding effect, remove the equipment, and clean up the site.

[0182] Example 3:

[0183] S1. Based on the location, shape, and size of the damage, after grinding and removing the damaged area, a type III defect 9 is formed (e.g., Figure 9 (As shown).

[0184] S2. Using the portable fixing clamp 1-3 at the bottom of the frame structure 1-2 of the welding robot 1, fix the welding robot 1 at a suitable position above the welding area of ​​the turnout 6. Check whether the various mechanisms of the robot body 1-1 and the welding torch 1-4 of the welding robot 1 are operating normally. After confirming that they are operating normally, start the device.

[0185] S3. Wait for the welding robot body 1-1 to move to the set origin point, and the status will be ready;

[0186] S4. Operate the robot teaching pendant and enter the operation interface of the "multi-layer multi-channel sampling" module. Manually observe the shape of the type 3 defect 9. Move the welding robot 1 so that the front end of the welding gun 1-4 is close to the sampling position. Extract the position points P1 to P8 of the type 3 defect 9 one by one in sequence.

[0187] S5. Operate the robot teach pendant and enter the operation interface of the "multi-layer multi-path point acquisition" module. Set the position point types of P1 to P4 and P5 to P8 according to the boundary type of the three types of defects 9.

[0188] S6. Operate the robot teach pendant and enter the operation interface of the "Set Parameters" operation unit. Based on the shape and size of the type 3 defect 9, manually determine and set the parameters of the number of layers, molten pool height, left width of the molten pool, and right width of the molten pool.

[0189] S7. Operate the robot teach pendant to enter the operation interface of the "Boundary Welding Program" module. Select a similar welding program based on the actual three-type defect length, three-type defect width, and three-type defect height; or modify or create a welding program in the operation interface of the "Create Welding Program" operation unit according to process requirements and apply it to the upcoming welding repair operation.

[0190] S8. After completing the pre-welding preparations, operate the robot teach pendant and enter the operation interface of the "Multi-layer Multi-pass Instruction" module on the touch screen 301. Click the "Automatic Mode" button on the robot teach pendant touch screen 301 to start the multi-layer multi-pass welding program from the first step of the program.

[0191] S9. Welding robot 1 starts and automatically performs welding repair work according to the set welding path.

[0192] S10. After each weld pass is completed, welding robot 1 retreats to the welding transition point and waits for manual removal of oxide scale, water cooling of the weld pass, and hammering of the weld pass.

[0193] If steps S11 and S10 are successful, click the F1 button on the human-machine interface 3 of the robot teach pendant to continue the welding repair operation.

[0194] S12. During the welding repair process, if the weld bead is not fully welded, the weld bead is offset, or the weld bead is interrupted, the welding of a certain weld bead shall be re-implemented. That is, enter the welding settings interface 5, insert the welding layer and number of passes as required, click "Setting Complete", press the F2 button, and execute the welding command of the newly inserted layer and number of passes.

[0195] S13. After the welding instructions for the newly inserted welding layer and number of passes are completed, press the F1 button to continue executing the instructions in the multi-layer multi-pass welding program of the previous stage, i.e., step S8.

[0196] S14. After welding is completed, check the welding effect, remove the equipment, and clean up the site.

[0197] As can be seen from the above description, this utility model solves the technical drawbacks of the fully automatic visual recognition described in the background technology, ensuring the welding repair effect; it relatively improves the welding repair efficiency, welding repair flexibility and adaptability, and meets the needs of accurate identification and welding path planning for complex defect locations of various types and sizes.

[0198] In this utility model, the welding robot 1 consists of a robot body 1-1 and a frame structure 1-2 for fixing the robot body 1-1. The frame structure 1-2 is equipped with a welding robot X-axis track 1-203 and a portable fixing fixture 1-3. The X-axis track 1-203 provides the robot with movement conditions in the X-axis direction. The fixing fixture 1-3 uses the wheel flange groove of the fork 6 to clamp and fix the welding robot 1 as a whole. It is easy to operate and highly adaptable. The overall structure of the device is compact, lightweight, and has good safety, which greatly improves the convenience and flexibility of the equipment.

[0199] This utility model welding robot control cabinet 2 integrates a robot controller and a welding power supply. A robot teach pendant is connected to the welding robot control cabinet 2. The welding robot control cabinet 2 is also equipped with a robot body wiring port 2-1, a teach pendant wiring port 2-2, and a main power switch 2-3. It also includes a welding torch interface and a power cord interface. All connecting wires are detachable to achieve a lightweight design of the welding robot control cabinet 2, which can enhance the safety and stability of the welding robot control cabinet 2.

[0200] In this invention, the defect locations P1 to P8 are manually picked up, and the welding robot controller automatically establishes the shape and size of the defect space based on the location points. By setting parameters or directly selecting stored parameters in the welding process software package, the welding path planning is completed.

[0201] The weld at the defect boundary marked as an open location point in this invention is welded using the boundary weld welding program parameters in the "Boundary Welding Program" module. Manual extraction of the defect location point avoids the drawback of visual sensor identification being easily affected by complex ambient lighting, eliminating the complex process of visual sensor identification of defect location, visual software establishing a spatial defect model, computer extraction of feature location points, and weld arrangement. Therefore, it can effectively save welding path planning time, improve the efficiency of on-line turnout repair welding, and the manual operation is highly adaptable and flexible, meeting the needs of identifying and planning welding paths for complex defect locations of different types and sizes.

[0202] The above description is merely a preferred embodiment of the present utility model and is not intended to limit the scope of protection of the present utility model. Any modifications and equivalent substitutions made within the spirit and principles of the present utility model are included within the scope of protection of the present utility model.

Claims

1. A semi-automatic welding and repair device for turnouts, characterized in that: Includes a welding robot (1) and a welding robot control cabinet (2); The welding robot (1) includes a robot body (1-1) and a frame structure (1-2) for fixing the robot body (1-1); a portable fixing clamp (1-3) is provided at the bottom of the frame structure (1-2). The welding robot control cabinet (2) integrates a robot controller, a robot teach pendant, and a welding power supply; wherein the robot controller is communicatively connected to the robot teach pendant.

2. The semi-automatic welding and repair device for turnouts according to claim 1, characterized in that: The welding robot control cabinet (2) also includes a robot body wiring port (2-1), a teach pendant wiring port (2-2), and a main power switch (2-3); it also includes a welding torch interface and a power cord interface.

3. The semi-automatic welding and repair device for turnouts according to claim 1, characterized in that: The portable fixing clamp (1-3) has two convenient locking structures; the first convenient locking structure (1-301) is used to adjust and fix the position of the portable fixing clamp (1-3) on the frame structure (1-2); the second convenient locking structure (1-302) is located at the bottom of the first convenient locking structure (1-301); the second convenient locking structure (1-302) is pressed against the fixing surface inside the wheel flange groove of the fork (6) by a pressing method, and the second convenient locking structure (1-302) is constrained and fixed in the wheel flange groove of the fork (6), thereby fixing the welding robot (1) above the fork (6) to be welded.

4. The semi-automatic welding and repair device for turnouts according to claim 1 or 3, characterized in that: The frame structure (1-2) has a horizontal frame (1-201), a vertical frame (1-202), and an X-axis track (1-203); wherein, the horizontal frame (1-201) is equipped with the portable fixing fixture (1-3); the vertical frame (1-202) is vertically connected to the horizontal frame (1-201); the top of the vertical frame (1-202) is vertically fixedly supported and connected to the X-axis track (1-203); the X-axis track (1-203) is equipped with a robot body (1-1) that moves linearly along its X-axis; the robot body (1-1) also includes a Y-axis mechanism; the execution end of the Y-axis mechanism is equipped with a Z-axis mechanism; the execution end of the Z-axis mechanism is equipped with a vertically downward welding torch (1-4).

5. The semi-automatic welding and repair device for turnouts according to claim 1, characterized in that: The robot controller or the robot teach pendant integrates a control board, a human-machine interface (3), a power on / off switch, an indicator button, and an emergency stop button (4).

6. The semi-automatic welding and repair device for turnouts according to claim 5, characterized in that: The human-machine interface (3) includes a central touch screen (301). The touch display screen (301) has a custom button area, a "lock" button, a "maintenance mode" button, an "automatic mode" button, and a "teach mode" button on the left side outside the screen, from top to bottom. The custom button area includes: an F1 button and an F2 button; The F1 button is used to continue executing the next welding command; The F2 button is used to execute the command to insert a weld layer; The touch display screen (301) has a speed percentage adjustment button area, a "Continue" button, a "Pause" button, and a "End" button arranged from top to bottom on the right side outside the screen. The speed percentage adjustment button area includes: a "+" button, an "F%" button, and a "-" button; The touch display screen (301) has a speed multiplier button area and a movement control button area on the bottom outer side; The speed multiplier button area includes: a "×1" button, a "×10" button, and a "×100" button; the movement control button area includes: multiple "A+ correction" buttons, multiple "A- correction" buttons; one "A+" button, one "A-" button; one "X+" button, one "X-" button; one "Y+" button, one "Y-" button; one "Z+" button, and one "Z-" button. The touch display screen (301) is also equipped with a "gas test" button, a "welding process" button, a "wire feed" button, a "wire retraction" button, an "arc start" button, an "arc extinguish" button, an "IO" button, a "main menu" button, a "handwheel" button, and a "continuous" button at the bottom of the screen. The touch display screen (301) has a USB interface and a "handwheel" button on the top outer side.

7. The semi-automatic welding and repair device for turnouts according to claim 1 or 5, characterized in that: The robot controller or the robot teach pendant includes a "multi-layer multi-channel point acquisition" module and a "multi-layer multi-channel instruction" module; The "multi-layer multi-channel sampling" module is used to sample the location points of the area to be welded; The "multi-layer multi-pass instruction" module is used to set specific welding parameters; The "multi-layer multi-pass point taking" module takes eight points to determine the weld size; the eight points include, in sequence: inner bottom start point I (P1), inner bottom end point I (P2), inner top start point (P3), inner top end point (P4), inner bottom start point II (P5), inner bottom end point II (P6), outer top start point (P7), and outer top end point (P8). The outer top starting point (P7) and outer top ending point (P8) can also be determined automatically based on the direction and spacing from P1 to P6.

8. The semi-automatic welding and repair device for turnouts according to claim 7, characterized in that, In the "multi-layer multi-channel sampling" module or "multi-layer multi-channel instruction" module, welding defects are classified into three types according to the different boundary characteristics of welding defects: Type I defects (7), Type II defects (8), and Type III defects (9). The type 1 defect (7) is a fully closed boundary structure; The type II defect (8) is a one-sided open structure; The three types of defects (9) are open structures on both sides; Among them, special markings are made for weld defects in open structures, and the welding parameters of the welds are adjusted adaptively.

9. The semi-automatic welding and repair device for turnouts according to claim 7, characterized in that: The touch screen (301) under the "multi-layer multi-channel point acquisition" module and the "multi-layer multi-channel instruction" module also includes a "welding gun output" operation unit, an "arc start" operation unit, a "continuation arc start" operation unit, an "arc end" operation unit, a "circular arc welding" operation unit, a "front and back swing welding" operation unit, a "left and right swing welding" operation unit, a "fish scale welding" operation unit, and a "path end" operation unit.

10. The semi-automatic welding and repair device for turnouts according to claim 6, characterized in that: The sub-interface of the touch display screen (301) also includes a welding setting interface (5); The welding settings interface (5) includes "run instruction" display information and "welding interruption control" unit; The welding setting interface (5) also includes "welding layer number display" information, and the "welding layer number display" information includes a "total number of layers" setting unit, a "current number of layers" setting unit, and an "obstacle avoidance running distance" setting unit; The welding settings interface (5) also includes "current welding position display" information, and the "current welding position display" information includes the current welding layer number display information and the current welding pass number display information; The welding settings interface (5) also includes "insertion welding layer number setting" display information, and the "insertion welding layer number setting" display information is provided with an insertion welding layer number setting unit and an insertion welding pass number setting unit below the insertion welding layer number setting unit; The welding settings interface (5) also includes a "Settings Complete" operation unit.

11. The semi-automatic welding and repair device for turnouts according to claim 4, characterized in that: The welding torch (1-4) is a dedicated gas shielded welding machine. The dedicated gas shielded welding machine has low current welding function, light spatter short circuit transition function, and is equipped with root welding function as standard.

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