Welded wear-resistant steel plate production system

Abstract

The utility model provides a welding wear-resisting steel plate production system which comprises a feeding system, a laser cleaning system, an induction heating system, a splicing welding system and a discharging heat preservation system. Compared with the prior art, the device has the advantages that 24-hour uninterrupted welding production of the wear-resistant steel plate can be achieved, and the device has the advantages of being compact in takt, high in production efficiency and the like.

Description

Technical Field

[0001] This utility model relates to the field of robotic welding technology, specifically to a welding production line for wear-resistant steel plates that requires preheating and heat preservation. Background Technology

[0002] In current industrial production, the manual welding process for conventional wear-resistant steel plates has many drawbacks, severely restricting the improvement of production efficiency and the stability of product quality. Manual welding first requires a manual grinding process, where operators expend considerable time and effort using grinding tools to meticulously grind the welding areas of the steel plate to ensure the flatness and smoothness of the weld surface, thus providing a good foundation for subsequent welding work. However, this process is not only labor-intensive but also inefficient and highly susceptible to human factors, such as the uniformity of grinding and the control of force, which can lead to inconsistent welding quality.

[0003] After manual grinding, the next step is assembly. Operators need to rely on experience and visual observation to precisely assemble and position the steel plate components to be welded, ensuring that parameters such as gaps and angles between components meet welding requirements. This process also requires a high degree of focus and patience; even slight deviations can affect the strength and stability of the entire welded structure. Moreover, because it is a manual operation, the assembly speed is relatively slow, making it difficult to meet the needs of large-scale production.

[0004] The problems become even more pronounced during the welding stage. During welding, the steel plate rapidly absorbs a large amount of heat, causing its temperature to rise sharply. Simultaneously, the intense light, high-temperature radiation, and harmful fumes produced during welding create an extremely harsh welding environment. Operators working in such an environment are not only prone to fatigue, but prolonged exposure to these harmful conditions also poses a potential threat to their health. These adverse working conditions significantly limit the operators' work efficiency and duration, thus becoming one of the key factors restricting the improvement of welding efficiency.

[0005] Furthermore, due to its unique material properties, wear-resistant steel plates require preheating before welding and heat preservation after welding to ensure the stability of the weld structure and prevent quality problems such as cracks and deformation. However, traditional preheating methods typically use conventional ovens, which have the drawback of long preheating times. It often takes several hours or even longer to heat the steel plate to the appropriate welding temperature, significantly increasing the overall production cycle. Moreover, in actual production, precise temperature control before welding is crucial to ensure welding quality, but conventional ovens have relatively low temperature control accuracy, making it difficult to meet this requirement. This results in the incompatibility of conventional preheating methods with advanced automated welding robot production systems, severely limiting the application of welding robots in the production of wear-resistant steel plates.

[0006] In conclusion, given the various problems existing in conventional wear-resistant steel plate welding production methods, and the ever-increasing demand from industrial production for efficient and high-quality welded products, there is an urgent market need for a welded wear-resistant steel plate production system that can solve these problems. This system should possess efficient grinding, assembly, and welding functions, significantly improving production efficiency while ensuring weld quality. Furthermore, it should meet the specific process requirements of wear-resistant steel plates in both preheating and post-weld heat preservation, thereby bringing higher economic benefits and market competitiveness to wear-resistant steel plate manufacturers and promoting technological progress and development throughout the industry. Utility Model Content

[0007] The purpose of this invention is to provide a welding wear-resistant steel plate production system that can achieve induction and controllable heating of wear-resistant steel plates, realize fully automatic 24-hour uninterrupted welding production, and has the characteristics of compact cycle and high production efficiency.

[0008] To address the shortcomings of existing technologies, this utility model proposes a production system for welded wear-resistant steel plates, comprising: a feeding system, a laser cleaning system, an induction heating system, an assembly welding system, and a material unloading and heat preservation system; wherein...

[0009] The feeding system includes: a wear-resistant steel plate feeding platform and a chuck feeding platform; the chuck feeding platform is used for feeding small chucks; the wear-resistant steel plate feeding platform is used for feeding large wear-resistant steel plates.

[0010] The laser cleaning system uses pulsed laser combined with a robot to remove rust and paint from wear-resistant steel plates;

[0011] The induction heating system heats wear-resistant steel plates of different specifications and thicknesses.

[0012] The assembly and welding system uses laser sensing to grasp, assemble, and weld wear-resistant steel plates and mating parts.

[0013] The material feeding and insulation system delays the cooling of the welded parts by using insulation material to completely wrap the feeding area.

[0014] Preferably, the loading platform includes a loading trolley, a positioning plate, and a handrail; wherein,

[0015] The loading trolley is a movable trolley that can be moved manually or mechanically. It has a buckle at the bottom for precise positioning. The buckle is used to position and lock the loading trolley to ensure that the loading trolley is in a precise position and is locked in place. The loading trolley is used to place and transport the product parts to be welded, and the positioning base is used to precisely position and lock the loading trolley.

[0016] The loading platform can have its handrail removed by removing and installing pins, and then be connected to an electric trolley for assisted movement and handling.

[0017] The wear-resistant steel plate has slots on the upper surface of the loading platform for placing positioning pins.

[0018] Preferably, the laser cleaning system includes: a laser cleaning head and a cleaning platform; wherein,

[0019] The laser cleaning head is integrated into the robot tooling gripper, and the robot rotates and repositions to remove rust from the product parts placed on the cleaning platform.

[0020] The product components on the loading trolley are transported to the laser cleaning platform by the magnetic gripper of the handling robot, and then laser cleaning begins; the cleaning position is the welding surface.

[0021] The laser cleaning system also includes a protective plate with an observation window and a smoke exhaust port on the top of the protective plate.

[0022] Preferably, the induction heating system uses a magnetic gripper of a transport robot to move product components from the laser cleaning platform to the induction heating platform, and then begins to heat wear-resistant steel plates of different specifications and thicknesses.

[0023] The induction heating system includes: an induction coil, a coil support, and an infrared sensor; wherein...

[0024] The infrared sensor is located below the induction coil and can move with the coil support to ensure that the temperature of the product components can always be measured.

[0025] The induction heating system uses two medium-frequency induction heaters with power ratings of 100KVA and 160KVA, respectively.

[0026] Preferably, the assembly and welding system includes: a handling robot, a horizontal rotation and positioning platform, a welding robot, and a laser tracker; wherein,

[0027] The transport robot moves to the splice loading platform to identify and grab the small splice, and then moves to transport the wear-resistant steel plate that has been induction heated to the horizontal rotation positioning platform. The welding robot splices and spot welds the small splice to the wear-resistant steel plate.

[0028] The transport robot moves the welded wear-resistant steel plate to the material unloading and insulation system.

[0029] The 3D vision system can identify the position of the workpiece on the loading platform, providing guidance for the robot gripper to grasp it; at the welding station, the vision system can locate the workpiece and guide the robot gripper to accurately place the small parts; and the laser sensor can further identify and locate the weld seam position, guiding the welding robot to perform welding operations.

[0030] The assembly and welding system is also equipped with a three-axis rotation and positioning platform for welding other materials when the wear-resistant steel plate is not being welded.

[0031] This utility model discloses a design for a production system for welding wear-resistant steel plates. The production line includes a feeding system, a laser cleaning system, an induction heating system, an assembly welding system, and a material unloading and heat preservation system. The advantages of this utility model are: 1. It realizes fully automatic welding production of wear-resistant materials; 2. It adopts induction heating to achieve efficient and controllable heating; 3. It can realize 24-hour uninterrupted production with a compact cycle and high production efficiency.

[0032] Compared with the prior art, the advantages of this utility model are: it can realize induction and controllable heating of wear-resistant steel plates, realize fully automatic 24-hour uninterrupted welding production, and has the characteristics of compact cycle and high production efficiency. Attached Figure Description

[0033] To more clearly illustrate the technical solutions in the embodiments of this utility model or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of this utility model. For those skilled in the art, other drawings can be obtained from these drawings without creative effort.

[0034] Figure 1 , Figure 2 This is a schematic diagram of the structure of the welded wear-resistant steel plate production system of this utility model.

[0035] Figure 3 This is a schematic diagram of the feeding system in this utility model.

[0036] Figure 4 This is a schematic diagram of the structure of the feeder platform in this utility model.

[0037] Figure 5This is a schematic diagram of the structure of the wear-resistant steel plate loading platform in this utility model.

[0038] Figure 6 This is a structural schematic diagram of the detachable handrail in this utility model.

[0039] Figure 7a , 7b This is a partial method diagram of the feeding system in this utility model.

[0040] Figure 8 This is a schematic diagram of the laser cleaning system in this utility model.

[0041] Figure 9 This is a schematic diagram of the laser cleaning robotic arm in this utility model.

[0042] Figure 10 This is a schematic diagram of the induction heating system of this utility model.

[0043] Figure 11 This is a partial enlarged view of the induction heating system of this utility model.

[0044] Figure 12 , 13 This is a structural schematic diagram of the assembly and welding system in this utility model.

[0045] Figure 14 This is a structural schematic diagram of the assembly and welding system in this utility model.

[0046] Figure 15 This is a schematic diagram of the material feeding bracket in this utility model.

[0047] Figure 16 This is a schematic diagram of the buckle structure in this utility model.

[0048] Figure 17 This is a schematic diagram of the material feeding area in this utility model.

[0049] Figure 18a , 18b This is a partial schematic diagram of the feeder platform of this utility model.

[0050] Figure 19a , 19b This is an enlarged view of the structure of the laser cleaning head part of this utility model.

[0051] Figure 20 This is a schematic diagram of the observation window of this utility model.

[0052] Figure 21 This is a schematic diagram of the product in the comparative example of this utility model.

[0053] Figure 22 This is a schematic diagram of the temperature rise curve in an embodiment of this utility model. Detailed Implementation

[0054] The utility model will be further described in detail below with reference to the specific embodiments and accompanying drawings. Except for the contents specifically mentioned below, the processes, conditions, and experimental methods for implementing this utility model are all common knowledge and general knowledge in the field, and this utility model has no particular limitations.

[0055] Figures 1-20 In the middle, 1-feeding system; 11-wear-resistant steel plate feeding platform; 111-slot; 12-hook feeding platform; 13-feeding trolley; 131-positioning plate; 132-guide pulley; 133-guide plate; 134-magnetic locking plate; 14-positioning base; 15-handrail; 16-buckle; 17-pin; 18-connecting hook;

[0056] 2-Laser cleaning system; 21-Laser cleaning head; 22-Cleaning platform; 23-Protective plate; 24-Observation window; 25-Smoke exhaust port; 26-Laser power supply;

[0057] 3-Induction heating system; 31-Induction coil; 32-Coil support; 33-Infrared sensor;

[0058] 4-Assembly welding system; 41-Robot; 42-Horizontal rotary positioning platform; 43-Laser tracker; 44-Three-axis rotary positioning platform; 45-Welding robot;

[0059] 5- Material feeding and insulation system; 51- Insulation room; 52- Material feeding bracket; 53- Movable buckle; 54- Guide pin.

[0060] The technical solution adopted in this utility model is as follows: the welding production line includes a feeding system, a laser cleaning system, an induction heating system, an assembly welding system, and a discharge and heat preservation system. The feeding system has four feeding platforms: two 1650mm x 780mm platforms for feeding wear-resistant steel plates, and two 1830mm x 680mm platforms for feeding mating components. The feeding platforms are movable trolleys that can be moved manually or mechanically, and have snap-lock positioning at the bottom for precise positioning. The laser cleaning system uses pulsed laser combined with a robot to remove rust and paint from the wear-resistant steel plates. Two medium-frequency induction heaters with power ratings of 100KVA and 160KVA respectively are used to heat wear-resistant steel plates of different thicknesses and specifications. The induction heating system has a built-in intelligent module that can automatically adjust the output power according to the thickness and weight of the wear-resistant steel plate, and, in conjunction with a sensing device, can achieve precise control of the heating temperature of the wear-resistant steel plate. The assembly welding system uses three-dimensional vision recognition combined with laser sensing to achieve the gripping, assembly, and welding of wear-resistant steel plates and mating components. The material feeding and insulation system adopts movable buckle positioning and guide pin 54 positioning for the material feeding tray. The material feeding area is completely wrapped with insulation material to delay the cooling of the welded parts.

[0061] Example

[0062] The welded wear-resistant steel plate production system provided in this embodiment includes: a feeding system, a laser cleaning system, an induction heating system, an assembly welding system, and a material unloading and heat preservation system; wherein,

[0063] The feeding system has four feeding platforms, including two 1650mm x 780mm platforms for feeding wear-resistant steel plates and two 1830mm x 680mm platforms for feeding with connecting parts. Each feeding platform includes a feeding trolley, a positioning plate, and handrails. The feeding trolley is a movable trolley that can be moved manually or mechanically, and has a locking buckle at the bottom for precise positioning. The buckle 16 is used to position and lock the feeding trolley, ensuring accurate positioning and preventing it from falling off. The feeding trolley is used to place and transport the product parts to be welded, and the positioning base is magnetic for precise positioning and locking of the feeding trolley.

[0064] The positioning base 14 includes: a guide pulley 132, a guide plate 133, and a magnetic locking plate 134; the positioning plate is fixed on the loading trolley and can slide into the positioning base 14 under the guidance of the guide plate 133 via the guide pulley 132; the magnetic locking plate 134 is used to cooperate with an electromagnet to fix the loading trolley.

[0065] The loading platform for small parts is used for loading small parts, while the loading platform for wear-resistant steel plates is used for loading large parts. The loading platform's manual handling arm can be removed by detaching pins, allowing it to be connected to an electric trolley for assisted movement and handling. Figure 6 As shown. The upper surface of the wear-resistant steel plate loading platform is provided with slots for placing positioning pins.

[0066] The laser cleaning system uses pulsed lasers combined with robots to remove rust and paint from wear-resistant steel plates. The system includes a cleaning platform. The laser cleaning head is integrated into the robot's gripper. The robot rotates and positions the product parts placed on the cleaning platform, and the areas requiring rust removal are determined through robot teaching programming.

[0067] The product components on the loading trolley are transferred to the laser cleaning platform using a magnetic gripper from a handling robot, and then laser cleaning begins. The cleaning location is the welded surface.

[0068] The laser cleaning system also includes a protective plate with an observation window and a smoke vent at the top.

[0069] The induction heating system employs two medium-frequency induction heaters with power ratings of 100KVA and 160KVA respectively to heat wear-resistant steel plates of varying thicknesses. The system incorporates an intelligent module that automatically adjusts the output power based on the thickness and weight of the wear-resistant steel plate. Combined with sensors, it enables precise temperature control of the heating process.

[0070] The induction heating system includes an induction coil, a coil support, and an infrared sensor. The sensor is positioned below the coil and moves with the coil support to ensure that the temperature of the product components is always being measured.

[0071] The product components on the laser cleaning platform are moved to the sensing heating platform by the magnetic gripper of the handling robot, and then induction heating begins.

[0072] Table 1 shows the relationship between the thickness and weight of the product components, steel plate dimensions and weight, and heating power, time, etc., as input manually.

[0073] Table 1

[0074]

[0075] Induction heating:

[0076] 1. The heating equipment detects the real-time heating temperature of the workpiece through sensors and displays it on the HMI main interface;

[0077] 2. During the equipment heating stage, the workpiece is heated to 200℃ and then heating is stopped. After the temperature is diffused and cooled, it is heated again until the cooling range is reduced to the required heat preservation range. The cumulative heating time at this time is recorded. This heating time is the temperature rise time.

[0078] 3. After the heated steel plate enters the heat preservation stage, the equipment will enter the heat preservation mode. The minimum heat preservation time will control the temperature difference between the surface and the center of the steel plate to within 8°C. The heat preservation time can also be extended according to the cycle time. The longer the time, the more uniform the temperature of the workpiece.

[0079] The heating curve is as follows Figure 22 As shown.

[0080] The assembly and welding system uses 3D vision recognition combined with laser sensing to grasp, assemble, and weld wear-resistant steel plates and matching components.

[0081] The assembly and welding system includes a horizontal rotation and positioning platform for a transport robot, and a laser tracker for a welding robot.

[0082] This utility model's three-dimensional vision system can identify the position of workpieces on the loading platform, guiding the robot gripper to grasp them. In the welding station, the vision system positions the workpiece and guides the robot gripper to place small parts relatively accurately. Laser sensing further identifies and positions the weld seam, guiding the welding robot to perform the welding operation.

[0083] This utility model uses vision to guide robots. Different workstations correspond to different templates: templates for cleaning, heating, and unloading stations; templates for loading cart 1 and loading cart 2 for large parts; templates for primary small part retrieval; and templates for secondary small part retrieval. By differentiating workpiece features, the vision inspection achieves high accuracy.

[0084] The template needs to be determined in advance by the camera position for robot loading. The vision software takes a picture at the camera position, selects the vision inspection area on the vision software, and paints the workpiece features. After the template is completed, the robot moves slightly to verify and inspect the stability of the template.

[0085] The assembly process involves a handling robot gripper picking up small parts and a welding robot working together to spot weld them. After spot welding, the welding robot uses a laser sensor to accurately identify the weld seam before performing full welding.

[0086] The assembly welding system can also be equipped with a three-axis rotation and positioning platform for other welding applications.

[0087] The material feeding and insulation system uses a snap-on positioning mechanism for the material feeding bracket, and the entire feeding area is wrapped with insulation material to delay the cooling of the welded parts.

[0088] The product components on the horizontal rotation and positioning platform are moved to the front of the insulation room by the magnetic gripper of the handling robot. The roller shutter door of the insulation room is opened, the handling robot places the product components on the unloading tray, and the roller shutter door of the insulation room is closed after the handling robot exits.

[0089] The production line starts working:

[0090] ① The transport robot moves the wear-resistant steel plate to the laser cleaning platform;

[0091] ②The laser cleaning head integrated into the handling robot begins cleaning the wear-resistant steel plate;

[0092] ③ After cleaning, the transport robot will move the wear-resistant steel plate to the induction heating platform;

[0093] ④ The induction heating platform begins to heat the wear-resistant steel plate;

[0094] ⑤ The transport robot moves to the loading platform to identify and grab the small assembly, and then moves to the welding horizontal rotation and positioning platform to transport the welded wear-resistant steel plate to the insulated room unloading bracket;

[0095] ⑥ Once induction heating is complete, the transport robot moves to the welding horizontal rotation positioning platform to transport the wear-resistant steel plate;

[0096] ⑦ The handling robot, in conjunction with the welding robot, assembles and spot-welds the small components to the wear-resistant steel plate;

[0097] ⑧ The welding robot begins welding, and the transport robot repeats step ①.

[0098]

[0099]

[0100] Comparative Example

[0101] This utility model will soon be used in the intelligent welding production of composite lining wear-resistant steel plates by the applicant company.

[0102] Figure 21 The product shown has a 6-piece lining frame, 40kg of wear-resistant steel plate, and a welding time of 12 minutes per piece at the workstation.

[0103] One piece can be assembled manually in 11 minutes, and one piece can be welded in 3.5 minutes. Production requires one welder and three sheet metal workers. The average production efficiency is 14.5 minutes per piece. Workstation efficiency has increased by 21%.

[0104] The scope of protection of this utility model is not limited to the above embodiments. Any variations and advantages that can be conceived by those skilled in the art without departing from the spirit and scope of the utility model are included in this utility model and are protected by the appended claims.

Claims

1. A production system for welded wear-resistant steel plates, characterized in that, include: The system comprises a feeding system (1), a laser cleaning system (2), an induction heating system (3), an assembly and welding system (4), and a discharge and heat preservation system (5); among which, The feeding system (1) includes: a wear-resistant steel plate feeding platform (11) and a clasp feeding platform (12); the clasp feeding platform (12) is used for feeding small clasps; the wear-resistant steel plate feeding platform (11) is used for feeding large wear-resistant steel plates; The laser cleaning system (2) uses pulsed laser combined with a robot (41) to remove rust and paint from wear-resistant steel plates; The induction heating system (3) heats wear-resistant steel plates of different specifications and thicknesses; The assembly and welding system (4) uses laser sensing to grasp, assemble and weld the wear-resistant steel plate and the matching parts; The material feeding insulation system (5) delays the cooling of the welded parts by using insulation material to completely wrap the material feeding area.

2. The welded wear-resistant steel plate production system as described in claim 1, characterized in that, The wear-resistant steel plate loading platform (11) and the trolley loading platform (12) both include a loading trolley (13), a positioning plate (131), and a handrail (15); among which, The loading trolley (13) is a movable trolley that can be moved manually or mechanically. It has a buckle (16) at the bottom for precise positioning. The buckle (16) is used to position and lock the loading trolley (13) to ensure that the loading trolley (13) is in a precise position and is locked in place. The loading trolley (13) is used to place and transport the product parts to be welded. The positioning base (14) is fixed to the ground and cooperates with the buckle (16) to precisely position and lock the loading trolley (13). Both the wear-resistant steel plate loading platform (11) and the trolley loading platform (12) can have their handrails (15) removed by removing and installing pins (17) and connected to an electric trolley for assisted movement and handling. The upper surface of the wear-resistant steel plate loading platform (11) is provided with slots (111) for placing positioning pins.

3. The welded wear-resistant steel plate production system as described in claim 2, characterized in that, The laser cleaning system (2) includes: a laser cleaning head (21) and a cleaning platform (22); wherein, The laser cleaning head (21) is integrated into the magnetic gripper of the handling robot (41), and the robot rotates and repositions to remove rust from the product parts placed on the cleaning platform (22). The product parts on the loading trolley (13) are transported to the cleaning platform (22) by the magnetic gripper of the handling robot (41), and then laser cleaning is started; the cleaning position is the welding surface.

4. The welded wear-resistant steel plate production system as described in claim 3, characterized in that, The laser cleaning system (2) also includes a protective plate (23), on which an observation window (24) is provided; and a smoke exhaust port (25) is provided on the top of the protective plate (23).

5. The welded wear-resistant steel plate production system as described in claim 2, characterized in that, The induction heating system (3) uses the magnetic gripper of the handling robot (41) to transport the product parts on the laser cleaning platform (22) to the induction heating system (3) to heat the wear-resistant steel plate.

6. The welded wear-resistant steel plate production system as described in claim 5, characterized in that, The induction heating system (3) includes: an induction coil (31), a coil support (32), and an infrared sensor (33); wherein, The infrared sensor (33) is located below the induction coil (31) and can move together with the coil support (32) to ensure that the temperature of the product components can always be measured; 7. The welded wear-resistant steel plate production system as described in claim 5, characterized in that, The induction heating system (3) uses two medium-frequency induction heaters with power of 100KVA and 160KVA respectively.

8. The welded wear-resistant steel plate production system as described in claim 1, characterized in that, The assembly and welding system (4) includes: a handling robot (41), a horizontal rotation and positioning platform (42), a welding robot (45), and a laser tracker (43); wherein, The transport robot (41) moves to the splice loading platform (12) to identify and grab the small splice, and then moves to the horizontal rotation and positioning platform (42) to transport the wear-resistant steel plate that has been heated by induction. The welding robot (45) splices and welds the small splice to the wear-resistant steel plate. The transport robot (41) transports the welded wear-resistant steel plate to the unloading and heat preservation system (5).

9. The welded wear-resistant steel plate production system as described in claim 1, characterized in that, The assembly and welding system (4) is also equipped with a three-axis rotation and positioning platform (44) for welding other materials when the wear-resistant steel plate is not being welded.

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