Full-automatic laser welding equipment

Abstract

The utility model provides full-automatic laser welding equipment. A feeding system is mainly used for completing the process of transferring a product from a positioning tray and a tool to a welding station; the visual system is mainly used for searching two welding positions of a product before welding and transmitting position coordinates back to the equipment control system; the welding system realizes two process requirements of spot welding and continuous welding by controlling different laser modes; the smoke purification system is mainly used for recycling waste gas generated in the welding process, and pollution is prevented. The equipment control cabinet completes the main control center of the equipment, realizes the control process of each execution mechanism part of the whole equipment, and ensures the stable operation of the welding process; the positioning material disc and the tool provide a platform for grabbing of the feeding system, and automatic welding after unified one-time feeding of a batch of materials is facilitated. The blowing system is mainly used for realizing gas protection in the welding process and preventing blackening; all assembly systems are integrated in one device through the device shell, and meanwhile the full sealing performance of the full-automatic welding process is guaranteed.

Description

Technical Field

[0001] This utility model relates to the field of automated welding equipment technology, and in particular to a fully automated laser welding equipment. Background Technology

[0002] With the rapid development of industrial automation and intelligent manufacturing, laser welding technology is increasingly being used in fields such as automobile manufacturing, aerospace, and electronic components due to its advantages of high efficiency, high precision, low deformation, and good adaptability. Laser welding can achieve high-quality joining of various materials such as metals and plastics, meeting the increasingly stringent requirements of modern manufacturing for welding technology.

[0003] Despite its many advantages, laser welding technology still faces several challenges in practical industrial applications. Existing laser welding equipment has limitations in automation and intelligence, is complex to operate, and requires a high level of operator skill. Furthermore, the stability and repeatability of existing equipment during the welding process need improvement. These issues limit the potential for wider application of laser welding technology. Utility Model Content

[0004] The purpose of this invention is to provide a fully automatic laser welding equipment for precision welding operations, especially for welding the housing and front cover, and the housing and rear cover of an RVDT angular displacement sensor.

[0005] This utility model achieves the above objectives through the following technical solution:

[0006] A fully automatic laser welding equipment includes: a feeding system, a vision system, a welding system, a fume purification system, an equipment control system, a positioning tray assembly, an air blowing system, an equipment base, a station switching system, and a barcode scanner;

[0007] The loading system transfers products from the positioning tray assembly to the station switching system; the vision system locates the two welding positions of the product before welding and transmits the position coordinates back to the equipment control system; the welding system welds the workpiece by selecting different welding modes; the fume extraction system recovers and treats the exhaust gas generated during the welding process to prevent pollution; the equipment control system controls the various actuators and components of the entire equipment to ensure stable welding; the positioning tray assembly provides a platform for the loading system to grasp the products; the air blowing system provides protective gas for the welding process; the equipment housing integrates all component systems; the station switching system moves the product between the loading station and the welding station; and the barcode scanner selects the welding process by scanning the QR code on the positioning tray assembly.

[0008] Furthermore, the equipment base includes: equipment tabletop, equipment sheet metal shell, profile frame, tri-color lights, computer monitor, touch screen, barcode scanner bracket, and NG material box;

[0009] The equipment platform supports the feeding system, vision system, welding system, positioning tray and tooling, and workstation switching system. It is installed inside the profile frame, with the sheet metal shell nested on the profile frame. The computer monitor and touch screen are installed on the sheet metal shell, the barcode scanner bracket is installed on the profile frame, the three-color lights are installed on the top sheet metal shell, and the NG material box is installed next to the positioning tray and tooling to recycle welding waste.

[0010] Furthermore, the feeding system includes: a feeding X-axis module, a first lowering cylinder, a second lowering cylinder, a feeding Y-axis module, a first gripper cylinder, a second gripper cylinder, a first gripper, a second gripper, a support column, a first gripper mounting bracket, and a second gripper mounting bracket;

[0011] The Y-axis loading module is mounted on the support column to ensure the accurate movement of the first and second grippers along the Y direction. The X-axis loading module is mounted on the Y-axis loading module, enabling the first and second grippers to move simultaneously along the X direction. A lowering cylinder is mounted on the X-axis loading module, enabling the first gripper to move simultaneously along the XY direction and the Z direction. A gripper mounting bracket is fixed to the lowering cylinder, and the first gripper is mounted on the gripper mounting bracket. A second lowering cylinder is mounted on the X-axis loading module, enabling the second gripper to move simultaneously along the XY direction and the Z direction. The first and second gripper cylinders are mounted on the first and second grippers respectively. When the cylinders extend the first and second grippers, they clamp, thereby gripping the product and realizing loading and unloading.

[0012] Furthermore, the welding system includes: a Z-axis module, a welding module X-axis, a laser emitter head, and a laser host;

[0013] The X-axis module is mounted on the equipment base, the Z-axis module is mounted on the X-axis module, the laser emitter is mounted on the Z-axis module, and the laser host is encapsulated at the bottom of the equipment base.

[0014] Furthermore, the smoke purification system is placed inside the right side of the equipment base and encapsulated in an independent space. The smoke purification system can be pushed out by opening the cabinet door to replace the filter.

[0015] Furthermore, the positioning tray assembly includes: a welding tray and welding fixtures; the welding tray consists of a handle, a positioning plate, and a QR code, with the handle fixed to both sides of the positioning plate and the QR code riveted to the lower right corner of the positioning plate; the welding fixture includes a positioning mandrel, a fixing block, a winding shaft, and a rubber sleeve, with the positioning mandrel passing through the product positioning hole, the stepped surface limiting the axial displacement of one end of the product, the fixing block pressing the other end of the product, and the winding shaft being fixed to the positioning mandrel by internal threads, winding the product's wire harness onto the winding shaft, and the rubber sleeve being fixed to the top of the winding shaft to prevent the wire harness from scattering; the welding tray is positioned and supported by pins on the positioning columns on the equipment table.

[0016] Furthermore, the air blowing system includes: an air hose, an air cylinder, an air blowing head, an air hose support, an air cylinder support, and a pressure gauge; the air cylinder is encapsulated inside the right side of the equipment housing and placed on a movable air cylinder support for easy replacement; a pressure gauge is installed at the air cylinder opening to help monitor the air volume; one end of the air hose is connected to the air cylinder and the other end is connected to the air blowing head; the air blowing head is fixed on the air hose support, and the air hose support is fixed on the Z-axis module to prevent the air blowing head from shaking.

[0017] Furthermore, the workstation switching system includes: a turntable, a Y-axis shifting module, a four-jaw positioning and clamping cylinder, and a turntable fixing bracket;

[0018] The Y-axis shifting module is fixed on the equipment table, the turntable fixing bracket is installed on the Y-axis shifting module, the turntable is installed on the turntable fixing bracket, and the four-jaw positioning clamping cylinder is installed on the turntable. The switching between the feeding position and the welding position is realized by moving the Y-axis shifting module, and the welding position is changed during the welding process by rotating the turntable along the R-axis.

[0019] Furthermore, the vision system includes: a camera, a lens, a light source, a vision bracket, and a light source bracket; the camera and lens are mounted on the vision bracket, which is mounted on the Z-axis module of the welding system to achieve product visual position recognition; the lens is mounted between the camera and the product and is fixed to the Z-axis module of the welding system by the light source bracket.

[0020] Compared with the prior art, the advantages of this fully automatic laser welding equipment are as follows:

[0021] It achieves automated operation, reducing reliance on operator skills;

[0022] This improved welding precision and stability, ensuring welding quality.

[0023] It simplified the operating procedures and improved production efficiency;

[0024] The design of safety light curtains and safety doors enhances operational safety. Attached Figure Description

[0025] Figure 1 This is a schematic diagram of the overall structure of a fully automatic laser welding equipment according to the present invention;

[0026] Figure 2 This is a schematic diagram of the internal structure of a fully automatic laser welding equipment according to the present invention;

[0027] Figure 3 This is a schematic diagram of the visual inspection system and welding system structure of a fully automatic laser welding equipment according to this utility model;

[0028] Figure 4 This is a schematic diagram of the feeding system of a fully automatic laser welding equipment according to the present invention;

[0029] Figure 5 This is a schematic diagram of the station switching mechanism of a fully automatic laser welding equipment according to the present invention;

[0030] Figure 6(a) is a schematic diagram of the welding tray of a fully automatic laser welding equipment according to the present invention;

[0031] Figure 6(b) is a schematic diagram of the welding fixture of a fully automatic laser welding equipment according to the present invention; Detailed Implementation

[0032] Figure 1 This utility model discloses a fully automatic laser welding equipment, which mainly consists of the following components: a feeding system 1, a vision system 2, a welding system 3, a fume purification system 4, an equipment control cabinet 5, a positioning tray and tooling 6, an air blowing system 7, an equipment base 8, a station switching system 9, and a barcode scanner 10. The fully automatic laser welding equipment integrates two welding processes for one product. The system comprises several components: a feeding system 1, a vision system 2, and an equipment housing 8. The feeding system 1 transports products from the positioning tray and tooling 6 to the welding station. The vision system 2 locates the welding positions of the products before welding and transmits the coordinates back to the equipment control system. The welding system 3 controls different laser modes to achieve spot welding and continuous welding. The fume extraction system 4 recovers and treats the waste gas generated during welding to prevent pollution. The equipment control cabinet 5 serves as the main control center, controlling all actuators and components to ensure stable welding. The positioning tray and tooling 6 provide a platform for the feeding system 1 to grip materials, facilitating automatic welding after a batch of materials is fed in one go. The air blowing system 7 provides gas protection during welding to ensure weld stability and prevent blackening. The equipment housing 8 integrates all components into one unit, ensuring a fully enclosed fully automated welding process.

[0033] Figure 4A schematic diagram of the feeding system of a fully automatic laser welding equipment. The feeding system 1 mainly consists of a feeding X-axis module 10, a first lowering cylinder 11, a second lowering cylinder 12, a feeding Y-axis module 13, a first gripper cylinder 14, a second gripper cylinder 15, a first gripper 16, a second gripper 17, a support column 18, a first gripper mounting frame 19, and a second gripper mounting frame 20. The Y-axis loading module 12 is mounted on the support column 16 to ensure the accurate movement of the first gripper 16 and the second gripper 17 along the Y direction. The X-axis loading module 10 is mounted on the Y-axis loading module 12, enabling the first gripper 16 and the second gripper 17 to move along the Y direction while simultaneously moving along the X direction. A lowering cylinder 11 is mounted on the X-axis loading module 10, enabling the first gripper 16 to move along the XY direction while simultaneously moving along the Z direction. A gripper mounting bracket 19 is mounted and fixed on the lowering cylinder 11, and the first gripper 16 is mounted on the gripper mounting bracket 19. The second lowering cylinder 12 is mounted on the X-axis loading module 10, enabling the second gripper 17 to move along the XY direction while simultaneously moving along the Z direction. A first gripper cylinder 14 and a second gripper cylinder 15 are mounted on the first gripper 16 and the second gripper 17, respectively. When the cylinders push out the first gripper 14 and the second gripper 15, they clamp, thereby gripping the product and realizing loading and unloading.

[0034] The vision system 2 mainly consists of a camera 20, a lens 21, a light source 22, a vision support 23, and a light source support 24. The camera 20 and lens 21 are mounted on the vision support 23, which is in turn mounted on the Z-axis module 30 in the welding system 3. This works in conjunction with the turntable 90 in the workstation switching system 9 to achieve visual position recognition at different locations. The lens 21 is mounted between the camera and the product and is fixed to the Z-axis module 30 in the welding system 3 by the light source support 24.

[0035] The welding system 3 mainly consists of a Z-axis module 30, a welding module X-axis 31, a laser emitter head 32, and a laser host 33. The X-axis module 31 is mounted on the table 80 of the equipment base 8, the Z-axis module 30 is mounted on the X-axis module 31, the laser emitter head 32 is mounted on the Z-axis module 30, and the laser host 33 is encapsulated at the bottom of the equipment base 8. The welding process is as follows: when the product is moved to the welding position, the welding module X-axis 31 moves to the welding position, the vision system 2 takes a picture and recognizes it, and the R-axis linkage compensation of the welding module X-axis 31, the Z-axis module 30, and the turntable 90 in the station switching system 9 determines the position of the circular hole of the product welding position. The laser emitter head emits light to weld the first point, and then the turntable 90 rotates 45° along the R-axis to weld the second point. The rotation angle is repeated until all four points are welded, and then it returns to the loading position to wait for unloading to the material tray. The second welding process is as follows: After the product is moved to the welding position, the vision system 2 takes a picture and identifies the weld position. Then the welding module moves to the welding position along the X-axis, rotates along the R-axis, and the laser emits light synchronously, welding eight points on the end cap. Then the Z-axis moves to the other end cap, the vision system 2 takes a picture and identifies the gaps at four positions, and finds the weld position. Then the welding module moves to the welding position along the X-axis 31, the turntable 90 rotates along the R-axis, and the laser emits light synchronously, welding eight points on the end cap. After welding is completed, the product returns to the loading position, waiting to be unloaded onto the material tray.

[0036] The fume purification system 4 is placed inside the right side of the equipment base 8, encapsulated in an independent space. The cabinet door can be opened to push out the fume purification system 4 for filter replacement. The equipment control cabinet 5 is installed at the bottom of the equipment base 8, encapsulating control components such as the PLC.

[0037] The positioning tray assembly 6 consists of a welding tray 60 and a welding fixture 61. The welding tray 60 includes a handle 600, a positioning plate 601, and a QR code 602. The handle 600 is fixed to both sides of the positioning plate 601, and the QR code 602 is riveted to the lower right corner of the positioning plate 601. Both welding processes share a single welding fixture 61, which includes a positioning mandrel 610, a fixing block 611, a winding shaft 612, and a rubber sleeve 613. The positioning mandrel 610 passes through the product positioning hole, and the stepped surface limits the axial displacement of one end of the product. The fixing block 611 presses down on the other end of the product. The winding shaft 612 is fixed to the positioning mandrel 610 by internal threads, and the product's wire harness is wound around the winding shaft 612. The rubber sleeve 613 is fixed to the top of the winding shaft 612 to prevent the wire harness from scattering. The welding tray 60 is positioned and supported by pins on the positioning columns on the equipment table 80.

[0038] The air blowing system 7 mainly consists of an air pipe 71, an air cylinder 72, an air blowing head 73, an air pipe bracket 74, an air cylinder bracket 75, and a pressure gauge 76. The air cylinder 72 is encapsulated inside the right side of the equipment housing 8 and placed on the movable air cylinder bracket 75 for easy replacement. The pressure gauge 76 installed at the air cylinder opening helps monitor the air volume. One end of the air pipe 71 is connected to the air cylinder 72, and the other end is connected to the air blowing head 73. The air blowing head 73 is fixed on the air pipe bracket 74, and the air pipe bracket 75 is fixed on the Z-axis module 30 to prevent the air blowing head from shaking.

[0039] The equipment base 8 mainly consists of an equipment table 80, a sheet metal shell 81, a profile frame 82, a tri-color light 83, a computer monitor 84, a touch screen 85, a barcode scanner bracket 86, and an NG (no-load) material box. The equipment table 80 supports the feeding system 1, vision system 2, welding system 3, positioning tray and tooling 6, and workstation switching system 9, and is installed inside the profile frame 82. The sheet metal shell 81 is nested on the profile frame 82. The computer monitor 84 and touch screen 85 are installed on the sheet metal shell 81. The barcode scanner bracket 86 is installed on the profile frame 82. The tri-color light 83 is installed on the top sheet metal shell 81. The NG material box is installed next to the positioning tray and tooling 6 to recycle welding waste.

[0040] The workstation switching system 9 mainly consists of a turntable 90, a Y-axis shifting module 91, a four-jaw positioning and clamping cylinder 92, and a turntable fixing bracket 93. The Y-axis shifting module 91 is fixed on the equipment table 80, the turntable fixing bracket 93 is mounted on the Y-axis shifting module 91, the turntable 90 is mounted on the turntable fixing bracket 93, and the four-jaw positioning and clamping cylinder 92 is mounted on the turntable 90. The switching between the material loading position and the welding position is achieved by moving the Y-axis shifting module 91, and the change of the welding position during the welding process is achieved by rotating the turntable 90 along the R-axis.

[0041] The operation procedure for this device is as follows:

[0042] (1) The operator places the workpiece to be welded into the positioning tray 7 and presses the start button.

[0043] (2) Close the safety door to ensure safety during the welding process.

[0044] (3) Each module and the cylinder gripper automatically execute the program action. The first gripper 16 clamps the first product and tooling placed in the positioning tray and tooling 6, and places it on the turntable 90 to realize the loading of the workpiece. After loading, the second gripper 17 automatically moves to the positioning tray and tooling 6 to clamp the second product and waits at the loading position to clamp the first product and load the second product, and so on.

[0045] (4) The vision system 2 identifies the welding position features of the workpiece and positions it. The welding system 3 moves to the welding position and starts welding.

[0046] (5) After welding is completed, move the workpiece back to the front of the positioning tray 7, the first clamp 16 unloads the material, the second clamp 17 loads the material, and after completion, place the welded product back on the welding tray 60, then clamp the third product and move it to the loading position to wait. At this time, the welding position is already welding the second product. Repeat the above steps.

[0047] (6) After all the workpieces in the positioning tray and tooling 6 are welded, the cylinders return to their initial positions. The operator opens the safety door 5, takes out the welded tray of products, and puts in new workpieces to be welded. The above welding process is repeated.

[0048] This invention simplifies operation steps and improves welding efficiency and quality through an automated welding process. Simultaneously, a precise positioning mechanism ensures the stability and repeatability of the welding process. Through integrated design, various subsystems are tightly integrated. This integrated design not only saves space in the production workshop but also reduces the complexity of equipment maintenance and management by minimizing physical connections between devices. Furthermore, by integrating welding processes, including continuous welding and spot welding, it enables the retrieval of different process parameters via interfaces, ensuring error prevention during production and meeting the production needs of different processes.

[0049] The above description and accompanying drawings are only used to illustrate the principles and embodiments of this utility model. For those skilled in the art, the implementation of this utility model is not limited to the details described above. Various equivalent changes or modifications can be made without departing from the spirit of this utility model, and all such changes or modifications should be covered within the protection scope of this utility model.

[0050] Furthermore, it should be understood that although this specification describes embodiments, not every embodiment contains only one independent technical solution. Those skilled in the art can appropriately combine the technical solutions in this specification to form new embodiments.

Claims

1. A fully automatic laser welding apparatus, characterized by, Comprise: The feeding system, vision system, welding system, smoke purification system, equipment control system, positioning tray assembly, blowing system, equipment base, station switching system, code scanning gun; The feeding system is used to transfer the product from the positioning tray assembly to the station switching system; the vision system is used to find the welding position of the two products before welding, and the position coordinates are returned to the equipment control system; the welding system selects different welding modes to weld the workpiece; the smoke purification system is used to recycle and process the waste gas generated during welding to prevent pollution; the equipment control system realizes the control process of each executive mechanism component of the whole equipment to ensure the stable welding process; the positioning tray assembly provides a platform for the grabbing of the feeding system; the blowing system provides protection gas for the welding process; the equipment shell integrates all component systems; the station switching system is used to switch the product between the feeding station and the welding station; the code scanning gun selects the welding process by scanning the two-dimensional code on the positioning tray assembly.

2. A fully automatic laser welding apparatus according to claim 1, characterized in that, The equipment base includes: equipment table, equipment sheet metal shell, profile frame, three-color lamp, computer display, touch screen, code scanning gun bracket, NG box; The equipment table bears the feeding system, vision system, welding system, positioning tray and tooling, station switching system, is installed in the profile frame, the sheet metal shell is nested on the profile frame, the computer display and the touch screen are installed on the sheet metal shell, the code scanning gun bracket is installed on the profile frame, the three-color lamp is installed on the top sheet metal shell, and the NG box is installed beside the positioning tray and tooling.

3. A fully automatic laser welding apparatus according to claim 2, characterized in that: The feeding system includes: feeding X-axis module, first descending cylinder, second descending cylinder, feeding Y-axis module, first clamping cylinder, second clamping cylinder, first clamping jaw, second clamping jaw, support column, first clamping jaw mounting bracket, second clamping jaw mounting bracket; The feeding Y-axis module is installed on the support column to ensure the accurate movement of the first and second clamping jaws along the Y direction; the feeding X-axis module is installed on the feeding Y-axis module to enable the first and second clamping jaws to move along the Y direction while moving along the X direction; the first descending cylinder is installed on the feeding X-axis module to enable the first clamping jaw to move along the XY direction while moving along the Z direction; the first clamping jaw mounting bracket is fixed on the first descending cylinder, and the first clamping jaw is installed on the first clamping jaw mounting bracket; the second descending cylinder is installed on the feeding X-axis module to enable the second clamping jaw to move along the XY direction while moving along the Z direction; the first and second clamping cylinders are installed on the first and second clamping jaws, respectively, and when the cylinders push out the first and second clamping jaws, they are clamped to grab the product for feeding and unloading.

4. A fully automatic laser welding apparatus according to claim 3, wherein The welding system includes: Z-axis module, welding module X-axis, laser exit head, laser main machine; The module X-axis is installed on the equipment base, the Z-axis module is installed on the module X-axis, the laser exit head is installed on the Z-axis module, and the laser main machine is packaged at the bottom of the equipment base.

5. A fully automatic laser welding apparatus according to claim 4, wherein is characterized by, The smoke purification system is placed in the right side of the equipment base and packaged in a separate space. The cabinet door can be opened to push out the smoke purification system for filter replacement.

6. A fully automatic laser welding apparatus according to claim 5, wherein The positioning tray assembly comprises a welding tray and a welding tool, wherein the welding tray comprises a handle, a positioning disc and a two-dimensional code, the handle is fixed on both sides of the positioning disc, and the two-dimensional code is riveted at the lower right corner of the positioning disc; the welding tool comprises a positioning mandrel, a fixed pressing block, a winding shaft and a rubber sleeve, the positioning mandrel passes through a product positioning hole, a stepped surface limits the axial displacement of one end of the product, the fixed pressing block presses the other end of the product, the winding shaft is fixed on the positioning mandrel through an internal thread, the wire harness of the product is wound on the winding shaft, and the rubber sleeve is fixed on the top of the winding shaft to prevent the wire harness from scattering; the welding tray is positioned and supported by a pin of a positioning column on the equipment table top.

7. A fully automatic laser welding apparatus according to claim 6, characterized in that The blowing system comprises a gas pipe, a gas cylinder, a blowing head, a gas pipe support, a gas cylinder support and a pressure gauge; the gas cylinder is packaged in the right side of the equipment shell, is placed on the movable gas cylinder support to facilitate replacement of the gas cylinder, and the gas cylinder port is provided with the pressure gauge to help monitor the gas amount of the gas cylinder; one end of the gas pipe is connected with the gas cylinder, and the other end is connected with the blowing head, the blowing head is fixed on the gas pipe support, the gas pipe support is fixed on the Z-axis module, and the blowing head is prevented from shaking.

8. A fully automatic laser welding apparatus according to claim 7, characterized in that: The station switching system comprises a rotary table, a Y-axis displacement module, a four-jaw positioning and clamping cylinder and a rotary table fixing support. The Y-axis displacement module is fixed on the equipment table top, the rotary table fixing support is installed on the Y-axis displacement module, the rotary table is installed on the rotary table fixing support, and the four-jaw positioning and clamping cylinder is installed on the rotary table; the switching of the feeding position and the welding position is realized through the movement of the Y-axis displacement module, and the change of the welding position in the welding process is realized through the rotation of the rotary table along the R-axis.

9. A fully automatic laser welding apparatus according to claim 8, characterized in that, The vision system comprises a camera, a lens, a light source, a vision support and a light source support; the camera and the lens are installed on the vision support, the vision support is installed on the Z-axis module in the welding system, and the vision position of the product is recognized; the lens is installed between the camera and the product, and is fixed on the Z-axis module in the welding system by the light source support.

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