Stud welding strength automatic detection equipment
By using an adaptive force-controlled collaborative robot and a six-dimensional torque sensor, combined with an automated guided vehicle and an audible and visual alarm device, the problems of automation and data quantification in stud welding strength detection were solved, achieving efficient welding quality control.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- GUANGZHOU AUTOMIBILE GRP MOTOR
- Filing Date
- 2025-05-23
- Publication Date
- 2026-05-08
AI Technical Summary
In existing technologies, the testing of stud welding strength relies on manual operation, which is subject to subjective differences and cannot achieve data quantification and process traceability, leading to welding quality problems.
An adaptive force-controlled collaborative robot and a six-dimensional torque sensor are used to detect the welding strength of studs through the detection head at the end of the collaborative robot. Combined with an automated guided vehicle and an audible and visual alarm device, automated detection and data quantification are achieved.
It achieves automated testing of stud welding strength, avoiding adverse risks caused by subjective human judgment, quantifies data, makes the process traceable, and has strength trend management and analysis functions.
Smart Images
Figure CN224216444U_ABST
Abstract
Description
Technical Field
[0001] This application relates to the technical field of automobile production, and particularly to an automatic detection equipment for stud welding strength. Background Art
[0002] In the manufacturing process of automobile body-in-white, many studs need to be welded on workpieces. Stud welding is to make the stud contact the workpiece, and after power-on, the stud clamping mechanism is used to lift the stud. At this time, a stable combustion arc appears between the stud and the workpiece. The arc heat melts the top of the stud and the surface of the workpiece. Then the stud clamping mechanism presses the stud to sink into the workpiece molten pool, and after power-off, the stud welding is formed. The conventional method for detecting the strength of stud welding is hammer testing. A 0.5-pound rubber hammer is used to strike the stud at a specified angle and force. The distance of the rubber hammer is within the range of 20 cm to 30 cm, the angle α is greater than 45°, the hammer falls freely, ensuring that the striking force angle β is less than 45°, ensuring the striking direction, and striking back and forth. If the stud does not fall off, it is qualified.
[0003] The hammer testing method for stud welding strength depends only on the operator to ensure. It has high requirements for the operator's proficiency and there are subjective individual differences. The detection data cannot be quantified and the process cannot be traced. It is easy for the poor welding strength to flow out, resulting in quality problems. Content of the Utility Model
[0004] Based on this, the purpose of the present utility model is to overcome the deficiency that the existing stud welding strength mainly relies on manual operation, and the detection data cannot be quantified and the process cannot be traced, and to provide an automatic detection equipment for stud welding strength. The present utility model avoids the product defect risk brought by manual subjective judgment, realizes the automation of strength detection, and has functions such as data quantification, process traceability, and strength trend management analysis.
[0005] To solve the above technical problems, the technical solution adopted by the present utility model is:
[0006] An automatic detection equipment for stud welding strength includes a collaborative robot and a detection head connected to the end of the collaborative robot. The detection head includes a stud sleeve and a torque sensor disposed between the stud sleeve and the collaborative robot. It also includes a control system, and the control system is respectively connected to the collaborative robot and the torque sensor.
[0007] This invention incorporates an adaptive force-controlled collaborative robot, utilizing automated inspection to replace repetitive manual labor. A detection head connected to the end effector of the collaborative robot is designed to inspect the welding strength of studs. After the collaborative robot controls the stud sleeve to fit over the welded stud, it performs programmed actions through a control system. A torque sensor collects and transmits real-time stud strength torque information to the control system. The control system collects, processes, and statistically analyzes the measurement data, displaying real-time stud welding strength information, pass rate statistics, or abnormal warnings, thus creating a user-friendly human-machine interaction with on-site workers. This invention avoids the product defect risks caused by subjective human judgment, automates strength inspection, quantifies data, ensures process traceability, and provides strength trend management and analysis.
[0008] Furthermore, the detection head also includes a mounting flange for connecting to the end effector of the collaborative robot, the mounting flange being coaxially arranged with the stud sleeve.
[0009] Furthermore, the torque sensor is a six-dimensional torque sensor, located between the mounting flange and the stud sleeve, and coaxially arranged with the stud sleeve and the mounting flange.
[0010] It should be noted that traditional stud welding strength is tested by manual hammering and visual inspection. This invention uses a six-dimensional torque sensor for data detection. It is securely connected to the collaborative robot via an installation flange. The six-dimensional torque sensor is coaxially connected to the stud sleeve and the installation flange. In this way, the six-dimensional torque sensor can more accurately sense the torque changes caused by the angle changes of the stud sleeve. The six-dimensional torque sensor detects the torque in multiple directions and compares it with the set torque to determine whether the stud strength is qualified.
[0011] Furthermore, the inner diameter of the stud sleeve is 1mm to 2mm larger than the outer diameter of the stud to be tested.
[0012] Furthermore, the depth of the stud sleeve is 3mm to 5mm longer than the length of the stud to be tested.
[0013] It should be noted that the inner diameter and depth of the stud sleeve need to be designed to have some redundancy than the size of the stud to be tested. This is so that the collaborative robot can achieve the set swinging motion. Secondly, the redundancy space cannot be too large, otherwise the swinging amplitude of the collaborative robot will be too large, and the corresponding torque cannot be accurately and quickly collected. After continuous experimentation, the inner diameter of the stud sleeve is designed to be 1mm to 2mm larger than the outer diameter of the stud to be tested, and the depth of the stud sleeve is 3mm to 5mm longer than the length of the stud to be tested.
[0014] Furthermore, the automated stud welding strength testing equipment also includes a testing table located within the working range of the collaborative robot.
[0015] Furthermore, the testing station includes an automated guided vehicle, a support frame mounted on the automated guided vehicle for placing workpieces, and a positioning fixture mounted above the support frame. The automated guided vehicle is connected to the control system.
[0016] This utility model uses an AGV (Automated Guided Vehicle) to enable the movement of the inspection platform. The control system can synchronously control the AGV to transport the workpiece to the working range of the collaborative robot. The positioning fixture on the support frame is used to position the workpiece. After the AGV reaches the designated location, the collaborative robot automatically finds the position of the stud to be tested according to the positioning information preset by the control system and completes the fitting. After the fitting is completed, multi-directional torque detection is performed according to the predetermined imaging.
[0017] Furthermore, the support frame is a frame structure. The frame structure is designed to provide sufficient operating space for the collaborative robot. Since the studs on different workpieces may be located on the surface or the bottom of the workpiece, the frame structure allows the collaborative robot to reach under the support frame to test the welding strength of the studs on the bottom of the workpiece, thus improving the operational capability and range of this invention.
[0018] Furthermore, the automated stud welding strength testing equipment also includes an audible and visual alarm device, which is connected to the control system. When poor welding strength is detected, the audible and visual alarm can prompt the operator to repair the abnormal stud, and the operator can manually confirm the completion of the repair welding online, forming a closed-loop management system.
[0019] Furthermore, the control system includes a control processor, and an operation panel and a display panel respectively connected to the control processor.
[0020] Compared with the prior art, the beneficial effects of this utility model are:
[0021] (1) This utility model introduces an adaptive force control collaborative robot, which uses the automated detection method of the collaborative robot to replace the repetitive manual work. The detection head connected to the end of the collaborative robot is designed to detect the welding strength of the stud. After the collaborative robot controls the stud sleeve to cover the welding stud, it performs programmed actions through the control system. The torque sensor collects and transmits the stud strength torque information to the control system in real time. The control system collects, processes and statistically analyzes the measurement data, and displays the stud welding strength information and pass rate statistics or abnormal warnings in real time, thus building a friendly human-machine interaction with the on-site operators.
[0022] (2) This utility model avoids the risk of product defects caused by subjective human judgment, realizes the automation of strength testing, and enables data quantification, process traceability, strength trend management and analysis, etc. Attached Figure Description
[0023] Figure 1 This is a schematic diagram illustrating the application of an automated stud welding strength testing equipment in one embodiment;
[0024] Figure 2 This is a schematic diagram of the detection head being connected to the stud in one embodiment;
[0025] Figure 3 This is a schematic diagram of the detection head and stud sleeve detection state in one embodiment.
[0026] 1-Collaborative robot, 2-Detection head, 21-Stud sleeve, 22-Torque sensor, 23-Mounting flange, 31-Automatic guide vehicle, 32-Support frame, 33-Positioning fixture, 100-Stud to be tested. Detailed Implementation
[0027] The present invention will be further described below with reference to specific embodiments. The accompanying drawings are for illustrative purposes only, representing schematic diagrams rather than actual physical objects, and should not be construed as limiting the scope of this patent. To better illustrate the embodiments of the present invention, some components in the drawings may be omitted, enlarged, or reduced, and do not represent the actual dimensions of the product. It is understandable to those skilled in the art that some well-known structures and their descriptions may be omitted in the drawings.
[0028] To make the objectives, technical solutions, and advantages of this application clearer, the following detailed description is provided in conjunction with the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative and not intended to limit the scope of this application.
[0029] In the accompanying drawings of this utility model, the same or similar reference numerals correspond to the same or similar components. In the description of this utility model, it should be understood that if terms such as "upper," "lower," "left," and "right" indicate the orientation or positional relationship based on the orientation or positional relationship shown in the drawings, they are only for the convenience of describing this utility model and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, the terms used to describe positional relationships in the drawings are only for illustrative purposes and should not be construed as limiting this patent. For those skilled in the art, the specific meaning of the above terms can be understood according to the specific circumstances.
[0030] Example 1
[0031] like Figures 1 to 3As shown, an automated testing equipment for stud welding strength includes a collaborative robot 1 and a testing head 2 connected to the end of the collaborative robot 1. The testing head 2 includes a stud sleeve 21 and a torque sensor 22 disposed between the stud sleeve 21 and the collaborative robot 1. It also includes a control system, which is connected to the collaborative robot 1 and the torque sensor 22.
[0032] like Figure 2 As shown, the detection head 2 also includes a mounting flange 23 for connecting to the end of the collaborative robot 1, and the mounting flange 23 is coaxially arranged with the stud sleeve 21.
[0033] In this embodiment, the torque sensor 22 is a six-dimensional torque sensor 22, which is located between the mounting flange 23 and the stud sleeve 21. The torque sensor 22 is coaxially arranged with the stud sleeve 21 and the mounting flange 23.
[0034] It should be noted that the welding strength of traditional stud welds is tested by manual hammering and visual inspection. In this embodiment, a six-dimensional torque sensor 22 is used for data detection. It is stably connected to the collaborative robot 1 through the mounting flange 23. The six-dimensional torque sensor 22 is coaxially connected to the stud sleeve 21 and the mounting flange 23. In this way, the six-dimensional torque sensor 22 can more accurately sense the torque change caused by the angle change of the stud sleeve 21. The six-dimensional torque sensor 22 detects the torque in multiple directions and compares it with the set torque to determine whether the stud strength is qualified.
[0035] In this embodiment, the inner diameter of the stud sleeve 21 is 1mm to 2mm larger than the outer diameter of the stud 100 to be tested.
[0036] In this embodiment, the depth of the stud sleeve 21 is 3mm to 5mm longer than the length of the stud 100 to be tested.
[0037] It should be noted that the inner diameter and depth of the stud sleeve 21 need to be designed to have some redundancy than the dimensions of the stud 100 under test. This is so that the collaborative robot 1 can achieve the set swinging motion. Secondly, the redundancy space cannot be too large, otherwise the swinging amplitude of the collaborative robot 1 will be very large and the corresponding torque cannot be accurately and quickly collected. After continuous experiments, the inner diameter of the stud sleeve 21 is designed to be 1mm to 2mm larger than the outer diameter of the stud 100 under test, and the depth of the stud sleeve 21 is 3mm to 5mm longer than the length of the stud 100 under test.
[0038] Specifically, in this embodiment, the collaborative robot 1 carries a detection head 2 of a six-dimensional torque sensor 22. By inserting a stud sleeve 21 into the stud to be tested, the collaborative robot 1 controls the stud sleeve 21 to rotate 15° in four directions. The six-dimensional torque sensor 22 detects the torque in each of the four directions and compares it with the set torque to determine the stud strength. That is, the collaborative robot 1 sets the torque Ms as the torque standard. During the test, the torque measured by the six-dimensional torque sensor 22 is Mc, that is: the measurement result in the RX direction is Mc≥Ms, the measurement result in the -RX direction is Mc≥Ms, the measurement result in the RY direction is Mc≥Ms, and the measurement result in the -RY direction is Mc≥Ms. When the above results are satisfied at the same time, it means that the measurement is passed, that is, the stud welding strength meets the standard.
[0039] The working principle of this embodiment is as follows: an adaptive force-controlled collaborative robot 1 is introduced, and the automated detection method of the collaborative robot is used to replace the repetitive manual work. The detection head 2 connected to the end of the collaborative robot 1 is designed to detect the welding strength of the stud. After the collaborative robot 1 controls the stud sleeve 21 to cover the welding stud, it performs programmed actions through the control system. The torque sensor 22 collects and transmits the stud strength torque information to the control system in real time. The control system collects, processes and statistically analyzes the measurement data, and displays the stud welding strength information and pass rate statistics or abnormal warnings in real time, thus building a friendly human-machine interaction with the on-site operators.
[0040] The advantages of this embodiment are: it avoids the risk of product defects caused by subjective human judgment, automates strength testing, and enables data quantification, process traceability, and strength trend management and analysis.
[0041] Example 2
[0042] This embodiment is similar to Embodiment 1, except that in this embodiment:
[0043] like Figure 1 As shown, the automated stud welding strength testing equipment also includes a testing table, which is located within the working range of the collaborative robot 1.
[0044] like Figure 1 As shown, the inspection station includes an automated guided vehicle 31, a support frame 32 mounted on the automated guided vehicle 31 for placing workpieces, and a positioning fixture 33 mounted above the support frame 32. The automated guided vehicle 31 is connected to a control system.
[0045] In this embodiment, the AGV (Automated Guided Vehicle) 31 enables the movement of the inspection platform. The AGV 31 can be synchronously controlled by the control system to transport the workpiece to the working range of the collaborative robot 1. The positioning fixture 33 on the support frame 32 is used to position the workpiece. After the AGV 31 reaches the designated location, the collaborative robot 1 automatically finds the position of the stud 100 to be tested according to the positioning information preset by the control system and completes the fitting. After the fitting is completed, multi-directional torque detection is performed according to the predetermined imaging.
[0046] like Figure 1 As shown, the support frame 32 is a frame structure.
[0047] The support frame 32 is designed as a frame structure to provide sufficient operating space for the collaborative robot 1. Since the studs of different workpieces may be located on the surface or the bottom of the workpiece, the frame structure allows the collaborative robot 1 to extend under the support frame 32 to test the welding strength of the studs on the bottom of the workpiece, thereby improving the work capability and operating range of this embodiment.
[0048] The working principle of this embodiment is as follows: an adaptive force-controlled collaborative robot 1 is introduced, and the automated detection method of the collaborative robot is used to replace the repetitive manual work. The detection head 2 connected to the end of the collaborative robot 1 is designed to detect the welding strength of the stud. After the collaborative robot 1 controls the stud sleeve 21 to cover the welding stud, it performs programmed actions through the control system. The torque sensor 22 collects and transmits the stud strength torque information to the control system in real time. The control system collects, processes and statistically analyzes the measurement data, and displays the stud welding strength information and pass rate statistics or abnormal warnings in real time, thus building a friendly human-machine interaction with the on-site operators.
[0049] The advantages of this embodiment are: it avoids the risk of product defects caused by subjective human judgment, automates strength testing, and enables data quantification, process traceability, and strength trend management and analysis.
[0050] The other structures and principles of this embodiment are the same as those of Embodiment 1.
[0051] Example 3
[0052] This embodiment is similar to Embodiment 1, except that in this embodiment:
[0053] In this embodiment, the automated stud welding strength testing equipment also includes an audible and visual alarm device, which is connected to the control system. When poor welding strength is detected, the audible and visual alarm can prompt the operator to repair the abnormal stud, and the operator can manually confirm the completion of the repair welding online, forming a closed-loop management system.
[0054] In this embodiment, the control system includes a control processor, and an operation panel and a display panel respectively connected to the control processor.
[0055] The working principle of this embodiment is as follows: an adaptive force-controlled collaborative robot 1 is introduced, and the automated detection method of the collaborative robot is used to replace the repetitive manual work. The detection head 2 connected to the end of the collaborative robot 1 is designed to detect the welding strength of the stud. After the collaborative robot 1 controls the stud sleeve 21 to cover the welding stud, it performs programmed actions through the control system. The torque sensor 22 collects and transmits the stud strength torque information to the control system in real time. The control system collects, processes and statistically analyzes the measurement data, and displays the stud welding strength information and pass rate statistics or abnormal warnings in real time, thus building a friendly human-machine interaction with the on-site operators.
[0056] The advantages of this embodiment are: it avoids the risk of product defects caused by subjective human judgment, automates strength testing, and enables data quantification, process traceability, and strength trend management and analysis.
[0057] The other structures and principles of this embodiment are the same as those of Embodiment 1.
[0058] Obviously, the above embodiments of this utility model are merely examples for clearly illustrating this utility model, and are not intended to limit the implementation of this utility model. Those skilled in the art can make other variations or modifications based on the above description. It is neither necessary nor possible to exhaustively describe all embodiments here. Any modifications, equivalent substitutions, and improvements made within the spirit and principles of this utility model should be included within the protection scope of the claims of this utility model.
Claims
1. An automated testing equipment for stud welding strength, characterized in that, The system includes a collaborative robot (1) and a detection head (2) connected to the end of the collaborative robot (1). The detection head (2) includes a stud sleeve (21) and a torque sensor (22) disposed between the stud sleeve (21) and the collaborative robot (1). The system also includes a control system connected to the collaborative robot (1) and the torque sensor (22).
2. The automated testing equipment for stud welding strength according to claim 1, characterized in that, The detection head (2) also includes a mounting flange (23) for connecting to the end of the collaborative robot (1), the mounting flange (23) being coaxially arranged with the stud sleeve (21).
3. The automated testing equipment for stud welding strength according to claim 2, characterized in that, The torque sensor (22) is a six-dimensional torque sensor (22). The torque sensor (22) is located between the mounting flange (23) and the stud sleeve (21). The torque sensor (22) is coaxially arranged with the stud sleeve (21) and the mounting flange (23).
4. The automated testing equipment for stud welding strength according to claim 1, characterized in that, The inner diameter of the stud sleeve (21) is 1mm to 2mm larger than the outer diameter of the stud (100) to be tested.
5. The automated testing equipment for stud welding strength according to claim 4, characterized in that, The depth of the stud sleeve (21) is 3mm to 5mm longer than the length of the stud (100) to be tested.
6. The automated testing equipment for stud welding strength according to claim 1, characterized in that, It also includes a testing station located within the working range of the collaborative robot (1).
7. The automated testing equipment for stud welding strength according to claim 6, characterized in that, The testing station includes an automated guided vehicle (31), a support frame (32) mounted on the automated guided vehicle (31) for placing workpieces, and a positioning fixture (33) mounted above the support frame (32). The automated guided vehicle (31) is connected to the control system.
8. The automated testing equipment for stud welding strength according to claim 7, characterized in that, The support frame (32) is a frame structure.
9. The automated testing equipment for stud welding strength according to claim 1, characterized in that, It also includes an audible and visual alarm device, which is connected to the control system.
10. The automated testing equipment for stud welding strength according to claim 1, characterized in that, The control system includes a control processor, and an operation panel and a display panel respectively connected to the control processor.