Automatic welding device for welding axial flow fan ducts

Abstract

The application provides an automatic welding device for welding of an axial flow fan wind tube, which comprises a welding power source, a robot electric control box and a system control cabinet, a double-shaft positioner is arranged on one side of the system control cabinet, a tool clamp for clamping a guide vane workpiece is arranged on the double-shaft positioner, a six-shaft welding robot with a laser vision system is arranged on one side of the tool clamp, and the welding gun mechanism comprises a welding gun main arm. According to the utility model, the positioner is equipped to realize 360-degree rotation of the workpiece, so that dead angles in welding are avoided. In the case of manual misoperation after equipment failure occurs in work, the detachable welding gun mechanism is additionally arranged, so that the situation that the welding gun collides with the workpiece or other obstacles can be avoided in time, and damage of the welding gun is prevented.

Description

Technical Field

[0001] This utility model belongs to the field of axial flow fan duct welding technology, and specifically relates to an automated welding device for welding axial flow fan ducts. Background Technology

[0002] Axial flow fans are widely used in industry, construction, shipbuilding, and other fields. The welding quality directly affects their structural strength, aerodynamic performance, and service life. Traditional manual welding is inefficient, inconsistent, and requires high labor costs for post-weld grinding. Therefore, it is necessary to develop fully automated welding processes to achieve efficient and high-precision production.

[0003] During operation, welding machines require a welding power source and a welding torch to weld the desired products into shape. However, during operation, in the event of equipment malfunction or human error, the welding torch often comes into contact with the workpiece or other obstacles, resulting in damage to the welding torch. Utility Model Content

[0004] In view of the problems existing in the background technology, the present invention provides an automated welding device for welding the duct of an axial flow fan, including a welding power source, a robot electrical control box and a system control cabinet. A dual-axis positioner is provided on one side of the system control cabinet. The dual-axis positioner is equipped with a tooling fixture for clamping the guide vane workpiece. A six-axis welding robot with a laser vision system is provided on one side of the tooling fixture. The welding torch mechanism includes a welding torch main arm.

[0005] Optionally, the welding torch main arm is fixed to the end of the six-axis welding robot arm by a fixed connection, and the welding torch main arm includes a connecting shaft integrally formed therewith.

[0006] Optionally, a first magnetic base is provided at the end of the connecting shaft away from the main arm of the welding torch, and a second magnetic base is magnetically connected to the first magnetic base.

[0007] Optionally, a magnetic suction hole is provided on the end face of the first magnetic base along its circumference, and an electrical connector connected to an external power source is provided in the magnetic suction hole. A first strong magnet connected to the electrical connector is soldered onto the electrical connector.

[0008] Optionally, the second magnetic base is provided with multiple sets of second strong magnets along its circumference, and the second strong magnets extend into the magnetic hole and are used in conjunction with the first magnet.

[0009] Optionally, the second magnetic base is provided with a welding torch auxiliary arm integrated therewith, and the welding torch auxiliary arm includes a welding torch. A connecting bracket is fixedly connected to the welding torch, and a sensor is connected through the connecting bracket.

[0010] Optionally, a receiver for use with the sensor is provided on the connecting shaft.

[0011] Optionally, the sensor includes a roller shaft, and the connecting ring of the connecting bracket is fixedly connected to the roller shaft. The sensor also includes a guide shaft disposed within the sensor housing, a spring disposed on the guide shaft, and a roller shaft disposed above the end face of the guide shaft away from the spring.

[0012] Optionally, holes are provided on both the roller and the end cap, and a ball bearing is provided between the roller and the end cap. The diameter of the hole is smaller than the diameter of the ball bearing, and both ends of the ball bearing extend into the hole of the roller and the hole of the end cap, respectively.

[0013] Optionally, a wedge is provided inside the sensor housing, and the wedge is connected to the guide shaft through a fixing member. When in a protected state, the side end face of the wedge away from the roller shaft is in close contact with the contact switch, and the contact switch is installed on the inner wall of the sensor housing.

[0014] In summary, the beneficial effects of this utility model are:

[0015] This invention features a positioner that enables 360° rotation of the workpiece, eliminating welding dead angles. In case of equipment malfunction or human error during operation, a detachable welding torch mechanism can be added to prevent the welding torch from colliding with the workpiece or other obstacles, thus preventing damage to the torch. Attached Figure Description

[0016] Figure 1 This is a schematic diagram of the overall structure of an embodiment of the automated welding device for welding the axial flow fan casing according to the present invention;

[0017] Figure 2 This is a welding torch assembly drawing of an embodiment of the automated welding device for welding the axial flow fan casing according to the present invention;

[0018] Figure 3 This is a schematic diagram of the welding torch mechanism of an embodiment of the automated welding device for welding the axial flow fan casing of the present invention.

[0019] Figure 4 This is a schematic diagram of the internal structure of the sensor in an embodiment of the automated welding device for welding the axial flow fan casing of this utility model.

[0020] Figure label:

[0021] 1. Welding power source; 2. Robot electrical control box; 3. System control cabinet; 4. Dual-axis positioner; 5. Guide vane workpiece; 6. Tooling fixture; 7. Laser vision system; 8. Six-axis welding robot; 9. Welding torch mechanism; 091. Welding torch main arm; 092. Connecting shaft; 093. Receiver; 094. First magnetic base; 096. Second magnetic base; 097. Welding torch auxiliary arm; 11. Welding torch; 12. Connecting bracket; 121. Connecting ring; 13. Sensor; 131. Roller; 132. Sensor housing; 133. Ball bearing; 134. End cap; 135. Guide shaft; 136. Wedge; 137. Fixture; 138. Contact switch; 139. Spring. Detailed Implementation

[0022] To make the objectives, technical solutions, and advantages of this utility model clearer, the present utility model will be further described in detail below with reference to the accompanying drawings and specific embodiments. Although exemplary embodiments are disclosed in the drawings, it should be understood that the present utility model can be implemented in various forms and should not be limited to the embodiments set forth herein. Rather, these embodiments are provided to facilitate a more thorough understanding of the present utility model and to fully convey the concept of the present utility model to those skilled in the art.

[0023] In the description of this specification, the references to terms such as "certain embodiments," "one embodiment," "some embodiments," "example," "specific example," or "some examples," etc., refer to specific features, structures, materials, or characteristics described in connection with that embodiment or example, which are included in at least one embodiment or example of this application. In this specification, the illustrative expressions of the above terms do not necessarily refer to the same embodiment or example. Furthermore, the specific features, structures, materials, or characteristics described may be combined in a suitable manner in any one or more embodiments or examples. Moreover, without contradiction, those skilled in the art can combine and integrate the different embodiments or examples described in this specification, as well as the features of different embodiments or examples.

[0024] In this utility model, the terms "first," "second," and "third" are used for descriptive purposes only and should not be construed as indicating or implying relative importance; the term "multiple" refers to two or more unless otherwise explicitly defined. The terms "install," "connect," "join," and "fix" should be interpreted broadly. For example, "connect" can be a fixed connection, a detachable connection, or an integral connection; "join" can be a direct connection or an indirect connection through an intermediate medium. Those skilled in the art can understand the specific meaning of the above terms in this utility model according to the specific circumstances.

[0025] like Figure 1-4As shown, this embodiment provides an automated welding device for welding the axial flow fan casing, including a welding power supply 1, a robot electrical control box 2, and a system control cabinet 3. The system control cabinet 3 controls the coordination between the axes of the six-axis welding robot. The welding power supply 1 adopts a commercially available three-phase 380V power supply with a frequency of 50HZ and a voltage fluctuation range of +10% and -15%. A single-station capacity robot welding power supply of 35KVA is acceptable.

[0026] The system control cabinet 3 adopts the ROB4V10-1600 control cabinet;

[0027] The robot electrical control box 2 adopts the XLH electrical control box. The coordination and connection between the welding power supply, the robot electrical control box, the system control cabinet and various devices are all existing technologies and will not be described in detail here.

[0028] Furthermore, a dual-axis positioner 4 is provided on one side of the system control cabinet 3. The dual-axis positioner 4 is equipped with a tooling fixture 6 for clamping the guide vane workpiece 5. The dual-axis positioner 4 is a dual-axis servo flipping positioner including a flipping active box, a flipping driven box, a horizontal rotation power box, a positioner base and a fixture placement connecting plate.

[0029] Furthermore, a six-axis welding robot 8 with a laser vision system 7 is provided on one side of the tooling fixture 6. The laser vision system 7 adopts a laser vision mechanism commonly found on the market, which has a high dynamic range vision camera, line laser and PLUS laser power supply.

[0030] The six-axis welding robot is an LH series six-axis welding robot, and the six-axis welding robot includes a welding torch mechanism 9 fixed at the end of the six-axis welding robot's robotic arm.

[0031] During operation, welding machines require a welding power source and a welding torch to weld the desired product into shape. However, during operation, in the event of equipment malfunction or human error, the welding torch often encounters the workpiece or other obstacles, resulting in damage to the torch. This application addresses these technical problems by redesigning the welding torch mechanism. (See reference...) Figure 1-4 As shown, the welding torch mechanism 9 includes a welding torch main arm 091, on which a connecting chain can be installed to connect the welding torch auxiliary arm 097.

[0032] The welding torch main arm 091 is fixed to the end of the six-axis welding robot arm by a fixed connection (e.g., welding). The welding torch main arm 091 includes a connecting shaft 092 integrally formed therewith, and a first magnetic base 094 integrally formed therewith is provided at the end of the connecting shaft 092 away from the welding torch main arm 091, and a second magnetic base 096 is magnetically connected through the first magnetic base 094.

[0033] Furthermore, a magnetic suction hole is provided on the end face of the first magnetic base 094 along its circumference, and an electrical connector for connecting to an external power source is provided in the magnetic suction hole. The electrical connector can be a common electrical connector on the market, which is existing technology and will not be described in detail here. A first strong magnet connected to it is soldered on the electrical connector.

[0034] Furthermore, the second magnetic base 096 is provided with multiple sets of second strong magnets along its circumference, and the second strong magnets extend into the magnetic holes and are used in conjunction with the first magnet. When in working condition, current passes through the coil of the first strong magnet, and the magnetic field generated in the coil causes the iron core of the first strong magnet to become a strong magnet, generating a magnetic pole pair, which in turn attracts the second strong magnet, completing the connection between the first magnetic base and the second magnetic base. The second strong magnet can be an N52 series magnet.

[0035] Furthermore, the second magnetic base 096 is provided with a welding gun auxiliary arm 097 integrated therewith, and the welding gun auxiliary arm 097 includes a welding gun 11. A connecting bracket 12 is installed on the welding gun 11 by a fixed connection method (e.g., welding, fastening screws, etc.), and the sensor 13 is connected through the connecting bracket 12.

[0036] Furthermore, a receiver 093 is provided on the connecting shaft 092 for use in conjunction with the sensor 13.

[0037] Furthermore, the sensor 13 includes a roller 131, and the connecting ring 121 of the connecting bracket 12 is installed on the roller 131 by a fixed connection method (e.g., welding, fastening screws, etc.) to realize the connection between the connecting bracket 12 and the sensor.

[0038] Furthermore, the sensor 13 also includes a guide shaft 135 disposed within the sensor housing 132, a spring 139 disposed on the guide shaft 135, and a roller 131 disposed above the end face of the guide shaft 135 away from the spring 139.

[0039] Furthermore, holes are provided on both the roller shaft 131 and the end cap 134, and a ball bearing 133 is provided between the roller shaft 131 and the end cap 134. The diameter of the hole is smaller than the diameter of the ball bearing 133, and the two ends of the ball bearing 133 extend into the hole of the roller shaft 131 and the hole of the end cap 134, respectively.

[0040] In this embodiment, those skilled in the art should understand that, since the diameter of the hole is smaller than the diameter of the ball 133, only a portion of the ball is embedded in the hole of the roller shaft and the end cap.

[0041] Furthermore, a wedge 136 is provided inside the sensor housing, and the wedge 136 is connected to the guide shaft 135 through a fixing member 137, preferably a positioning pin; when in the protected state, the side end face of the wedge 136 away from the roller shaft 131 is in close contact with the contact switch 138, and the contact switch 138 is installed on the inner wall of the sensor housing 132 by means of adhesive, welding or other fixed connection.

[0042] In this embodiment, those skilled in the art should understand that when the sensor is subjected to pressure from the Z direction, the other two forces, Fz and Ty, are eventually converted into pressure in the Z direction, thus achieving protection.

[0043] When a six-axis welding robot is welding, the welding torch collides with the workpiece or other parts, generating a collision force Fz, which is calculated according to the formula:

[0044] X=.Fz

[0045] Where X is the compressive displacement along the -Z direction, and K is the spring stiffness;

[0046] Because the displacement of the guide shaft is proportional to the impact force under a certain spring stiffness, when a certain impact force is reached, the sensor is subjected to a bending moment along the X or Y direction. The roller transmits the torque force Tz to itself. When the ball bearing the torque force Tz, it generates a torque opposite to Tz, causing relative slippage between the roller and the ball. The ball's limiting effect at the upper end of the roller restricts its movement in the Z-direction, forcing the lower end face of the roller to deflect. Only one side contacts the guide shaft, compressing it and causing it to move in the -Z direction. This forces the guide shaft to move the wedge towards the contact switch. When the wedge contacts the contact switch, the switch sends a control signal. The receiver on the connecting shaft receives the protection signal from the contact switch, decodes it into a control command, and transmits it to the system control cabinet. The system control cabinet then issues a control command to cut off the power supply to the electrical connector. At this point, the first magnetic base loses its magnetism, disconnecting from the second magnetic base, allowing the welding torch to disengage from its original position and preventing collision.

[0047] Finally, it should be noted that the above embodiments are only used to illustrate the technical solution of this utility model and are not restrictive. Although this utility model has been described in detail with reference to the embodiments, those skilled in the art should understand that modifications or equivalent substitutions to the technical solution of this utility model do not depart from the spirit and scope of the technical solution of this utility model, and all such modifications or substitutions should be covered within the scope of the claims of this utility model.

Claims

1. An automated welding device for welding the casing of an axial flow fan, characterized in that, The system includes a welding torch mechanism, a welding power source, a robot electrical control box, and a system control cabinet. A dual-axis positioner is located on one side of the system control cabinet, and the dual-axis positioner is equipped with a tooling fixture for clamping the guide vane workpiece. A six-axis welding robot with a laser vision system is located on one side of the tooling fixture. The welding torch mechanism includes a welding torch main arm. A first magnetic base is integrated with the welding torch main arm at the end of the connecting shaft away from the welding torch main arm, and a second magnetic base is magnetically connected to the first magnetic base. A welding torch auxiliary arm is integrated with the second magnetic base, and the welding torch auxiliary arm includes the welding torch. A connecting bracket is fixedly connected to the welding torch, and a sensor is connected to the connecting bracket.

2. The automated welding device for welding the axial flow fan casing according to claim 1, characterized in that, The welding torch main arm is fixed to the end of the six-axis welding robot arm by a fixed connection, and the welding torch main arm includes a connecting shaft integrally formed therewith.

3. The automated welding device for welding the axial flow fan casing according to claim 2, characterized in that, A magnetic suction hole is provided on the end face of the first magnetic base along its circumference, and an electrical connector connected to an external power source is provided in the magnetic suction hole. A first strong magnet is soldered onto the electrical connector.

4. The automated welding device for welding the axial flow fan casing according to claim 3, characterized in that, The second magnetic base is provided with multiple sets of second strong magnets along its circumference, and the second strong magnets extend into the magnetic hole and are used in conjunction with the first magnet.

5. The automated welding device for welding the axial flow fan casing according to claim 4, characterized in that, A receiver is provided on the connecting shaft for use with the sensor.

6. The automated welding device for welding the axial flow fan casing according to claim 5, characterized in that, The sensor includes a roller shaft, and the connecting ring of the connecting bracket is fixedly connected to the roller shaft. The sensor also includes a guide shaft disposed inside the sensor housing, a spring disposed on the guide shaft, and a roller shaft disposed above the end face of the guide shaft away from the spring.

7. The automated welding device for welding the axial flow fan casing according to claim 6, characterized in that, Both the roller and the end cap have holes, and a ball bearing is provided between the roller and the end cap. The diameter of the hole is smaller than the diameter of the ball bearing, and the two ends of the ball bearing extend into the hole of the roller and the hole of the end cap, respectively.

8. The automated welding device for welding the axial flow fan casing according to claim 7, characterized in that, The sensor housing is provided with a wedge, and the wedge is connected to the guide shaft by a fixing member. When in the protected state, the side end face of the wedge away from the roller shaft is in close contact with the contact switch, and the contact switch is installed on the inner wall of the sensor housing.

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