Integrated single machine intelligent welding device

Abstract

The utility model relates to an integral type single machine intelligence welding device, including welding torch, positioner system and visual guidance module, the positioner system is used to install and fix the electric power tower angle of waiting for processing, the visual guidance module guides the welding torch and carries out the welding to the electric power tower angle, the utility model discloses a mode of welding torch of L type positioner and automatic mechanical arm collocation realizes the robot automatic welding processing of the welding seam of various electric power tower angles such as all kinds of electric power tower angles of waiting for welding, can adapt to various complex environment.

Description

Technical Field

[0001] This utility model relates to the field of mechanical processing technology, and in particular to an integrated single-machine intelligent welding device. Background Technology

[0002] Welding is a commonly used production process. The biggest drawback of the welding machines currently in use is that they all require manual operation. Workers face sparks from the welding torch, which not only involves high labor intensity but also seriously affects their health due to photoelectric radiation.

[0003] In recent years, welding robots have become increasingly popular. Welding robots, when combined with tooling and additional motion equipment, have enabled various types of welding. However, in many application scenarios, welding robots generally suffer from problems such as excessively large workstation size, poor precision, and difficult operation. Moreover, because welding robots cannot achieve linkage, they suffer from low production efficiency and the inability to achieve multi-dimensional weld joints.

[0004] Taking the invention patent CN115446507A entitled "A Multi-Axis Linkage Automatic Welding System and Intelligent Manufacturing Platform for Exhaust Pipes" as an example, it achieves a more intelligent welding through multi-axis linkage. The integrated center positioning installation realizes one-stop clamping of products to improve welding accuracy. However, this multi-axis linkage is more complex and the overall product cost is high.

[0005] The industry urgently needs a product or device that can solve the above problems. Utility Model Content

[0006] In view of this, the purpose of this utility model is to propose an integrated single-machine intelligent welding device.

[0007] To achieve the above objectives, this utility model provides an integrated single-machine intelligent welding device, including a welding torch, a positioner system, and a vision guidance module. The positioner system is used to install and fix the power tower corner to be processed, and the vision guidance module guides the welding torch to weld the power tower corner.

[0008] The welding torch is mounted on the end segment of the automated robotic arm. The automated robotic arm includes two or more shaft joints, and the arm segment of the automated robotic arm is formed between two adjacent shaft joints. The automated robotic arm is electrically connected to and driven by an AC servo motor.

[0009] The positioner system includes an L-shaped base, a transmission mechanism disposed inside the L-shaped base, and a star-shaped fixture disposed on the L-shaped base. The star-shaped fixture is used to fix the corner of the power tower. When the transmission mechanism is in motion, the star-shaped fixture drives the corner of the power tower to rotate. The welding gun is used to perform corner seam welding on the fixed corner of the power tower.

[0010] The cross-shaped fixture includes cross-shaped fixed beams arranged longitudinally and transversely, with reinforcing wing plates between adjacent fixed beams, and the transmission mechanism of the positioner system is fixed at the middle position of the cross-shaped fixture.

[0011] The visual guidance module is fixedly installed on the upper end of the welding torch.

[0012] For another purpose of this utility model, each of the fixed beams is provided with a spiral adjusting rod for adjusting the length.

[0013] For another purpose of this utility model, it also includes a first base and a second base, the first base being used to fix the automatic robotic arm, the second base being used to install and fix the positioner system, and the L-shaped base being fixed to the side of the second base away from the first base.

[0014] For another purpose of this utility model, the adjacent fixed beams are spaced 90 degrees apart, and each fixed beam is provided with several sets of through holes, through which detachable triangular reinforcing wing plates are installed.

[0015] For another purpose of this utility model, each of the cross-shaped fixing beams is provided with a fixing clamp perpendicular to the plane where the cross-shaped fixing beam is located, so as to fix the corner of the power tower by means of each of the fixing clamps.

[0016] For another purpose of this utility model, it also includes a gun cleaning station, which is disposed on one side of the first base that fixes the automatic robotic arm.

[0017] For another purpose of this utility model, a numerical control system for controlling the automatic robotic arm and the positioner system is installed and fixed on the first base.

[0018] For another purpose of this utility model, the first base and the second base are connected separately, and the bottom of both the first base and the second base are provided with ground rails and ground bolts.

[0019] For another purpose of this utility model, the gun neck assembly of the welding gun adopts at least one of water-cooled gun neck assembly and air-cooled gun neck assembly.

[0020] As can be seen from the above, the integrated single-machine intelligent welding device provided by this utility model achieves automated robotic welding of parts to be welded, such as the corner welds of various power towers, by using an L-shaped positioner and an automatic robotic arm in conjunction with a welding torch. In this process, the first-level positioner can realize the rotation of the workpiece at different angles to achieve welding of the workpiece with a smaller welding torch offset, thereby improving accuracy and reducing energy consumption. The integrated single-machine intelligent welding device of this utility model can be installed and placed on the ground rail according to the workshop layout and production process, and can realize various welds such as straight angle welds, planar zigzag corner welds, vertical corner welds, and corner wrap welds. Attached Figure Description

[0021] To more clearly illustrate the technical solutions in this utility model or related technologies, the drawings used in the description of the embodiments or related technologies will be briefly introduced below. Obviously, the drawings described below are only embodiments of this utility model. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0022] Figure 1 This is a schematic diagram of the overall structure of the integrated single-machine intelligent welding device according to an embodiment of the present invention;

[0023] Figure 2 This is a top-view structural diagram of the integrated single-machine intelligent welding device according to an embodiment of the present invention.

[0024] In the diagram, 1-welding torch; 101-torch neck assembly; 2-positioner system; 201-L-shaped base; 202-transmission mechanism; 203-star-shaped tooling; 204-fixed beam; 2041-through hole; 205-reinforcing wing plate; 206-fixed clamp; 207-screw adjustment rod; 3-vision guidance module; 4-automatic robotic arm; 401-end arm section; 402-axis joint; 5-AC servo motor; 6-first base; 7-second base; 8-torch cleaning station; 9-CNC system; 10-ground rail; 11-ground bolt. Detailed Implementation

[0025] 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 specific embodiments and accompanying drawings.

[0026] It should be noted that, unless otherwise defined, the technical or scientific terms used in the embodiments of this utility model should have the ordinary meaning understood by one of ordinary skill in the art to which this utility model pertains. The terms "first," "second," and similar words used in the embodiments of this utility model do not indicate any order, quantity, or importance, but are merely used to distinguish different components. Terms such as "comprising" or "including" mean that the element or object preceding the word covers the element or object listed after the word and its equivalents, without excluding other elements or objects. Terms such as "connected" or "linked" are not limited to physical or mechanical connections, but can include electrical connections, whether direct or indirect. Terms such as "upper," "lower," "left," and "right" are only used to indicate relative positional relationships; when the absolute position of the described object changes, the relative positional relationship may also change accordingly.

[0027] This utility model relates to an integrated single-machine intelligent welding device, which mainly utilizes an automatic robotic arm combined with welding and an L-shaped positioner system to achieve integrated single-machine intelligent welding. It occupies a small area and is mainly used in scenarios where multi-angle precise welding of workpieces is required. It can be installed and placed according to the workshop layout and production process to realize various welds on power tower corners, such as straight angle welds, planar zigzag corner welds, vertical corner welds, and corner wrapping welds.

[0028] Specifically, in some embodiments, combined with Figure 1 The schematic diagram of the overall structure of the integrated single-unit intelligent welding device shown is as follows: Figure 1 As shown, the integrated single-machine intelligent welding device of this utility model mainly includes a welding torch 1, a positioner system 2, and a vision guidance module 3. The positioner system 2 is used to install and fix the power tower corner to be processed, and the vision guidance module 3 guides the welding torch 1 to weld the power tower corner. Specifically:

[0029] The welding torch 1 is installed on the end arm segment 401 of the automatic robotic arm 4. The automatic robotic arm 4 includes two or more shaft joints 402, and the arm segment of the automatic robotic arm is formed between two adjacent shaft joints 402. The automatic robotic arm 4 is electrically connected to and driven by the AC servo motor 5. The AC servo motor 5 is the power source of the automatic robotic arm 4 with high precision, fast response and excellent controllability. It can perform precise movement of position, speed and torque according to the precise instructions issued by the CNC system 6 of the host computer.

[0030] The positioner system 2 includes an L-shaped base 201, a transmission mechanism 202 disposed inside the L-shaped base 201, and a star-shaped fixture 203 disposed on the L-shaped base. The star-shaped fixture 203 is used to fix the corner of the power tower. When the transmission mechanism 202 is in operation, the star-shaped fixture 203 drives the corner of the power tower to rotate. The welding torch 1 is used to perform corner seam welding on the fixed corner of the power tower. The star-shaped fixture 203 includes cross-shaped fixing beams 204 arranged longitudinally and transversely. Reinforcing wing plates 205 are disposed between adjacent fixing beams 204. The transmission mechanism 202 of the positioner system is fixed at the middle position of the star-shaped fixture.

[0031] The cross-shaped tooling 203 achieves multi-stage rotation through shaft movement to achieve a 90-degree offset of the workpiece to be processed, and the welding torch 1 achieves welding according to preset instructions through the automatic robotic arm 4.

[0032] The L-shaped base 201 provides stable support and installation space for the transmission mechanism of the positioner system 2. The cross-shaped tooling 203 achieves a rigid structure through cross beams and reinforcing wing plates, and the transmission mechanism is directly connected in the middle to ensure torque transmission efficiency.

[0033] In one feasible embodiment of an exemplary embodiment of this utility model, each of the cross-shaped fixing beams 204 is provided with a fixing clamp 206 perpendicular to the plane where the cross-shaped fixing beams 204 are located, so as to fix the power tower corner through each fixing clamp 206. The specific working process of this utility model includes: installing the workpiece to be processed, such as the power tower corner, onto the star-shaped fixture 203, and fastening the workpiece to be processed through the vertical tower corner fixing clamp 206. After receiving the command, the transmission mechanism 202 drives the star-shaped fixture 203 to rotate, so that the corner seam to be welded is in the optimal welding position. At this time, the welding gun 1 is started to automatically perform welding of the corner seam, etc. The star-shaped fixture 203 rotates continuously or in increments at a set speed. After welding is completed, the workpiece can be unloaded through the reverse transmission mechanism.

[0034] In one feasible embodiment of an exemplary embodiment of this utility model, the visual guidance module 3 is fixedly installed on the upper end of the welding torch 1. From a top-down perspective, the visual guidance module 3 is installed directly above the welding torch 1 so that the welding torch 1 covers the welding range of the star-shaped fixture 203. The visual guidance module 3 is used to scan the corner seam position of the workpiece to be processed in real time, guide the welding torch 1 to accurately connect the weld seam, and can detect the installation deviation of the workpiece to be processed on the star-shaped fixture 203, and feed it back to the CNC system of the host computer to compensate for the rotation angle. In addition, since the reinforcing wing plate 205 and the longitudinal fixing clamp 206 of the star-shaped fixture 203 may obstruct the visual line of sight, raising the height of the visual guidance module 3 installed on the upper end of the welding torch 1 to completely cover the highest point of the fixture can avoid such problems.

[0035] In one feasible embodiment of an exemplary embodiment of this utility model, each of the fixed beams 204 is provided with a spiral adjusting rod 207 for adjusting the length. The adjustment of the spiral adjusting rod 207 allows the fixed beam 204 to adapt to different sizes of the workpiece to be processed by a small range. Since the number of workpieces to be processed in each batch is large and the number of times they are used is small, this step can be adjusted manually.

[0036] Referring to the top view of the integrated single-machine intelligent welding device of this utility model, as shown in the schematic diagram... Figure 2 As shown, in one feasible embodiment of an exemplary embodiment of the present invention, a first base 6 and a second base 7 are further included. The first base 6 is used to fix the automatic robotic arm 4, and the second base 7 is used to install and fix the positioner system 2. The L-shaped base 201 is fixed on the side of the second base 7 away from the first base 6. Due to the complexity of the welding environment, the control lines and drive devices of the automatic robotic arm 4 and the positioner system 2 are also relatively complex and easily affected by the environment. By hiding the control lines and drive devices in the space within the first base 6 and the second base 7, the present invention can be formed into an integrated workstation.

[0037] In one feasible embodiment of an exemplary embodiment of the present invention, the adjacent fixed beams 204 are spaced 90 degrees apart, and each fixed beam is provided with a plurality of through holes 2041, through which detachable triangular reinforcing wing plates 205 are installed.

[0038] The cross-shaped tooling 203 of this utility model is equipped with a detachable triangular reinforcing wing plate 205 through the through hole 2041, so that the whole is formed into a high-rigidity and modular welding displacement system, realizing the error-proof positioning of the workpiece to be processed.

[0039] In one feasible embodiment of an exemplary embodiment of this utility model, a cleaning station 8 is further included, which is disposed on one side of the first base 6 that fixes the automatic robotic arm. This allows the automatic robotic arm 4 to perform the cleaning work of the welding torch 1 with minimal rotation. The cleaning steps for the welding torch 1 are set in the welding process to ensure the quality of automated welding. These steps include wire cutting and cleaning, nozzle cleaning, oil spraying, and deep cleaning.

[0040] In one feasible embodiment of an exemplary embodiment of this utility model, a numerical control system 9 for controlling the automatic robotic arm and the positioner system is installed and fixed on the first base. The numerical control system 9 is mainly a collaborative system for the welding torch 1 and the positioner system 2. It mainly realizes an intelligent numerical control scheme for unmanned intervention-level automation of corner welding of power towers through coding, and the details of the collaborative scheme can be re-coded through the numerical control system.

[0041] In one feasible embodiment of an exemplary embodiment of the present invention, the first base 6 and the second base 7 are connected separately. The bottom of both the first base and the second base is provided with a ground rail 10 and a ground bolt 11, which facilitates the separate movement of the positioner system 2 and the welding torch 1, and enables the integrated intelligent welding device of the present invention to adapt to more complex working environments that require handling.

[0042] In one feasible embodiment of an exemplary embodiment of this utility model, the neck assembly 101 of the welding torch 1 adopts at least one of a water-cooled neck assembly and an air-cooled neck assembly. Preferably, depending on the usage environment, the welding torch 1 adopts a water-cooled neck assembly 101, and the shielding gas adopts a dual-path shielding gas design. The shielding gas in the outer channel forms an axial airflow, while the shielding gas in the inner channel forms a radial airflow, which mixes in the nozzle to form a laminar flow shielding. Due to the enhanced flow control of the shielding gas, the gas shielding effect during welding is excellent, the weld quality is improved, and the amount of shielding gas used is greatly reduced.

[0043] As can be seen from the above, the integrated single-machine intelligent welding device provided by this utility model achieves automated robotic welding of parts to be welded, such as the corner welds of various power towers, by using an L-shaped positioner and an automatic robotic arm in conjunction with a welding torch. In this process, the first-level positioner can realize the rotation of the workpiece at different angles to achieve welding of the workpiece with a smaller welding torch offset, thereby improving accuracy and reducing energy consumption. The integrated single-machine intelligent welding device of this utility model can be installed and placed on the ground rail according to the workshop layout and production process, and can realize various welds such as straight angle welds, planar zigzag corner welds, vertical corner welds, and corner wrap welds.

[0044] It should be noted that the method of this embodiment can be executed by a single device, such as a computer or server. The method of this embodiment can also be applied in a distributed scenario, where multiple devices cooperate to complete the task. In such a distributed scenario, one of these devices may execute only one or more steps of the method of this embodiment, and the multiple devices will interact with each other to complete the method described.

[0045] It should be noted that the above description describes some embodiments of the present invention. Other embodiments are within the scope of the appended claims. In some cases, the actions or steps described in the claims can be performed in a different order than that shown in the above embodiments and still achieve the desired result. Furthermore, the processes depicted in the drawings do not necessarily require a specific or sequential order to achieve the desired result. In some embodiments, multitasking and parallel processing are also possible or may be advantageous.

[0046] Those skilled in the art should understand that the discussion of any of the above embodiments is merely exemplary and is not intended to imply that the scope of the present invention (including the claims) is limited to these examples; within the framework of the present invention, the technical features of the above embodiments or different embodiments can also be combined, the steps can be implemented in any order, and there are many other variations of different aspects of the embodiments of the present invention as described above, which are not provided in the details for the sake of brevity.

[0047] Additionally, to simplify the description and discussion, and to avoid obscuring the embodiments of the present invention, the well-known power / ground connections to the integrated circuit (IC) chip and other components may or may not be shown in the provided drawings. Furthermore, the apparatus may be shown in block diagram form to avoid obscuring the embodiments of the present invention, and this also takes into account the fact that the details of the implementation of these block diagram apparatuses are highly dependent on the platform on which the embodiments of the present invention will be implemented (i.e., these details should be fully understood by those skilled in the art). While specific details (e.g., circuits) have been set forth to describe exemplary embodiments of the present invention, it will be apparent to those skilled in the art that the embodiments of the present invention can be implemented without these specific details or with variations thereof. Therefore, these descriptions should be considered illustrative rather than restrictive.

[0048] The embodiments of this utility model are intended to cover all such substitutions, modifications, and variations that fall within the broad scope of the appended claims. Therefore, any omissions, modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the embodiments of this utility model should be included within the protection scope of this utility model.

Claims

1. An integrated single-machine intelligent welding device, characterized in that, The system includes a welding torch, a positioner system, and a vision guidance module. The positioner system is used to install and fix the power tower corner to be processed. The vision guidance module guides the welding torch to weld the power tower corner. The welding torch is mounted on the end segment of the automated robotic arm. The automated robotic arm includes two or more shaft joints, and the arm segment of the automated robotic arm is formed between two adjacent shaft joints. The automated robotic arm is electrically connected to and driven by an AC servo motor. The positioner system includes an L-shaped base, a transmission mechanism disposed inside the L-shaped base, and a star-shaped fixture disposed on the L-shaped base. The star-shaped fixture is used to fix the corner of the power tower. When the transmission mechanism is in motion, the star-shaped fixture drives the corner of the power tower to rotate. The welding gun is used to perform corner seam welding on the fixed corner of the power tower. The cross-shaped fixture includes cross-shaped fixed beams arranged longitudinally and transversely, with reinforcing wing plates between adjacent fixed beams, and the transmission mechanism of the positioner system is fixed at the middle position of the cross-shaped fixture. The visual guidance module is fixedly installed on the upper end of the welding torch.

2. The integrated single-machine intelligent welding device according to claim 1, characterized in that, Each of the fixed beams is equipped with a screw adjustment rod for adjusting the length.

3. The integrated single-machine intelligent welding device according to claim 1, characterized in that, It also includes a first base and a second base, the first base being used to fix the automated robotic arm, and the second base being used to install and fix the positioner system, the L-shaped base being fixed to the side of the second base away from the first base.

4. The integrated single-machine intelligent welding device according to claim 1, characterized in that, The adjacent fixed beams are spaced 90 degrees apart, and each fixed beam has several sets of through holes, through which detachable triangular reinforcing wing plates are installed.

5. The integrated single-machine intelligent welding device according to claim 3, characterized in that, Each of the cross-shaped fixing beams is provided with a fixing clamp perpendicular to the plane of the cross-shaped fixing beam, so as to fix the corner of the power tower by means of each fixing clamp.

6. The integrated single-machine intelligent welding device according to claim 3, characterized in that, It also includes a gun cleaning station, which is located on one side of the first base that fixes the automated robotic arm.

7. The integrated single-machine intelligent welding device according to claim 3, characterized in that, A numerical control system for controlling the automated robotic arm and the positioner system is installed and fixed on the first base.

8. The integrated single-machine intelligent welding device according to claim 3, characterized in that, The first base and the second base are connected separately, and both the first base and the second base are provided with ground rails and ground bolts at their bottoms.

9. The integrated single-machine intelligent welding device according to claim 1, characterized in that, The neck assembly of the welding torch is at least one of a water-cooled neck assembly and an air-cooled neck assembly.

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