An eight-axis intelligent welding robot workstation

Abstract

This utility model relates to the field of welding robot technology and discloses an eight-axis intelligent welding robot workstation, including a robot welding platform and an intelligent control system. The robot welding platform includes a ground rail walking mechanism, a column, a crossbeam, a welding system, a robot system, a vision unit, a torch cleaning station, and a wire feed hopper. A column that moves with the ground rail walking mechanism is mounted on the ground rail walking mechanism. A crossbeam is fixedly connected to the top of the column, and the welding system, robot system, and vision unit are connected to the crossbeam. The intelligent control system includes a central control cabinet and an operating table. The central control cabinet is located on one side of the ground rail walking mechanism and moves with the column. The operating table is located near one end of the robot welding platform in the length direction, and the operating table and welding system are both located on one side of the ground rail walking mechanism. The design aims to expand the length and width dimensions of weldable workpieces; simultaneously, by incorporating a vision unit, it improves the adaptability to overall workpiece errors.

Description

Technical Field

[0001] This utility model relates to the field of welding robot technology, and in particular to an eight-axis intelligent welding robot workstation. Background Technology

[0002] Currently, welding robot operations are becoming increasingly common in industrial production. The welding robots commonly used on the market are six-degree-of-freedom. However, when welding various types of ultra-long and ultra-wide workpieces such as bridge grids, H-shaped steel structures, crane beams, partition units, ship assembly, beams and columns, the working range is still limited if only a six-axis welding robot is used.

[0003] After prolonged operation, welding robots are prone to zero-point drift at various joints of the robotic arm, leading to welding torch positioning deviations. This is especially true in multi-axis linkage systems, where gear wear or loose lead screws can accumulate errors, requiring periodic shutdowns for calibration. Furthermore, the welding torch angle adjustment mechanism is susceptible to deformation under high temperatures, potentially resulting in poor weld formation.

[0004] Existing vision systems are prone to misjudgment under complex conditions such as strong light and dust, for example, the recognition rate of welds on reflective metal surfaces drops significantly. Some workstations rely on fixed calibration plates, and if the workpiece is misplaced or obstructed, an alarm will be triggered to interrupt the operation. During dynamic welding, the camera's frame rate cannot keep up with the robotic arm's speed, resulting in a delay in real-time correction. Utility Model Content

[0005] To address existing problems, this utility model provides an eight-axis intelligent welding robot workstation, which aims to expand the length and width dimensions of weldable workpieces. At the same time, by setting up a vision unit, it improves the adaptability to comprehensive errors in workpieces (such as loading errors, manufacturing errors, and thermal deformation errors), and can be applied to discrete manufacturing scenarios with diverse workpiece and weld seam combinations.

[0006] To achieve the above objectives, the present invention provides the following technical solution.

[0007] An eight-axis intelligent welding robot workstation includes a robot welding platform and an intelligent control system. The robot welding platform includes a ground rail walking mechanism, a column, a crossbeam, a welding system, a robot system, a vision unit, a torch cleaning station, and a wire feed hopper. The ground rail walking mechanism has a column that can move with it. A crossbeam is fixedly connected to the top of the column, and the welding system, robot system, and vision unit are connected to the crossbeam. The intelligent control system includes a central control cabinet and an operating console. The central control cabinet is located on one side of the ground rail walking mechanism and moves with the column. The operating console is located near one end of the robot welding platform along its length, and the operating console and welding system are both located on one side of the ground rail walking mechanism.

[0008] As a further improvement of this utility model, the vision unit includes a global vision unit and a local vision unit. The global vision unit is disposed on the side of the crossbeam and is used to identify the position of the workpiece. The local vision unit is connected to the robot system and is used to accurately locate the weld position.

[0009] As a further improvement of this utility model, the ground rail traveling mechanism is equipped with a slide assembly, an X-direction guide rail and an X-direction drag chain, and the X-direction drag chain moves back and forth on the X-direction guide rail along with the slide assembly.

[0010] As a further improvement of this utility model, the welding system includes a welding machine, a water tank, a welding torch, and a wire feeder; the welding machine, the water tank, and the wire feeder are all mounted on the slide assembly.

[0011] As a further improvement of this utility model, the robot system includes a robot and a robot control cabinet; the welding torch is mounted on the robot.

[0012] As a further improvement of this utility model, the robot control cabinet is disposed on the slide assembly.

[0013] As a further improvement of this utility model, the operating table includes a foldable table, and the tabletop of the foldable table is embedded with a display screen.

[0014] As a further improvement of this utility model, an industrial control computer is provided at the bottom of the foldable table.

[0015] As a further improvement of this utility model, the robot system also includes a voltage regulator, which is disposed on one side of the central control cabinet.

[0016] As a further improvement of this utility model, the wire feeding drum is disposed on the slide assembly.

[0017] This utility model has the following beneficial effects: Adopting an eight-axis design, compared to the commonly used six-degree-of-freedom welding robots on the market, the addition of a ground-rail walking mechanism provides extra degrees of freedom, greatly expanding the working range. It can effectively handle the welding needs of various ultra-long and ultra-wide workpieces such as bridge grids, H-shaped steel structures, crane beams, partition units, ship assembly, beams and columns, solving the problem of limited working range of six-axis welding robots. The intelligent control system rationally arranges the central control cabinet and the operating table. The central control cabinet moves with the column to facilitate centralized control of the welding platform. The operating table is attached to one end of the robot welding platform in the length direction, making it convenient for operators to work and check the welding deviation along the length of the platform, improving the overall operability and work efficiency of the workstation.

[0018] Preferably, two types of vision units are set up: a global vision unit and a local vision unit. The global vision unit identifies the workpiece position and provides preliminary positioning information for the entire welding operation, while the local vision unit connects with the robot system to precisely locate the weld seam. This division of labor and cooperation improves the accuracy of the vision system in recognizing the workpiece and the weld seam. Compared with the problem of existing vision systems being prone to misjudgment under complex working conditions, this dual-vision unit design can acquire information more accurately in different environments, reduce misjudgments caused by factors such as workpiece placement deviation and occlusion, avoid triggering alarms and interrupting the operation, and improve the stability and reliability of the welding operation.

[0019] Preferably, the ground rail traveling mechanism is equipped with a slide assembly, an X-direction guide rail, and an X-direction cable chain, enabling the slide assembly to move flexibly in the X direction. This design further increases the horizontal freedom of movement of components such as the welding system and robot system, helping to more accurately adjust the welding position, adapt to the welding needs of workpieces of different shapes and sizes, and improve the flexibility and adaptability of the workstation.

[0020] Preferably, the welding machine, water tank, and wire feeder are mounted on the slide assembly, allowing the main components of the welding system to move together with the slide assembly. This ensures that the components move synchronously when adjusting the welding position, guaranteeing stable relative positions between components during welding, reducing welding quality issues caused by asynchronous component movement, and improving welding stability and consistency.

[0021] Preferably, the welding torch is mounted on a robot. The robot's multi-axis motion allows for flexible adjustment of the torch's angle and position, better adapting to the welding requirements of different weld seams. Compared to some welding torch angle adjustment mechanisms that are prone to deformation under high temperatures, the robot's structure and motion control are relatively more stable, reducing weld seam defects caused by torch angle issues and improving welding quality.

[0022] Preferably, the robot control cabinet is mounted on the slide assembly, close to the robot, which reduces signal transmission distance, lowers the possibility of signal interference, and enables more precise control of the robot's movements. Simultaneously, moving along with the slide assembly facilitates overall robot debugging and maintenance, improving the workstation's reliability and maintainability.

[0023] Preferably, the workbench adopts a foldable table design, which can be folded up when not in use to save space and facilitate the layout and transportation of the workstation. The desktop is equipped with a display screen, which allows operators to more clearly observe various parameters and information during the welding process when the screen is unfolded, facilitating operation and monitoring and improving the convenience and accuracy of operation; when the screen is closed, it reduces the damage to the display caused by strong light and dust.

[0024] Preferably, an industrial control computer is installed under the foldable table, making efficient use of space. As the core control device of the workstation, the industrial control computer can centrally process and store data during the welding process, providing operators with powerful computing and control support. Used in conjunction with a display screen, it facilitates various settings and operations for the workstation, improving its level of intelligence.

[0025] Preferably, a voltage regulator provides a stable voltage to the robot system, preventing unstable operation of the robot's joint motors due to voltage fluctuations. This reduces the possibility of zero-point drift in the robotic arm's joints, thereby lowering welding torch positioning deviation and improving welding accuracy. Simultaneously, a stable voltage helps extend the robot system's lifespan, reducing equipment failures and downtime for calibration caused by voltage issues, thus improving workstation reliability and production efficiency.

[0026] Optionally, the wire feed hopper is mounted on the slide assembly, allowing it to move with the welding position, ensuring the stability and continuity of wire feeding. This avoids problems caused by excessively long wire feeding distances or complex wire feeding paths, reduces defects arising from wire feeding issues during welding, and improves welding quality and work efficiency. Attached Figure Description

[0027] The accompanying drawings described herein are for illustrative purposes only and do not limit the scope of this invention in any way. Furthermore, the shapes and proportions of the components in the drawings are merely schematic to aid in understanding the invention and do not specifically limit the shapes and proportions of the components. In the drawings: Figure 1 Left is an isometric view of an eight-axis intelligent welding robot workstation as described in Example 1. Figure 2 Right is an isometric view of an eight-axis intelligent welding robot workstation as described in Example 1. Figure 3 This is a schematic diagram of the opening and closing of the operating console of an eight-axis intelligent welding robot workstation as described in Example 1; Figure 4 This is a bottom view of the control panel of an eight-axis intelligent welding robot workstation as described in Example 1; Among them, 1. Ground rail walking mechanism, 1-1. Slide table assembly, 1-2. X-direction guide rail, 1-3. X-direction drag chain, 2. Column, 3. Crossbeam, 3-1. Global vision unit assembly, 3-2. Y-direction guide rail, 3-3. Y-direction moving assembly, 3-4. Y-direction drag chain, 4. Welding system, 4-1. Welding machine, 4-2. Water tank, 4-3. Welding torch, 4-4. Wire feeder, 5. Robot system, 5-1. Robot, 5-2. Robot control cabinet, 6. Intelligent control system, 6-1. Central control cabinet, 6-2. Operating console, 6-2-1. Display screen, 6-2-2. Industrial computer, 7. Vision unit, 7-1. Global vision unit, 7-2. Local vision unit, 8. Torch cleaning station, 9. Wire feed drum. Detailed Implementation

[0028] To enable those skilled in the art to better understand the technical solutions of this utility model, the technical solutions of the embodiments of this utility model will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this utility model, and not all embodiments. Based on the embodiments of this utility model, all other embodiments obtained by those skilled in the art without creative effort should fall within the protection scope of this utility model.

[0029] It should be noted that when an element is referred to as being "set on" another element, it can be directly on the other element or there may be an intervening element. When an element is referred to as being "connected to" another element, it can be directly connected to the other element or there may be an intervening element. The terms "vertical," "horizontal," "left," "right," and similar expressions used herein are for illustrative purposes only and do not represent the only embodiments.

[0030] Unless otherwise defined below, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention pertains. The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the invention. The term "and / or" as used herein includes any and all combinations of one or more of the associated listed items.

[0031] Example 1 like Figure 1 As shown, an eight-axis intelligent welding robot workstation includes a robot welding platform and an intelligent control system 6; the robot welding platform includes a ground track walking mechanism 1, a column 2, a crossbeam 3, a welding system 4, a robot system 5, a vision unit 7, a torch cleaning station 8, and a wire feeding drum 9.

[0032] The ground-rail walking mechanism 1 is equipped with a column 2 that can move with it. A crossbeam 3 is fixedly connected to the top of the column 2. The welding system 4, robot system 5, and vision unit 7 are connected to the crossbeam 3. Specifically, a global vision unit bracket 3-1 is installed on the side of the crossbeam 3. A Y-direction guide rail 3-2, a Y-direction moving component 3-3, and a Y-direction cable chain 3-4 are installed below the crossbeam 3. The Y-direction cable chain 3-4 moves left and right on the Y-direction guide rail 3-2 along with the Y-direction moving component 3-3. The Y-direction moving component 3-3 is powered by an eighth-axis motor (located on the crossbeam 3). The Y-direction moving component 3-3 is connected to the welding system 4, robot system 5, and vision unit 7. A cleaning station 8 is located on the side of the column 2.

[0033] The intelligent control system 6 includes a central control cabinet 6-1 and an operating console 6-2. The central control cabinet 6-1 is located on one side of the ground rail walking mechanism 1 and moves with the column 2. The operating console 6-2 is located near one end of the robotic welding platform along its length, and the operating console 6-2 and the welding system 4 are both located on one side of the ground rail walking mechanism 1. The operating console is attached to one end of the robotic welding platform along its length, which facilitates operator work. It allows for checking welding deviations along the length of the platform, enabling a rough check followed by a detailed inspection, thus improving the overall operability and work efficiency of the workstation.

[0034] The vision unit 7 includes a global vision unit 7-1 and a local vision unit 7-2. The global vision unit 7-1 is located on the side of the crossbeam 3 and is used to identify the workpiece position. The local vision unit 7-2 is connected to the robot system 5 and is used to accurately locate the weld position. In use, when the column 2 and the crossbeam 3 move along the X direction, the global vision unit 7-1 takes a picture to identify the workpiece placement position. The intelligent control system 6 generates a 3D model of the workpiece, extracts the weld, and after the weld to be welded is manually selected, the local vision unit 7-2 takes a picture to identify the weld position. Due to large actual assembly errors, the intelligent control system 6 can adaptively adjust the welding trajectory based on the results of the local vision unit 7-2, thereby ensuring the welding quality of the weld.

[0035] The ground rail traveling mechanism 1 is equipped with a slide assembly 1-1, an X-direction guide rail 1-2, and an X-direction drag chain 1-3. The X-direction drag chain 1-3 moves back and forth on the X-direction guide rail 1-2 along with the slide assembly 1-1. The X-direction moving assembly 1-3 is powered by a seventh-axis motor (located on the ground rail traveling mechanism 1). Specifically, the ground rail walking mechanism 1 is directly fixed to the ground. The slide assembly 1-1 on the ground rail walking mechanism 1 can move back and forth along the X-direction guide rail 1-2. The column 2, welding machine 4-1, water tank 4-2, central control cabinet 6-1, and robot control cabinet 5-2 are all installed on the slide assembly 1-1. The overall structure is compact and saves space. The column 2, welding machine 4-1, water tank 4-2, central control cabinet 6-1, and robot control cabinet 5-2 can move together with the slide assembly 1-1. The cables and water pipes of the components are routed through the drag chains on the ground rail walking mechanism 1 and the crossbeam 3, the column 2, and the crossbeam 3, etc., to avoid the cables and water pipes being dragged on the ground, which would affect the overall aesthetics of the equipment. At the same time, it expands the welding range in the X direction.

[0036] The welding system 4 includes a welding machine 4-1, a water tank 4-2, a welding torch 4-3, and a wire feeder 4-4; the welding machine 4-1, the water tank 4-2, and the wire feeder 4-4 are all mounted on the slide assembly 1-1.

[0037] The robot system 5 includes a robot 5-1 and a robot control cabinet 5-2; the welding torch 4-3 is mounted on the robot 5-1. Specifically, the bottom of the robot 5-1 is mounted on a Y-direction moving component 3-3, which can move along the Y-direction guide rail 3-2 with the Y-direction moving component 3-3, thus expanding the weldable range in the Y direction. A wire feeder 4-4 is mounted on the back of the robot body to ensure stable wire feeding and improve welding quality. The welding torch 4-3 and a local vision unit 7-2 are mounted at the end of the robot, and a global vision unit bracket 3-1 and a global vision unit 7-1 are mounted on the side of the crossbeam 3.

[0038] The robot control cabinet 5-2 is located on the slide assembly 1-1.

[0039] The workbench 6-2 includes a foldable table with a display screen 6-2-1 embedded in its desktop. The foldable design allows the workbench to be folded up when not in use, saving space and facilitating workstation layout and transportation. The embedded display screen allows operators to clearly observe various parameters and information during the welding process when the screen is unfolded, facilitating operation and monitoring and improving operational convenience and accuracy. When the screen is closed, it reduces damage to the display from strong light and fumes.

[0040] An industrial control computer (6-2-2) is installed at the bottom of the foldable table. This placement of the industrial control computer at the bottom of the foldable table makes efficient use of space. As the core control device of the workstation, the industrial control computer can centrally process and store data during the welding process, providing operators with powerful computing and control support. Used in conjunction with the display screen, it facilitates various settings and operations for the workstation, improving its level of intelligence.

[0041] The wire feeding drum 9 is mounted on the slide assembly 1-1.

[0042] Example 2 The difference between this embodiment and Embodiment 1 is that: 1) The robot system 5 also includes a voltage regulator, which is located on one side of the central control cabinet 6-1.

[0043] Setting up a voltage regulator provides a stable voltage for the robot system, preventing unstable operation of the robot's joint motors due to voltage fluctuations. This reduces the possibility of zero-point drift in the robotic arm's joints, thereby reducing welding torch positioning deviation and improving welding accuracy. Simultaneously, stable voltage helps extend the robot system's lifespan, reducing equipment failures and downtime for calibration caused by voltage issues, thus improving workstation reliability and production efficiency.

[0044] Compared with existing technologies, the advantages of this utility model are: This eight-axis intelligent welding robot can be customized in terms of ground rail length and crossbeam guide rail length according to customer or workpiece requirements, thus greatly expanding the range of large-sized workpieces in the X and Y directions. The control cabinet is custom-made by our company, minimizing its size while ensuring functionality. The welding machine, water tank, control cabinet, and robot control cabinet are stacked to minimize floor space. The welding machine, water tank, control cabinet, robot control cabinet, wire feed drum, etc., are all mounted on the slide assembly, allowing them to move along the X direction with the slide assembly. This reduces the amount of cables and water pipes used and avoids them dragging on the ground, thus preserving the overall aesthetics of the equipment.

[0045] The intelligent control system is divided into two parts: a central control cabinet and an operating console. Commercially available intelligent control systems are usually a single unit, which is large and bulky and requires operators to stand while operating. This patent divides the intelligent control system into two parts: the central control cabinet moves along the X-direction with the column, while the operating console is similar to an office desk, allowing operators to sit and operate the system. The desktop is equipped with a display screen that can be opened and closed. When in use, the display screen can be opened, and when not in use, it can be closed to prevent the display screen from being contaminated. The industrial control computer is placed in a cabinet under the operating console, making the overall structure of the operating console relatively compact.

[0046] The eight-axis intelligent welding robot of this patent is also equipped with a global vision unit (which can move along the Y direction with the robot) and a local vision unit. For scenarios with large comprehensive errors in workpieces (feeding errors, manufacturing errors, thermal deformation errors, etc.), diverse combinations of workpieces and welds, and arbitrary placement of workpieces, it can autonomously identify the position of the workpiece, autonomously calculate and plan the optimal welding path, and adaptively weld, greatly improving the overall intelligence of the equipment.

[0047] The above embodiments are merely one of the implementation methods for achieving the technical solution of this utility model. The scope of protection claimed by this utility model is not limited to this embodiment, but also includes any variations, substitutions, and other implementation methods that are easily conceived by those skilled in the art within the scope of the technology disclosed in this utility model. Although embodiments of this utility model have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions, and variations can be made to these embodiments without departing from the principles and spirit of this utility model. The scope of this utility model is defined by the appended claims and their equivalents.

Claims

1. An eight-axis intelligent welding robot work station, characterized in that, The system includes a robotic welding platform and an intelligent control system (6). The robotic welding platform includes a ground rail walking mechanism (1), a column (2), a crossbeam (3), a welding system (4), a robot system (5), a vision unit (7), a cleaning station (8), and a wire feeding drum (9). The ground rail walking mechanism (1) is equipped with a column (2) that can move with the ground rail walking mechanism (1). The top of the column (2) is fixedly connected to the crossbeam (3). The welding system (4), the robot system (5), and the vision unit (7) are connected to the crossbeam (3). The intelligent control system (6) includes a central control cabinet (6-1) and an operating table (6-2). The central control cabinet (6-1) is located on one side of the ground rail walking mechanism (1) and moves with the column (2). The operating table (6-2) is located near one end of the robotic welding platform in the length direction. The operating table (6-2) and the welding system (4) are both located on one side of the ground rail walking mechanism (1).

2. The eight-axis intelligent welding robot workstation according to claim 1, characterized in that, The vision unit (7) includes a global vision unit (7-1) and a local vision unit (7-2). The global vision unit (7-1) is located on the side of the crossbeam (3) and is used to identify the position of the workpiece. The local vision unit (7-2) is connected to the robot system (5) and is used to accurately locate the weld position.

3. The eight-axis intelligent welding robot workstation according to claim 1, characterized in that, The ground track walking mechanism (1) is equipped with a slide assembly (1-1), an X-direction guide rail (1-2), and an X-direction drag chain (1-3). The X-direction drag chain (1-3) moves back and forth on the X-direction guide rail (1-2) along with the slide assembly (1-1).

4. The eight-axis intelligent welding robot workstation according to claim 3, characterized in that, The welding system (4) includes a welding machine (4-1), a water tank (4-2), a welding torch (4-3), and a wire feeder (4-4); the welding machine (4-1), the water tank (4-2), and the wire feeder (4-4) are all located on the slide assembly (1-1).

5. An eight-axis intelligent welding robot workstation according to claim 4, characterized in that, The robot system (5) includes a robot (5-1) and a robot control cabinet (5-2); the welding torch (4-3) is mounted on the robot (5-1).

6. An eight-axis intelligent welding robot workstation according to claim 5, characterized in that, The robot control cabinet (5-2) is located on the slide assembly (1-1).

7. The eight-axis intelligent welding robot workstation according to claim 1, characterized in that, The control panel (6-2) includes a foldable table with a display screen (6-2-1) embedded in the tabletop.

8. An eight-axis intelligent welding robot workstation according to claim 7, characterized in that, The lower part of the foldable table is equipped with an industrial control computer (6-2-2).

9. An eight-axis intelligent welding robot workstation according to claim 1, characterized in that, The robot system (5) also includes a voltage regulator, which is located on one side of the central control cabinet (6-1).

10. An eight-axis intelligent welding robot workstation according to claim 9, characterized in that, The wire feeding drum (9) is mounted on the slide assembly.

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