A welding stability monitoring system and welding apparatus

Abstract

The utility model discloses a kind of welding stable monitoring systems, comprising: collector, install on welder, for collecting the visual information of welding position;Clamper, the clamper one end installs and clamps the collector, other end is connected with welding torch, the clamper can move with welding torch, and can be rotated according to the position to be welded to adjust the collection angle of the collector;Sensor, including current sensor and / or voltage sensor, one end of the sensor is connected welding power supply, other end is connected electric signal acquisition power supply, for the collection of welding process electric signal;Information acquisition terminal is connected with collector, electric signal acquisition power supply respectively, for collecting and viewing the real-time state of arc visual signal and electric signal in welding process;The application also discloses a kind of welding equipment, apply the welding stable monitoring system described above.The utility model can realize real-time monitoring to welding process, save time and effort, improve product welding efficiency and welding quality.

Description

Technical Field

[0001] This utility model relates to the field of material welding technology, and in particular to a welding stability monitoring system and welding equipment. Background Technology

[0002] Ultrasonic vibration-assisted welding technology for automotive aluminum radiators is a novel welding method proposed and gradually developed in the early 21st century. Its main advantage lies in utilizing the cavitation effect of ultrasound at the solid-liquid interface and the acoustic flow effect in the molten pool during welding to effectively suppress porosity defects in the weld and refine the grain size of the weld metal, thereby improving the mechanical properties of the welded joint. However, the interaction between ultrasonic vibration and welding process stability is complex, especially in the welding of automotive radiators. The effect of ultrasonic vibration on the appearance of the joint obtained from arc welding of automotive aluminum radiators is unclear. Current technologies relying on manual periodic inspection are not only time-consuming and labor-intensive, but also inefficient, lack continuous monitoring, and are susceptible to external interference, leading to low product quality and reduced production efficiency.

[0003] In view of this, this utility model is proposed. Utility Model Content

[0004] To address the shortcomings of the aforementioned technologies, this invention provides a welding stability monitoring system. This system can collect real-time visual and electrical signals of the electric arc during the welding process of automotive aluminum radiators, thereby promptly identifying quality problems in the welding process, achieving real-time monitoring of the welding process, saving time and effort, and improving product welding quality and production efficiency.

[0005] Therefore, the technical solution provided by this utility model is as follows:

[0006] On the one hand, this application discloses a welding stability monitoring system, including:

[0007] The data acquisition device, mounted on the welding machine, is used to collect visual information about the welding position.

[0008] The holder has a clamping device installed at one end and is connected to the welding torch at the other end. The holder can move with the welding torch and can rotate according to the position to be welded to adjust the acquisition angle of the device.

[0009] The sensor, including a current sensor and / or a voltage sensor, is connected at one end to the welding power source and at the other end to the electrical signal acquisition power source for acquiring electrical signals during the welding process.

[0010] The information acquisition terminal is connected to the collector and the electrical signal acquisition power supply, respectively, and is used to collect and view the real-time status of the arc visual signal and electrical signal during the welding process.

[0011] Furthermore, the data acquisition device includes an arc vision acquisition camera, which includes a power supply module, an electromagnetic coil, a filter, and a lens;

[0012] The power supply module is electrically connected to the control circuit and the camera motherboard. The electromagnetic coil is connected to the control circuit and is used to drive the shutter or filter wheel. The filter is set in the optical path and is driven by the electromagnetic coil. The lens is set at the front of the arc vision acquisition camera and is used to focus the image of the arc area and transmit it to the camera sensor.

[0013] Furthermore, a safe acquisition distance of 10~25cm is set between the lens and the material to be welded.

[0014] Furthermore, the material to be welded is placed on the welding platform;

[0015] An ultrasonic vibration head is installed below the welding platform. The ultrasonic vibration head is used to introduce high-frequency vibration to improve material flowability or refine grains.

[0016] Furthermore, the clamp includes a clamping base, a clamping cantilever, and a chuck, with the clamping base being detachably connected to the welding torch or robotic arm;

[0017] One end of the clamping arm is connected to the clamping base, and the other end is connected to the chuck. The clamping arm can drive the chuck to rotate and adjust the angle. The chuck is engaged with the data collector.

[0018] Furthermore, the clamping cantilever includes a first support rod, a second support rod, and a screw-in sleeve. The screw-in sleeve is a smooth right-angle shape, with one end of the screw-in sleeve fitted into the first support rod and the other end fitted into the second support rod.

[0019] The screw-fit sleeve has several slots, and the outer walls of the end of the first support rod and the starting section of the second support rod are respectively provided with protrusions. The protrusions fit into the slots to fix the relative positions of the first support rod, the second support rod and the screw-fit sleeve.

[0020] Furthermore, the current sensor is connected to the welding wire spool, and the voltage sensor is connected to the ground wire of the welding power supply, with the ground wire located between the negative terminal of the welding machine and the welding platform.

[0021] Furthermore, the information acquisition terminal includes a data acquisition computer, which is connected or electrically connected to the data acquisition device and the power supply for electrical signal acquisition.

[0022] On the other hand, this application also discloses a welding device, a welding stability monitoring system applying any of the above, which further includes a welder, the welder being a welding robot, the welding robot being equipped with a rotatable robotic arm, and a welding torch being provided at the end of the robotic arm.

[0023] Furthermore, it also includes a wire feeder and a shielding gas cylinder. The wire feeder is connected to the welding torch to continuously and stably supply welding wire to the welding torch, and the shielding gas cylinder is connected to the welding torch and provides welding shielding gas for the welding process.

[0024] The protective gas is pure argon with a purity of ≥99.99%.

[0025] Compared with the prior art, the beneficial technical effects of this utility model are as follows:

[0026] (1) The monitoring system in this application can acquire the arc visual signal and electrical signal in real time during the welding process. The dual-modal monitoring method can assist staff in supervising the welding process and troubleshooting welding faults, enabling managers to continuously monitor the welding process without being affected by external factors, thereby improving welding quality control capabilities and process adaptability, and improving the product welding quality and production efficiency of automotive radiators.

[0027] By integrating a data acquisition device that can move synchronously with the welding torch and rotate to adjust its angle with a current / voltage sensor, the information acquisition terminal uniformly collects arc visual signals and electrical signals (welding power supply current status and / or voltage status), realizing the synchronous acquisition of multi-source data. This avoids the blind spots of single monitoring methods (visual or electrical signals only), improves the rapid identification of welding abnormalities (such as spatter, short circuit, arc deviation), and facilitates timely response by management personnel. Attached Figure Description

[0028] Figure 1 This is a schematic diagram of the welding stability monitoring system in this utility model;

[0029] Figure 2 This is a schematic diagram of the welding equipment in this utility model.

[0030] Marked in the image:

[0031] 1. Welding machine; 2. Welding torch; 3. Material to be welded; 4. Welding platform; 5. Ultrasonic vibrating head; 6. Data acquisition device; 7. Clamp; 71. Base; 72. Chuck; 73. Clamping cantilever; 731. First support rod; 732. Second support rod; 733. Screw-on sleeve; 8. Electrical signal acquisition power supply; 9. Current sensor; 10. Voltage sensor; 11. Information acquisition terminal; 12. Wire feeder; 13. Protective gas tank; 14. Welding machine control cabinet; 15. Ultrasonic vibration system power supply; 16. Welding system power supply; 17. Robotic arm. Detailed Implementation

[0032] To make the objectives, technical solutions, and advantages of the embodiments of this utility model clearer, the technical solutions in the embodiments will be clearly and completely described below with reference to the accompanying drawings. The following embodiments are used to illustrate this utility model, but are not intended to limit the scope of this utility model.

[0033] In the description of this utility model, it should be noted that the terms "upper", "lower", "front", "rear", "left", "right", "vertical", "inner", and "outer" indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying 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, they should not be construed as limitations on this utility model.

[0034] In the description of this utility model, it should be noted that, unless otherwise explicitly specified and limited, the terms "installation," "connection," and "joining" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to 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 based on the specific circumstances.

[0035] As attached Figure 1 As shown, a welding stability monitoring system includes:

[0036] The data acquisition device 6 is installed on the welder 1 and is used to acquire visual information about the welding position.

[0037] The clamp 7 has a clamping collector 6 installed at one end and is connected to the welding torch 2 at the other end. The clamp 7 can move with the welding torch 2 and can rotate according to the position to be welded to adjust the collection angle of the collector 6.

[0038] The sensor includes a current sensor 9 and / or a voltage sensor 10. One end of the sensor is connected to the welding power source, and the other end is connected to the electrical signal acquisition power source 8 for acquiring electrical signals during the welding process.

[0039] The information acquisition terminal 11 is connected to the collector 6 and the electrical signal acquisition power supply 8, respectively, and is used to collect and view the real-time status of the arc visual signal and electrical signal during the welding process.

[0040] Obviously, by integrating the collector 6, which can move and rotate synchronously with the welding torch 2, with the current sensor 9 and / or voltage sensor 10, and having the information acquisition terminal 11 uniformly collect the arc visual signal and electrical signal, the synchronous acquisition of multi-source data is realized, avoiding the blind spots of a single monitoring method (visual or electrical signal only), improving the rapid identification of welding abnormalities (such as spatter, short circuit, arc deviation), and facilitating timely response by management personnel.

[0041] As an embodiment of this application, the collector 6 includes an arc vision acquisition camera, which includes a power supply module, an electromagnetic coil, a filter, and a lens.

[0042] The power supply module is electrically connected to the control circuit and the camera motherboard. The electromagnetic coil is connected to the control circuit and is used to drive the shutter or filter wheel. The filter is set in the optical path and is driven by the electromagnetic coil. The lens is set at the front of the arc vision acquisition camera and is used to focus the image of the arc area and transmit it to the camera sensor.

[0043] The arc vision acquisition camera can dynamically switch the filter mode (such as strong light suppression and specific wavelength transmission) according to the welding conditions, effectively overcoming the interference of strong arc light during electric welding, improving the image signal-to-noise ratio, and thus improving the monitoring quality.

[0044] Furthermore, a safe acquisition distance of 10~25cm is set between the lens and the material to be welded 3.

[0045] Limiting the safe acquisition distance ensures image resolution and field of view coverage while preventing damage to optical components from high temperatures and splashes. It also ensures imaging quality and equipment lifespan, and guarantees long-term stable operation of the monitoring system.

[0046] Furthermore, the material to be welded 3 is placed on the welding platform 4; an ultrasonic vibration head 5 is installed below the welding platform 4. The ultrasonic vibration head 5 is used to introduce high-frequency vibration to improve material flowability or refine grain size. The ultrasonic vibration can not only suppress porosity defects in the weld of the aluminum radiator, but also refine the grain size of the weld to improve the mechanical properties of the joint. It can also reduce the post-weld deformation of the base material, thereby increasing the weld strength and improving the quality of the product to be welded.

[0047] During the welding of automotive radiators, the operating parameters of the ultrasonic vibrating head 5 include: the vibration frequency of the ultrasonic vibrating head 5 is 20kHz, and the output power of the ultrasonic vibration system power supply 15 is 840W.

[0048] As an embodiment of this application, the clamp 7 includes a clamping base 71, a clamping cantilever 73 and a chuck 72, and the clamping base 71 is detachably connected to the welding torch 2 or the robotic arm 17.

[0049] One end of the clamping cantilever 73 is connected to the clamping base 71, and the other end is connected to the chuck 72. The clamping cantilever 73 can drive the chuck 72 to rotate and adjust the angle. The chuck 72 is engaged with the data collector 6.

[0050] For example, the clamping base 71 is provided with a rectangular cross-section snap-fit ​​slot, which is engaged with the robotic arm 17 (the part directly connected to the welding gun 2 and rotatable) and then fastened by a fastener.

[0051] Furthermore, the clamping cantilever 73 includes a first support rod 731, a second support rod 732, and a screw-fit sleeve 733. The screw-fit sleeve 733 is a smooth right angle shape. One end of the screw-fit sleeve 733 is fitted with the first support rod 731, and the other end is fitted with the second support rod 732.

[0052] The screw-fit sleeve 733 is provided with several slots, and the outer walls of the end of the first support rod 731 and the starting section of the second support rod 732 are respectively provided with protrusions. The protrusions are fitted into the slots to fix the relative positions of the first support rod 731, the second support rod 732 and the screw-fit sleeve 733.

[0053] In the structural design of the clamping cantilever 73, those skilled in the art can design the shape and number of the latching protrusions according to actual needs, as long as the locking and matching between the two can be achieved.

[0054] For example, the number of locking protrusions is less than or equal to the number of locking slots. The locking slots are arc-shaped grooves distributed circumferentially along the inner wall of the screw-fit sleeve 733, and their cross-sectional shape is any one of rectangle, semi-circle, or trapezoid. In addition, the shape of the locking slots matches the outer contour shape of the locking protrusions, which facilitates the locking and positioning between the support rod and the screw-fit sleeve 733.

[0055] When rotating the clamping cantilever 73 to adjust the clamping angle of the chuck 72, the first support rod 731 or the second support rod 732 needs to be separated from the screw-fit sleeve 733. Then, the "second support rod 732" or the "integrated structure of the second support rod 732 and the screw-fit sleeve 733" is rotated by a preset angle. Finally, the rotation action is completed after the cam and slot are matched and installed.

[0056] The clamp 7 can achieve angle adjustment and stable positioning through the cooperation of the locking protrusion and the locking groove, so that the acquisition device 6 can adjust the acquisition angle according to the position of the weld (such as overhead welding, vertical welding), ensuring that the acquisition device 6 is always facing the arc area, and improving the accuracy of image acquisition in complex path welding.

[0057] As an embodiment of this application, the current sensor 9 is connected to the welding wire spool, and the voltage sensor 10 is connected to the ground wire of the welding power supply. The ground wire is located between the negative terminal of the welding machine and the welding platform 4.

[0058] In detail, current sensor 9 is connected to the welding wire spool, and the other end of the welding wire is fed out from welding torch 2. Voltage sensor 10 is connected to the ground wire of the welding power supply. The welding power supply has positive and negative terminals. The positive terminal is built into welding torch 2, and the negative terminal is grounded. The grounding method is a grounding wire from the negative terminal of the welding machine to the welding platform 4. Voltage sensor 10 passes through this grounding wire, and the welding power supply electrical signal is collected based on this.

[0059] As an embodiment of this application, the information acquisition terminal 11 includes a data acquisition computer, which is connected to the data acquisition device 6 and the electrical signal acquisition power supply 8 via signal or electrical connection.

[0060] A dedicated data acquisition computer is used as the information acquisition terminal 11, which supports high-speed synchronous acquisition and real-time display, facilitating immediate intervention by operators or providing high-quality raw data for subsequent data analysis.

[0061] The operation process of the welding stability monitoring system in this application specifically includes the following:

[0062] Step 1: Assemble the welding platform 4, connect all parts of the monitoring system, and turn on the arc vision acquisition camera, electrical signal acquisition power supply 8, current sensor 9, voltage sensor 10 and data acquisition computer for debugging.

[0063] Step 2: Adjust the clamping arm 73 so that the field of view of the arc vision acquisition camera is located at the welding position, and then adjust the camera focus to ensure a clear field of view.

[0064] Step 3: Use the data acquisition computer to set the acquisition parameters for the arc vision signal and the electrical signal, and then set the required process parameters for the welding platform 4 to prepare for the acquisition of welding process signals.

[0065] Step 4: While welding, collect the arc visual signal and electrical signal. After confirming that the welding process is correct, turn off the monitoring system.

[0066] As attached Figure 2 As shown, this application also discloses a welding device, a welding stability monitoring system applying any of the above, which further includes a welder 1, the welder 1 being a welding robot, the welding robot being provided with a rotatable robotic arm 17, and a welding torch 2 being provided at the end of the robotic arm 17.

[0067] Furthermore, the welder 1 is connected to a welder control cabinet 14, which controls the process parameters of the welding process. The specific parameters include: welding current 40~100A, arc voltage 10~16V, wire feeding speed 2.5~5.5m / min, and welding speed 10~16mm / s.

[0068] Obviously, the welder 1 is also connected to a welding system power supply 16, which provides power for the entire welding process. During welding, after turning on the welding system power supply 16, the welding process parameters can be set through the welder control cabinet 14. For example, the welding mode is DC mode, the welding current is 45A, the arc voltage is 11V, the wire feed speed is 2.9m / min, and the welding speed is 12mm / s.

[0069] In some embodiments, the welding equipment further includes a wire feeder 12 and a shielding gas cylinder 13. The wire feeder 12 is connected to the welding torch 2 to continuously and stably supply welding wire to the welding torch 2. The shielding gas cylinder 13 is connected to the welding torch 2 and provides welding shielding gas for the welding process. The shielding gas is pure argon gas with a purity ≥ 99.99%.

[0070] Integrating the aforementioned monitoring system into the welding robot, along with a high-purity argon gas protection system and a stable wire feeder 12, not only enables the monitoring system to perform closed-loop quality control over the robot's welding process, significantly improving product consistency and yield, but also achieves a high-cleanliness welding environment, meeting the requirements of intelligent, high-quality, and high-efficiency welding.

[0071] During the production process, firstly, the clamping angle of the gas metal arc welding torch 2 and the welding distance from the welding platform are adjusted using the welding control cabinet 14. Secondly, the welding start point, welding end point, welding path, and welding speed are set using the welding control cabinet 14. Taking an "L"-shaped welding path as an example: the welding robot's clamping motion trajectory moves from coordinate point A in the upper left of the "L", to coordinate point B in the lower left of the "L", and finally to coordinate point C in the lower right of the "L". This point-to-point movement path ensures the precise welding process of the welding torch 2.

[0072] The above description is merely a preferred embodiment of the present utility model and is not intended to limit the present utility model in any way. Although the present utility model has been disclosed above with reference to preferred embodiments, it is not intended to limit the present utility model. Any person skilled in the art can make some modifications or alterations to the above-described technical content to create equivalent embodiments without departing from the scope of the present utility model. The implementation schemes in the above embodiments can also be further combined or replaced. Any simple modifications, equivalent changes and alterations made to the above embodiments based on the technical essence of the present utility model without departing from the scope of the present utility model shall still fall within the scope of the present utility model.

Claims

1. A welding stability monitoring system, characterized in that, include: The data acquisition device, mounted on the welding machine, is used to collect visual information about the welding position. A clamp is provided, with one end of the clamp holding the collector and the other end connected to the welding torch. The clamp can move with the welding torch and can rotate according to the position to be welded to adjust the collection angle of the collector. The sensor, including a current sensor and / or a voltage sensor, is connected at one end to a welding power source and at the other end to an electrical signal acquisition power source for acquiring electrical signals during the welding process. The information acquisition terminal is connected to the collector and the electrical signal acquisition power supply, respectively, and is used to collect and view the real-time status of the arc visual signal and electrical signal during the welding process.

2. The welding stability monitoring system according to claim 1, characterized in that, The data acquisition device includes an arc vision acquisition camera, which includes a power supply module, an electromagnetic coil, a filter, and a lens. The power supply module is electrically connected to the control circuit and the camera motherboard. The electromagnetic coil is connected to the control circuit and is used to drive the shutter or filter wheel. The filter is set in the optical path and is driven by the electromagnetic coil. The lens is set at the front end of the arc vision acquisition camera and is used to focus the image of the arc area and transmit it to the camera sensor.

3. The welding stability monitoring system according to claim 2, characterized in that, A safe acquisition distance of 10-25cm is set between the lens and the material to be welded.

4. The welding stability monitoring system according to claim 3, characterized in that, The material to be welded is placed on the welding platform; An ultrasonic vibration head is provided below the welding platform. The ultrasonic vibration head is used to introduce high-frequency vibration to improve material flowability or refine grains.

5. The welding stability monitoring system according to claim 1, characterized in that, The clamp includes a clamping base, a clamping cantilever, and a chuck, and the clamping base is detachably connected to the welding torch or robotic arm. One end of the clamping cantilever is connected to the clamping base, and the other end is connected to the chuck. The clamping cantilever can drive the chuck to rotate and adjust the angle. The chuck is engaged with the data collector.

6. The welding stability monitoring system according to claim 5, characterized in that, The clamping cantilever includes a first support rod, a second support rod, and a screw-fitting sleeve. The screw-fitting sleeve is a smooth right-angle shape. One end of the screw-fitting sleeve is fitted with the first support rod, and the other end is fitted with the second support rod. The screw-fit sleeve has several slots, and the outer walls of the end of the first support rod and the starting section of the second support rod are respectively provided with protrusions. The protrusions are fitted into the slots to fix the relative positions of the first support rod, the second support rod and the screw-fit sleeve.

7. A welding stability monitoring system according to any one of claims 1-6, characterized in that, The current sensor is connected to the welding wire spool, and the voltage sensor is connected to the ground wire of the welding power supply. The ground wire is located between the negative terminal of the welding machine and the welding platform.

8. The welding stability monitoring system according to claim 7, characterized in that, The information acquisition terminal includes a data acquisition computer, which is connected or electrically connected to the data acquisition device and the power supply signal for electrical signal acquisition.

9. A welding device, characterized in that, The welding stability monitoring system according to any one of claims 1-8 further includes a welder, which is a welding robot, the welding robot being provided with a rotatable robotic arm, and a welding torch being provided at the end of the robotic arm.

10. A welding device according to claim 9, characterized in that, It also includes a wire feeder and a shielding gas cylinder. The wire feeder is connected to the welding torch to continuously and stably supply welding wire to the welding torch. The shielding gas cylinder is connected to the welding torch and provides welding shielding gas for the welding process. The protective gas is pure argon with a purity of ≥99.99%.

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