An automatic laser welding machine

Abstract

This application provides an automatic laser welding machine, including a feeding module, a welding module, and a PLC control system. The feeding module includes a first linear guide rail, a first drive cylinder, and two sets of tooling modules mounted on a worktable. The two sets of tooling modules are spaced apart, and each set of tooling modules is used to place and fix the workpiece to be processed. The first drive cylinder can simultaneously drive the two sets of tooling modules to move along the length of the first linear guide rail to a first position or a second position. When the two sets of tooling modules move to one of the two positions, one set of tooling modules is in the feeding position, and the other set of tooling modules is in the welding position. The welding module performs welding operations at the welding position. The welding module includes a movable tooling and a welding gun clamp. The welding gun clamp is fixed on the movable tooling and is used to hold and fix the welding gun. The movable tooling is designed to move back and forth along a direction perpendicular to the length of the first linear guide rail.

Description

Technical Field

[0001] This application relates to the technical field of laser welding, and more particularly to an automatic laser welding machine. Background Technology

[0002] Currently, argon arc welding is commonly used to connect the busbars and junction box leads of photovoltaic modules (such as cylindrical / tubular modules). Argon arc welding requires filler wire, has a large heat input, and is prone to causing microcracks in the cells and deformation of the busbars. Welding slag remains after welding, requiring an additional manual cleaning process, which wastes materials and reduces the production cycle. At the same time, the argon arc welding process requires high worker skills and produces serious arc light and fume pollution, making it difficult to meet the photovoltaic manufacturing requirements of "high output, low consumption, and no damage".

[0003] To reduce the heat impact, single-point laser welding solutions have emerged in the industry, but most of them remain in a semi-automatic stage with single workstations, fixed optical paths, or manual movement of the laser head, resulting in extremely low production efficiency. Utility Model Content

[0004] In view of the above practical problems and the shortcomings of existing technologies, the main technical problem to be solved by this utility model is to provide an automatic laser welding machine that can perform dual-station reciprocating feeding and automatic laser head movement, so as to replace traditional argon arc welding and existing semi-automatic laser welding, and realize high-efficiency welding of photovoltaic modules.

[0005] To solve the above-mentioned technical problems, this application provides an automatic laser welding machine, which adopts the following technical solution:

[0006] An automatic laser welding machine includes a feeding module, a welding module, and a PLC control system, wherein both the feeding module and the welding module are controlled by the PLC control system.

[0007] The feeding module includes a first linear guide rail, a first drive cylinder and two sets of tooling modules installed on the workbench. The two sets of tooling modules are arranged at intervals, and each set of tooling modules is used to place and fix the workpiece to be processed.

[0008] The first driving cylinder can simultaneously drive the two sets of tooling modules to move to the first position or the second position along the length direction of the first linear guide rail; when the two sets of tooling modules move to one of the two positions, one set of tooling modules is in the loading position and the other set of tooling modules is in the waiting position for welding.

[0009] The welding module performs welding operations at the position to be welded; the welding module has a moving fixture and a welding gun clamp, the welding gun clamp is fixed on the moving fixture, and the welding gun clamp is used to hold and fix the welding gun; the moving fixture is configured to move back and forth along a direction perpendicular to the length of the first linear guide rail.

[0010] In a preferred embodiment, two first sliding seats are slidably disposed on the first linear guide rail, and the tops of the two first sliding seats are fixedly connected by a mounting plate;

[0011] The two sets of tooling modules are fixed on the mounting plate. A connecting plate is provided on one side of the mounting plate. The connecting plate is fixedly connected to the driving end of the first driving cylinder so that the mounting plate is driven by the first driving cylinder to move to the first position or the second position.

[0012] In a preferred embodiment, a first displacement sensor is provided at each end of the first linear guide rail along its length, and the first displacement sensor is electrically connected to the input module of the PLC control system.

[0013] In a preferred embodiment, a positioning sensing device is provided at the corresponding position of the first linear guide rail at the position to be welded, and the positioning sensing device is electrically connected to the input module of the PLC control system; the positioning sensing device adopts a positioning optical fiber.

[0014] In a preferred embodiment, the tooling module has a placement slot for placing the workpiece to be processed. A pushing component is provided on one side of the placement slot along the length direction of the first linear guide rail, and a positioning block is provided on the other side.

[0015] The pushing component can push the workpiece to be processed located in the placement slot and form a clamping and fixing of the workpiece to be processed with the positioning block.

[0016] In a preferred embodiment, the pushing assembly includes a pushing cylinder and a push block disposed at the telescopic end of the pushing cylinder, the pushing cylinder driving the push block to move back and forth along the direction toward the positioning block.

[0017] In a preferred embodiment, the movable fixture is provided with two sets of welding gun clamps, each set of welding gun clamps holds and fixes a set of welding guns, and the laser heads of the two sets of welding guns are arranged in parallel back and forth along the weld direction; the welding guns are fiber lasers.

[0018] In a preferred embodiment, the movable fixture includes a base plate, a mounting bracket mounted on the base plate, and a linear drive module. The base plate is used to mount the fixture on a workbench, and the welding torch clamp is fixed on the mounting bracket.

[0019] The linear drive module includes two sets of parallel second linear guide rails and a second drive cylinder. Two second sliding seats are slidably arranged on each of the two sets of second linear guide rails, and the second sliding seats are fixed to the bottom of the mounting bracket.

[0020] The driving end of the second driving cylinder is connected to the mounting bracket. Driven by the second driving cylinder, and in conjunction with the sliding of the second sliding seat on the second linear guide rail, the mounting bracket can be driven to move back and forth along a direction perpendicular to the length of the first linear guide rail.

[0021] In a preferred embodiment, a guide block with a through hole is provided at the middle position of the bottom of the mounting bracket, two sets of the second linear guide rails are provided on both sides of the bottom plate along the length direction of the bottom plate, and a guide rod is provided at the middle position of the bottom plate along its width direction.

[0022] The guide rod is fixed to the base plate by a mounting seat, the guide block slides on the guide rod, and the guide block is fixedly connected to the drive end of the second drive cylinder.

[0023] In a preferred embodiment, a second displacement sensor is provided on one side of the base plate.

[0024] In summary, this application has the following beneficial effects:

[0025] 1. This utility model adopts a first drive cylinder to synchronously drive two sets of tooling modules to alternately enter and exit the "material loading position / welding position" along the first linear guide rail. Material loading and laser welding are carried out in parallel, which can reduce labor costs and improve production efficiency.

[0026] 2. This utility model achieves automatic welding of the welding torch by setting up a movable fixture. The welding torch uses a fiber laser to replace argon arc welding, resulting in low heat and high efficiency. The dual fiber laser heads are arranged front and back to complete deep penetration and shaping in one go, reducing heat input, eliminating welding wire and slag, eliminating subsequent cleaning processes, and reducing the rate of microcracks in the product. Attached Figure Description

[0027] Figure 1 This is a schematic diagram of the overall structure of the automatic laser welding machine in this embodiment;

[0028] Figure 2 This is a schematic diagram showing the cooperation between the feeding module and the welding module in this embodiment;

[0029] Figure 3 This is a structural schematic diagram of the feeding module at one angle in this embodiment;

[0030] Figure 4 This is a structural schematic diagram of the feeding module from another angle in this embodiment;

[0031] Figure 5 This is a schematic diagram of the overall structure of the welding module in this embodiment.

[0032] Explanation of reference numerals in the attached drawings: 1. Workbench; 2. Feeding module; 21. First linear guide rail; 211. First sliding seat; 212. Mounting plate; 213. Connecting plate; 22. First drive cylinder; 23. Tooling module; 231. First tooling module; 232. Second tooling module; 233. Placement slot; 234. Push cylinder; 235. Push block; 236. Positioning block; 24. First displacement sensor; 25. Positioning sensing device; 3. Welding module; 31. Moving tooling; 311. Base plate; 312. Mounting bracket; 313. Second linear guide rail; 314. Second drive cylinder; 315. Second sliding seat; 316. Guide block; 317. Guide rod; 318. Mounting seat; 32. Welding torch clamp; 33. Welding torch; 34. Second displacement sensor; 4. PLC control system; 5. Workpiece to be processed. Detailed Implementation

[0033] The technical solutions of the present utility model will be clearly and completely described below with reference to the accompanying drawings of the embodiments of the present utility model. Obviously, the described embodiments are only some embodiments of the present utility model, and not all embodiments. All other embodiments obtained by those skilled in the art based on the embodiments of the present utility model without creative effort are within the protection scope of the present utility model.

[0034] In the description of this utility model, it should be noted that the terms "upper," "lower," "inner," "outer," "top / bottom," etc., indicating the orientation or positional relationship are based on the orientation or positional relationship shown in the accompanying drawings, and 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, and therefore should not be construed as a limitation of this utility model. Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance.

[0035] In the description of this utility model, it should be noted that, unless otherwise explicitly specified and limited, the terms "installed", "equipped with", "sleeved / connected", "connected", etc., should be interpreted broadly. For example, "connection" can be a wall-mounted connection, a detachable connection, or an integral connection; it can be a mechanical connection or an electrical connection; it can be a direct connection or an indirect connection through an intermediate medium; it can be a connection within two components. For those skilled in the art, the specific meaning of the above terms in this utility model can be understood according to the specific circumstances.

[0036] The following is in conjunction with the appendix Figures 1-5 This application will be described in further detail.

[0037] This embodiment provides an automatic laser welding machine, including a feeding module 2, a welding module 3, and a PLC control system 4. Both the feeding module 2 and the welding module 3 are controlled by the PLC control system 4. The feeding module 2 adopts a dual-station reciprocating feeding method. During the dual-station reciprocating motion, one station moves to the welding position for welding, while the other station moves to the unloading position for unloading finished products and loading the workpiece 5 to be processed. The welding gun 33 of the welding module 3 uses a fiber laser for welding. The welding gun 33 is set on a linearly movable fixture 31 to achieve welding along a preset trajectory when the workpiece 5 to be processed moves to the welding position. Welding and loading / unloading can be performed simultaneously.

[0038] Specifically, the feeding module 2 includes a first linear guide rail 21, a first drive cylinder 22, and two sets of tooling modules 23 mounted on the workbench 1 (such as...). Figure 3 The two sets of tooling modules 23 are spaced apart, and each set of tooling modules 23 is used to place and fix the workpiece 5 to be processed. The first drive cylinder 22 can simultaneously drive the two sets of tooling modules 23 to reciprocate along the length direction of the first linear guide rail 21.

[0039] like Figure 3 Two first sliding seats 211 are slidably disposed on the first linear guide rail 21. The tops of the two first sliding seats 211 are fixedly connected by a mounting plate 212. The two sets of tooling modules are fixed on the mounting plate 212. A connecting plate 213 (e.g., ...) is provided on one side of the mounting plate 212. Figure 4 The connecting plate 213 is fixedly connected to the driving end of the first driving cylinder 22. When the first driving cylinder 22 moves in extension and retraction, it can drive the mounting plate 212 to reciprocate along the length direction of the first linear guide rail 21.

[0040] The mounting plate 212 is driven by the first driving cylinder 22 to have a first position or a second position. The two sets of tooling modules are divided into a first tooling module 231 and a second tooling module 232. They move and reciprocate along a dual-station trajectory. The two sides of the first linear guide 21 are the loading positions, and the middle area is the welding position.

[0041] When the first tooling module 231 moves to a position close to one end of the length direction of the first linear guide rail 21, the second tooling module 232 moves to the middle area of ​​the length direction of the first linear guide rail 21. At this time, the first tooling module 231 can perform loading and unloading operations, and the second tooling module 232 can perform welding operations.

[0042] When the second tooling module 232 moves to a position close to the other end of the length direction of the first linear guide rail 21, the first tooling module 231 moves to the middle area of ​​the length direction of the first linear guide rail 21. At this time, the second tooling module 232 can perform loading and unloading operations, and the first tooling module 231 can perform welding operations.

[0043] To better control the reciprocating motion of the two sets of tooling modules, improve the adaptability of manual loading, and facilitate product input, this embodiment employs first displacement sensors 24 (e.g., ...) installed at both ends of the first linear guide rail 21 along its length. Figure 2 The first displacement sensor 24 is electrically connected to the input module of the PLC control system 4. The first displacement sensor 24 is used to detect in real time whether the first tooling module 231 or the second tooling module 232 has reached the designated loading position. When either tooling module triggers the first displacement sensor 24 at the corresponding end, the PLC control system 4 immediately outputs a braking command to control the first drive cylinder 22 to stop moving, so as to ensure the repeatability of the positioning accuracy of the dual-station reciprocating motion.

[0044] To ensure welding accuracy, this embodiment employs a positioning sensing device 25 (e.g., ...) at the corresponding position of the first linear guide rail 21 where it is located to be welded. Figure 1 The positioning sensing device 25 is electrically connected to the input module of the PLC control system 4. The positioning sensing device 25 uses a positioning optical fiber. When the first tooling module 231 or the second tooling module 232 moves to the position to be welded, the positioning optical fiber is used to confirm whether the workpiece 5 to be processed is placed on the tooling module. If the optical fiber is not blocked, it is judged that "part is missing" or "not in place". The system alarms and prohibits welding. If both the positioning optical fiber and the first displacement sensor 24 signal are normal, the welding module 3 can be controlled to perform welding operation.

[0045] Specifically, the tooling module 23 has a placement slot 233 (e.g., Figure 3 The placement slot 233 is used to place the workpiece 5 to be processed. A pushing component is provided on one side of the placement slot 233 along the length direction of the first linear guide rail 21, and a positioning block 236 is provided on the other side. The pushing component includes a pushing cylinder 234 and a push block 235 provided at the telescopic end of the pushing cylinder 234. When the operator places the workpiece 5 to be processed in the placement slot 233 and aligns it with the push block 235, the pushing cylinder 234 drives the push block 235 to push the workpiece 5 to fit the positioning block 236. Under the action of the pushing cylinder 234, the workpiece 5 to be processed is clamped and fixed by the push block 235 and the positioning block 236.

[0046] A miniature pressure sensor is embedded on the side of the push block 235 facing the workpiece. The pressure sensor is electrically connected to the input module of the PLC control system 4. When the pressure value reaches the set threshold, the PLC control system 4 “clamping complete” and immediately shuts off the push cylinder 234 to prevent overpressure from causing microcracks in the component.

[0047] Meanwhile, an installation slot is opened at the bottom of the placement slot 233, and a photoelectric sensor is installed in the installation slot. The photoelectric sensor is electrically connected to the input module of the PLC control system 4. The photoelectric sensor is used to identify whether there is a workpiece 5 to be processed in the placement slot 233. Only when the workpiece to be processed is placed in and identified by the photoelectric sensor will the PLC control system 4 confirm that "the physical object exists", thereby driving the push cylinder 234 to perform a clamping operation.

[0048] Specifically, the welding module 3 includes a movable fixture 31 and a welding gun clamp 32. The welding gun clamp 32 is fixed on the movable fixture 31 and is used to clamp and fix the welding gun 33. Two sets of welding gun clamps 32 are provided on the movable fixture 31. Each set of welding gun clamps 32 clamps and fixes a set of welding guns 33. The laser heads of the two sets of welding guns 33 are arranged in parallel back and forth along the weld direction. The front gun is responsible for deep penetration and the rear gun is responsible for surface shaping, realizing the "dual gun time-sharing, one-time forming" process.

[0049] The welding torch 33 uses a fiber laser with adjustable power and wavelength. Welding parameters can be called or set within the PLC control system 4, such as a laser power of 200W and a welding speed of 5-10mm / s. Parameter templates can be stored within the PLC control system 4 and can be recalled with a single click.

[0050] To achieve automatic welding and retraction of the welding torch 33, the movable fixture 31 in this embodiment is designed to move back and forth along a direction perpendicular to the length of the first linear guide rail 21. For example... Figure 5 The movable fixture 31 includes a base plate 311, a mounting bracket 312 mounted on the base plate 311, and a linear drive module. The base plate 311 is used to mount on the workbench 1. The welding torch clamp 32 is fixed on the mounting bracket 312. The linear drive module includes two sets of parallel second linear guide rails 313 and a second drive cylinder 314. Two second sliding seats 315 are slidably mounted on each of the two sets of second linear guide rails 313. The second sliding seats 315 are fixed to the bottom of the mounting bracket 312. The drive end of the second drive cylinder 314 is connected to the mounting bracket 312. By driving the second drive cylinder 314 and cooperating with the sliding of the second sliding seats 315 on the second linear guide rails 313, the mounting bracket 312 can be driven to move back and forth along a direction perpendicular to the length of the first linear guide rail 21.

[0051] To ensure the stability of the second drive cylinder 314, a guide block 316 with a through hole is provided at the middle position of the bottom of the mounting bracket 312. Two sets of second linear guide rails 313 are arranged on both sides of the base plate 311 along the length direction of the base plate 311. A guide rod 317 is arranged at the middle position of the base plate 311 along its width direction. The guide rod 317 is fixed to the base plate 311 by the mounting seat 318. The guide block 316 slides on the guide rod 317. The guide block 316 is fixed to the drive end of the second drive cylinder 314, forming a symmetrical guide structure of "central push-pull, double-sided guide rails". This ensures smooth sliding and can directly transmit the lateral force of the second drive cylinder 314 to the base plate 311 through the guide rod 317, avoiding additional bending moment on the two sides of the second linear guide rails 313 and extending the life of the guide rails.

[0052] To better control the movement of the mounting bracket 312 and ensure high repeatability of the dual-gun laser head during reciprocating welding, this embodiment uses a second displacement sensor 34 on one side of the base plate 311. The second displacement sensor 34 is a slotted photoelectric encoder, with its scale strip pasted along the entire length of the forward and backward movement direction on the side of the second sliding seat 315. The reading head is fixed to one side of the second linear guide rail 313 by an L-shaped bracket. The reading head outputs A / B phase quadrature pulses to the high-speed counting port of the PLC with a resolution of 0.005mm, which can record the absolute displacement of the mounting bracket 312 relative to the reference zero point in real time.

[0053] The PLC program of the PLC control system 4 sets the coordinates of three points: "front limit", "back limit" and "welding start". When the second drive cylinder 314 pushes the mounting bracket 312, the reading head continuously feeds back the position at a frequency of 2kHz to ensure the repeatability and positioning accuracy of the dual-gun laser head during the reciprocating welding process.

[0054] The automatic laser welding machine provided in this embodiment has the following working process:

[0055] Step 1: Parameter preset. According to the specifications of the workpiece 5, call or set the welding parameters in the PLC control system 4 (such as laser power 200W welding speed 5-10mm / S).

[0056] Step 2: Manual loading. The operator holds the workpiece 5 to be processed and places it in the placement slot 233 of the first tooling module 231 or the second tooling module 232 at the loading position. The push component clamps and fixes it in the placement slot 233. Then, the first drive cylinder 22 transports the workpiece 5 to the welding position.

[0057] Step 3: After the positioning sensor 25 senses that the workpiece 5 has been placed on the tooling module at the welding position, the PLC control system 4 controls the second drive cylinder 314 to drive the welding gun 33 to the welding position. After the laser welding is started, the welding is completed along the preset trajectory.

[0058] Step 4: After welding is completed, the PLC control system 4 controls the second drive cylinder 314 to drive the welding gun 33 to retract, and the first drive cylinder 22 transports the finished product to the unloading position. The unloading is done manually, the welded workpiece is taken out, the next set of welded components is installed, and the next welding process is carried out.

[0059] The above description is only a preferred embodiment of the present utility model, but the design concept of the present utility model is not limited thereto. Any non-substantial modifications made to the present utility model by those skilled in the art within the scope of the technology disclosed in the present utility model using this concept shall be deemed as an infringement of the protection scope of the present utility model.

Claims

1. An automatic laser welding machine, characterized in that: It includes a feeding module, a welding module, and a PLC control system, wherein both the feeding module and the welding module are controlled by the PLC control system; The feeding module includes a first linear guide rail, a first drive cylinder, and two sets of tooling modules installed on the workbench. The two sets of tooling modules are arranged at intervals, and each set of tooling modules is used to place and fix the workpiece to be processed. The first driving cylinder can simultaneously drive the two sets of tooling modules to move to the first position or the second position along the length direction of the first linear guide rail; when the two sets of tooling modules move to one of the two positions, one set of tooling modules is in the loading position and the other set of tooling modules is in the waiting position for welding. The welding module performs welding operations at the position to be welded; the welding module includes a movable fixture and a welding gun clamp, the welding gun clamp is fixed on the movable fixture, and the welding gun clamp is used to hold and fix the welding gun; the movable fixture is configured to move back and forth along a direction perpendicular to the length of the first linear guide rail.

2. The automatic laser welding machine according to claim 1, characterized in that: Two first sliding seats are slidably disposed on the first linear guide rail, and the tops of the two first sliding seats are fixedly connected by a mounting plate; The two sets of tooling modules are fixed on the mounting plate. A connecting plate is provided on one side of the mounting plate. The connecting plate is fixedly connected to the driving end of the first driving cylinder so that the mounting plate is driven by the first driving cylinder to move to the first position or the second position.

3. An automatic laser welding machine according to claim 2, characterized in that: The first linear guide rail is equipped with a first displacement sensor at each end along its length, and the first displacement sensor is electrically connected to the input module of the PLC control system.

4. An automatic laser welding machine according to claim 3, characterized in that: A positioning sensing device is installed at the corresponding position of the first linear guide rail to be welded, and the positioning sensing device is electrically connected to the input module of the PLC control system; the positioning sensing device adopts a positioning optical fiber.

5. An automatic laser welding machine according to claim 1, characterized in that: The tooling module has a placement slot for placing the workpiece to be processed. A pushing component is provided on one side of the placement slot along the length direction of the first linear guide rail, and a positioning block is provided on the other side. The pushing component can push the workpiece to be processed located in the placement slot and form a clamping and fixing of the workpiece to be processed with the positioning block.

6. An automatic laser welding machine according to claim 5, characterized in that: The pushing assembly includes a pushing cylinder and a push block disposed at the telescopic end of the pushing cylinder. The pushing cylinder drives the push block to move back and forth along the direction toward the positioning block.

7. An automatic laser welding machine according to claim 1, characterized in that: The mobile fixture is equipped with two sets of welding gun clamps, each set of welding guns is fixedly clamped on one set of welding guns, and the laser heads of the two sets of welding guns are arranged in parallel back and forth along the weld direction; the welding guns are fiber lasers.

8. An automatic laser welding machine according to claim 1, characterized in that: The mobile fixture includes a base plate, a mounting bracket mounted on the base plate, and a linear drive module. The base plate is used to mount the welding torch on the workbench, and the welding torch clamp is fixed on the mounting bracket. The linear drive module includes two sets of parallel second linear guide rails and a second drive cylinder. Two second sliding seats are slidably arranged on each of the two sets of second linear guide rails, and the second sliding seats are fixed to the bottom of the mounting bracket. The driving end of the second driving cylinder is connected to the mounting bracket. Driven by the second driving cylinder, and in conjunction with the sliding of the second sliding seat on the second linear guide rail, the mounting bracket can be driven to move back and forth along a direction perpendicular to the length of the first linear guide rail.

9. An automatic laser welding machine according to claim 8, characterized in that: A guide block with a through hole is provided at the middle position of the bottom of the mounting bracket, and two sets of the second linear guide rails are provided on both sides of the bottom plate along the length direction of the bottom plate. A guide rod is provided at the middle position of the bottom plate along its width direction. The guide rod is fixed to the base plate by a mounting seat, the guide block slides on the guide rod, and the guide block is fixedly connected to the drive end of the second drive cylinder.

10. An automatic laser welding machine according to claim 9, characterized in that: A second displacement sensor is installed on one side of the base plate.

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