CN115026489A

CN115026489A - Full-automatic steel frame single-piece welding system

Info

Publication number: CN115026489A
Application number: CN202210715455.6A
Authority: CN
Inventors: 孙宏伟; 张本顺; 李萌萌; 张乐乐; 范小卿; 沈言; 曹荣祥
Original assignee: 716th Research Institute of CSIC; Jiangsu Jari Technology Group Co Ltd
Current assignee: 716th Research Institute of CSIC; Jiangsu Jari Technology Group Co Ltd
Priority date: 2022-06-23
Filing date: 2022-06-23
Publication date: 2022-09-09

Abstract

The invention discloses a full-automatic steel frame single-sheet welding system which comprises a safety protection unit, wherein a movable ground rail unit, a welding robot unit, a welding equipment unit and a positioner tool unit are fixed in the safety protection unit; the movable ground rail unit is fixed on the ground and is linked with the welding robot unit, and the welding equipment unit provides welding wires for the welding robot unit and cuts the welding wires; the positioner frock unit is used for fixing and upset work piece, welding robot unit includes welding robot, switch board and demonstrator for to the automatic weld of work piece, the demonstrator passes through integrated cable connection control cabinet, the linkage of welding robot is realized to switch board control removal ground rail unit and welding equipment unit. The welding machine realizes the front and back welding of the workpiece through the rotation of the positioner, improves the welding quality and efficiency of the steel frame single piece, reduces the welding deformation and reduces the labor cost.

Description

Full-automatic steel frame single-piece welding system

Technical Field

The invention relates to the field of welding, in particular to a full-automatic steel frame single-piece welding system.

Background

The steel frame single sheet is formed by splicing and welding a plurality of square shapes. The steel frame single-chip structural style of different types is the same, and only the overall size and the square-shaped steel specification are different. The square-shaped steel is assembled and clamped by a worker on a tool table with better flatness after flame cutting, and spot welding is carried out after clamping. The weld mainly consists of a vertical fillet weld, a flat fillet weld and a butt weld on the reverse side. Firstly, welding a vertical fillet weld and a horizontal fillet weld, opening the clamp after welding, overturning the workpiece, and then clamping again to weld a back side butt weld. After welding, because the welding seam on the back is not welded at all when the middle is reversed, large welding stress exists, and the welding stress is released when the tool clamp is opened, so that the welding deformation is large, and therefore manual leveling is needed. At present, the manual welding mode is adopted for welding steel frame single sheets at home and abroad, the welding efficiency is low, the welding quality is uncontrollable, the welding deformation is large, and the labor cost is higher.

Disclosure of Invention

The invention aims to provide a steel frame single sheet full-automatic welding system, which realizes automatic welding of the front and back surfaces of a workpiece through rotation of a positioner, improves the welding quality and efficiency of the steel frame single sheet, reduces welding deformation and reduces labor cost.

The technical scheme for realizing the purpose of the invention is as follows: a full-automatic steel frame single-sheet welding system comprises a safety protection unit, wherein a movable ground rail unit, a welding robot unit, a welding equipment unit and a positioner tool unit are fixed in the safety protection unit; the movable ground rail unit is fixed on the ground and is linked with the welding robot unit, and the welding equipment unit provides welding wires for the welding robot unit and cuts the welding wires; the positioner frock unit is used for fixing and upset work piece, welding robot unit includes welding robot, switch board and demonstrator for to the automatic weld of work piece, the demonstrator passes through integrated cable connection control cabinet, the linkage of welding robot is realized to switch board control removal ground rail unit and welding equipment unit.

Further, the mobile ground rail unit comprises a ground rail; the ground rail is fixed on the ground, a rack and a sliding groove are fixed on the ground rail, mechanical limit and electrical limit are arranged at two ends of the ground rail, the ground rail is connected with a movable upright sliding table in a sliding manner, the movable upright sliding table is embedded into the sliding groove through a sliding block and is connected with the ground rail in a sliding manner, a movable upright is fixed above the movable upright sliding table, and a cross arm is fixed at the end part of the movable upright; a support platform is fixed on one side of the movable upright column sliding table, an oil pump, a motor, a speed reducer, a gear and a control cabinet are mounted on the support platform, the oil pump lubricates the movable upright column sliding table, the gear and a rack, the motor is connected with the gear through the speed reducer, and the gear is meshed with the rack; and a welding robot is fixed at the end part of the cross arm.

Furthermore, mechanical limit is provided with a rubber anti-collision block, electrical limit comprises a sensing block and a distance sensor, the sensing block is installed at a position preset on the inner side of the mechanical limit, and the distance sensor is installed on a movable upright sliding table.

Furthermore, the control cabinet supplies power to the welding robot through a power line, controls the motor communication through an encoder cable, and is connected with the welding robot through a yellow and black wire to realize grounding.

Furthermore, the welding equipment unit comprises a welding power supply, a wire feeder, a welding gun, a wire disc, a gun cleaning and wire cutting device and an anti-collision sensor; welding power supply fixes and supplies power for sending a machine on supporting platform, terminal installation anticollision sensor of welding robot and welder, a welding robot end installation send a machine, and the silk dish is fixed on supporting platform, and the silk dish is through sending a union coupling to send a machine, send a pipe both ends all to have quick plug interface to connect the silk dish respectively and send a machine, clear rifle is cut a device and is installed on portable stand.

Further, the welding robot is a six-joint welding robot.

Further, the positioner tool unit comprises a main positioner, a slave positioner and a tool clamp, a workpiece is fixed on the tool clamp and is installed between the main positioner and the slave positioner, and the main positioner and the slave positioner drive the tool clamp to rotate around a horizontal shaft by adopting a speed reducer matched with a robot servo motor.

Further, frock clamp includes backup pad, a plurality of locating piece, a plurality of locating pin and a plurality of manual jig, the machine that becomes with carry on the backup pad in the middle of the machine that shifts, locating piece and manual jig pass through locating pin and bolt fastening in the backup pad, fix the work piece through locating piece, locating pin and manual jig.

Furthermore, the safety protection unit comprises a safety door, a safety lock, a three-color lamp, a safety fence and a light-shading curtain; a safety door is arranged at a position corresponding to the safety fence, and the safety door is provided with a safety lock and a three-color lamp; when the safety door is opened, the welding robot unit is informed to prepare for operation, after the safety door is closed, the welding robot unit starts to operate, and the upper half part of the safety fence is provided with a shading curtain.

Furthermore, the safety fence takes aluminum alloy as a frame and is filled with a steel wire mesh.

Compared with the prior art, the invention has the remarkable effects that:

(1) the original manual welding operation of the whole steel frame single piece is changed into full-automatic welding, and the robot welding has the characteristics of good stability, controllable quality and the like, so that the welding quality of the product is ensured; (2) the positioner is adopted for overturning, so that manual intervention is reduced, and labor cost is reduced; (3) the welding machine moves along with the robot, manual intervention is not needed for dragging a cable, the workpiece is directly turned over by the positioner, secondary clamping is not needed, the use frequency of a travelling crane is reduced, and the working efficiency is greatly improved; (4) when the back surface of the workpiece is welded, the tool clamp does not need to be opened, after the back surface is welded, the welding stress of the front surface and the back surface is counteracted, after the tool clamp is opened, the deformation of the workpiece meets the technical requirements, and the detection and manual leveling processes are reduced; (5) when welding operation is carried out, the supporting table, the positioning block and the positioning pin can refer to the position of the opening of the supporting table to realize quick positioning and clamping of workpieces with different sizes; (6) according to the invention, the workpiece is positioned and clamped through the positioner tool unit, and two sides of the workpiece are welded by one-time clamping, so that the use times of travelling cranes are reduced, and the working efficiency is greatly improved; meanwhile, full-automatic welding of the whole steel frame single sheet is realized, participation of manual spot welding is reduced, stability is improved, and welding quality is guaranteed.

Drawings

FIG. 1 is a diagram of a full-automatic steel frame single-sheet welding system.

FIG. 2 is a schematic structural diagram of the movable ground rail unit and the positioner.

Fig. 3 is a schematic diagram of a welding robot unit and a welding equipment unit.

Fig. 4 is a schematic structural view of a welding robot and joint mounting equipment.

FIG. 5 is a schematic view of a workpiece and a tooling fixture.

Fig. 6 is a schematic structural diagram of a safety protection unit.

Fig. 7 is a schematic diagram of a positioner.

Fig. 8 is a schematic view of a tooling fixture.

FIG. 9 is a flow chart of a full-automatic steel frame single-piece welding process.

In the figure: 1. the welding robot comprises a movable ground rail unit, 11, a ground rail, 111, an electrical limit unit, 112, a mechanical limit unit, 12, a movable upright post, 13, a cross arm, 14, an oil pump, 15, a movable upright post sliding table, 16, a supporting platform, 2, a welding robot unit, 21, a welding robot, 22, a control cabinet, 23, a demonstrator, 3, a welding equipment unit, 31, a welding power supply, 32, a wire feeder, 33, a welding gun, 34, a wire disc, 35, a gun cleaning and wire shearing device, 36, an anti-collision sensor, 4, a positioner tooling unit, 41, a positioner, 411, a main positioner, 412, a slave positioner, 42, a tooling clamp, 421, a supporting plate, 422, a positioning block, 423, a positioning pin, 424, a manual clamp, 5, a safety protection unit, 51, a safety door, 52, a safety lock, 53, a trichromatic lamp, 54, a safety fence, 55, a shading curtain, 6 and a workpiece.

Detailed Description

The technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings, and it is obvious that the described embodiments are only a part of the embodiments of the present invention, and not all of the embodiments. All other embodiments, which can be derived by a person skilled in the art from the embodiments given herein without making any creative effort, shall fall within the protection scope of the present invention.

As shown in fig. 1 to 8, the present embodiment provides a full-automatic steel frame single-sheet welding system, which includes a mobile ground rail unit 1, a welding robot unit 2, a welding equipment unit 3, a positioner tool unit 4, and a safety protection unit 5; the movable ground rail unit 1 comprises a ground rail 11, a movable upright post 12, a cross arm 13 and an oil pump 14; the welding robot unit 2 includes a welding robot 21, a control cabinet 22, and a demonstrator 23; the welding equipment unit 3 comprises a welding power supply 31, a wire feeder 32, a welding gun 33, a wire reel 34, a gun cleaning and wire cutting device 35 and an anti-collision sensor 36; the positioner tool unit 4 comprises a positioner 41 and a tool clamp 42; the safety protection unit 5 comprises a safety door 51, a safety lock 52, a three-color lamp 53, a safety fence 54 and a window shade 55. The method comprises the steps that an original manual welding method is converted into a robot full-automatic mode through the movable ground rail unit 1, the welding robot unit 2, the welding equipment unit 3, the positioner tooling unit 4 and the safety protection unit 5.

Referring to fig. 2, the ground rail 11 of the movable ground rail unit 1 is fixed on the ground through anchor bolts, two ends of the ground rail 11 are provided with a mechanical limit 111 and an electrical limit 112, the electrical limit 111 and the mechanical limit 112 ensure that the welding robot operates within a safe range, the mechanical limit 111 limit anti-collision block is a rubber block, and the relative linear distance between the two rubber blocks is at least greater than +20mm of an effective stroke; the electrical limit 112 mainly comprises an induction block arranged at the 10mm inward position of a mechanical limit rubber block of the mechanical limit 111 and arranged at the side edge of the ground rail, a distance sensor is arranged on the movable upright column sliding table 15, and when the movable upright column sliding table 15 moves to the position of the electrical limit induction block, the sensor is triggered, so that software electrical limit alarm is triggered; the single-side rack and the double-side sliding grooves are fixed on the ground rail 11 through bolts. But ground rail top installation portable stand slip table, two embedded structure sliders are equipped with to portable stand slip table 15 bottom both sides, and through the two side sliding groove pairs of embedded structure slider with the ground rail, portable stand slip table 15 can fix in the ground rail 11 directly over by the level, and the slider can be guaranteed to the spout and portable stand slip table 15 zonulae occludens. Supporting platform 16 is with portable stand slip table 15 bolt-up, and 16 trompils of supporting platform, top one-time erection oil pump 14, motor, speed reducer, gear all through bolted connection, and the gear is connected with the close meshing of ground rail unilateral rack, supporting platform 16 still is used for installing switch board 22, welding power supply 31, oil pump 14 is used for lubricated portable stand slip table 15 and rack and pinion. Portable stand 12 passes through the bolt-up in portable stand slip table 15 top, portable stand 12 and xarm 13 adopt the supporting accurate speed reducer drive of servo motor as the external axle of welding robot 21, and the gear is connected to the speed reducer to rotate through motor and speed reducer, drive the gear along the rack, the slider removes in the spout, realizes portable stand 12 and slides on the ground rail, is connected with switch board power line and encoder cable through the motor, and software configuration has good driver, can realize linking with welding robot 21.

Referring to fig. 3 and 4, the welding robot 21 of the welding robot unit 2 is fixed on the robot mounting base at the end of the beam of the movable upright 12 by bolts and positioning pins, and the control cabinet 22 is fixed on the support platform 15 by a limiting block and bolts. The control cabinet 22 supplies power to the robot body through a power line, realizes communication control over the six-shaft motor through an encoder cable, and is connected with the robot body 21 through a yellow-black electric wire to realize grounding. The demonstrator 23 is connected with the control cabinet 22 through an integrated cable.

The welding robot 21 is a 12kg six-joint welding robot, and the tail end of the welding robot is provided with an anti-collision sensor 36 and a welding gun 33; the wire feeder 32 is installed at the tail end of the third shaft of the welding robot 21, the wire barrel 34 is fixed on the supporting platform 16, the wire barrel 34 is connected with the wire feeder 32 through a wire feeding pipe, and the two ends of the wire feeding pipe are provided with quick plugging interfaces to realize quick connection of the wire barrel 16 and the wire feeder 34.

With reference to fig. 5, 7 and 8, the positioner 41 is driven by a robot servo motor and a precision speed reducer, and can rotate around a horizontal axis, and the positioner tooling unit 4, the positioner 41, includes a main positioner 411 and a slave positioner 412, which are fixed on the ground (depending on the self-weight). The tooling fixture 42 mainly comprises a support plate 421, a positioning block 422, a positioning pin 423, a manual fixture 424 and the like. The supporting plate 421 is used for supporting the workpiece 6 and a security positioning and clamping device, a plurality of openings are formed in the supporting plate 421, welding operations of the front side and the back side of all welding seams can be met, the supporting plate 421 is fixed between a master positioner and a slave positioner through positioning holes and positioning pins 423 arranged on the positioner 41, the supporting plate 421 is used for supporting the workpiece 6, a positioning block 422 and a manual clamp 424 are fixed on the supporting plate 421 through the positioning pins 423 and bolts, after the workpiece 6 is installed in place, the workpiece 6 is fixed through the manual clamp 424, and the workpiece 6 is positioned in the length direction through the positioning block 422 and the positioning pins 423; a supporting plate 421 is arranged between the main positioner 411 and the slave positioner 412, the workpiece 6 is fixed through a positioning block 422, a positioning pin 423 and a manual clamp 424, and the welding seam position is rotated to the optimal welding position for welding through the rotation of the positioner; the supporting plate 421 is designed with corresponding positioning holes according to the positioning requirements of different workpieces, so as to realize the positioning of the beam of the workpiece 6, the positioning block 422 is quickly and accurately positioned in a plugging and unplugging mode of the positioning pin 423, and the workpiece 6 is clamped by the manual clamp 424.

The workpiece 6 is positioned in the length direction by adopting a positioning block 422 and a positioning pin 423; two positioning blocks 422 and a manual clamp 424 are arranged on the supporting plate 421 and close to two sides of the positioner 41, and corresponding positioning holes are designed according to the positioning requirements of different workpieces, so that the cross beam of the workpiece 6 is positioned.

The workpiece 6 is positioned in the width direction by adopting a positioning block 422 and a positioning pin 423; the supporting plate 421 is designed with corresponding positioning holes according to the positioning requirements of different workpieces, the positioning block 422 is quickly and accurately positioned by plugging and unplugging the positioning pin 423, and the workpiece 6 is clamped by the manual clamp 424.

Referring to fig. 6, the safety protection unit 5 has safety rails 54 fixed to the ground by anchor bolts, and the safety rails 54 are connected to each other by fasteners. A rail is arranged above a safety fence 54 on one side of the safety door 51, the safety door can move left and right in the rail, and the safety lock 52 is fixed on the safety door through bolts. The three-color lamp 53 is fixed above the safety door 51 by bolts. The safety fence 54 is formed by filling an aluminum alloy frame with a steel wire mesh, and the upper half part of the fence is provided with a light-shading curtain 53 for shading arc light; a safety door 51 is arranged at a position corresponding to the safety fence 54, and the safety door 51 is provided with a safety lock 52 and a three-color lamp 53; the safety door 51 is opened, the robot system immediately informs the operation, the safety door 51 is closed, and the robot system can operate; the safety door 51 is provided with a three-color lamp 53 for displaying different working states of different welding operations.

The welding robot unit 2 controls the movable ground rail unit 1 and the welding equipment unit 3 to realize linkage, and manual intervention is not needed to drag cables.

The positioner tool unit 4 only needs one-time clamping on the workpiece 6 through the positioner 41, the supporting plate 421, the positioning block 422, the positioning pin 423 and the manual clamp 424, and after the front welding is finished, the tool clamp 42 does not need to be opened, the positioner 41 is adopted to directly overturn the workpiece, the reverse welding is carried out, and the full-automatic welding of the whole welding operation is realized.

The supporting plate 421 is provided with holes according to the welding positions of the workpieces 6, the workpieces are fixed by the aid of the positioning blocks 422, the positioning pins 423 and the manual clamp 424, the welding positions of the front and the back of the workpieces 6 are exposed at the holes of the supporting plate 421, the front and the back of the workpieces are conveniently welded by the aid of the positioner 41, and secondary clamping is avoided; after the front welding is finished, the work fixture 42 does not need to be opened, the workpiece is directly turned by the positioner 41, and then the back welding is carried out, so that the full-automatic welding of the whole welding operation is realized.

As shown in fig. 9, the full-automatic steel frame single-sheet welding system is used by the following steps: the manual work is assembled in the backup pad to the work piece, and the robot is accomplished spot welding, vertical position welding and fillet weld to the test piece, and is rotatory through the machine of shifting, accomplishes the butt welding of robot, and after all welds, the manual work opens anchor clamps, hangs away the work piece with the help of the driving.

It will be appreciated that modifications and variations are possible to those skilled in the art in light of the above teachings, and it is intended to cover all such modifications and variations as fall within the scope of the appended claims.

Claims

1. The utility model provides a full-automatic steel frame monolithic welding system which characterized in that: the device comprises a safety protection unit (5), wherein a movable ground rail unit (1), a welding robot unit (2), a welding equipment unit (3) and a positioner tooling unit (4) are fixed in the safety protection unit (5); the movable ground rail unit (1) is fixed on the ground and is linked with the welding robot unit (2), and the welding equipment unit (3) provides welding wires for the welding robot unit (2) and cuts the welding wires; positioner frock unit (4) are used for fixing and upset work piece, welding robot unit (2) are including welding robot (21), switch board (22) and demonstrator (23) for to the automatic weld of work piece, demonstrator (23) are through integrated cable connection control cabinet (22), switch board (22) control is removed ground rail unit (1) and welding equipment unit (3) and is realized welding robot (21) linkage.

2. The fully automatic steel frame single sheet welding system according to claim 1, wherein: the mobile ground rail unit (1) comprises a ground rail (11); the ground rail (11) is fixed on the ground, a rack and a sliding groove are fixed on the ground rail (11), a mechanical limit (111) and an electrical limit (112) are arranged at two ends of the ground rail (11), the ground rail (11) is connected with a movable upright column sliding table (15) in a sliding mode, the movable upright column sliding table (15) is embedded into the sliding groove through a sliding block and is connected with the ground rail in a sliding mode, a movable upright column (12) is fixed above the movable upright column sliding table, and a cross arm (13) is fixed at the end portion of the movable upright column (12); a supporting platform (16) is fixed on one side of the movable upright column sliding table (15), an oil pump (14), a motor, a speed reducer, a gear and a control cabinet (22) are mounted on the supporting platform (16), the oil pump (14) lubricates the movable upright column sliding table (15), the gear and a rack, the motor is connected with the gear through the speed reducer, and the gear is meshed with the rack; and a welding robot (21) is fixed at the end part of the cross arm (13).

3. The fully automatic steel frame single sheet welding system of claim 2, wherein: mechanical spacing (111) are equipped with the rubber anticollision piece, electrical spacing (112) are including responding to piece and distance sensor, respond to the piece and install in the inboard predetermined position of mechanical spacing (111), distance sensor installs on portable stand slip table (15).

4. The fully automatic steel frame single sheet welding system of claim 2, wherein: the control cabinet (22) supplies power to the welding robot (21) through a power line, controls the motor communication through an encoder cable, and is connected with the welding robot (21) through a yellow-black electric wire to realize grounding.

5. The fully automatic steel frame single sheet welding system of claim 2, wherein: the welding equipment unit (3) comprises a welding power supply (31), a wire feeder (32), a welding gun (33), a wire disc (34), a gun cleaning and wire cutting device (35) and an anti-collision sensor (36); welding power supply (31) are fixed and are sent a quick-witted (32) power supply on supporting platform (16), terminal installation anticollision sensor (36) of welding robot (21) and welder (33), an end installation send a quick-witted (32) of welding robot (21), and wire reel (34) are fixed on supporting platform (16), and wire reel (34) are through sending a union coupling to send a quick-witted (32), send a pipe both ends all to have quick plug interface to connect wire reel (34) and send a quick-witted (32) respectively, clear rifle is cut a device (35) and is installed on portable stand (12).

6. The fully automatic steel frame single sheet welding system of claim 5, wherein: the welding robot (21) is a six-joint welding robot.

7. The fully automatic steel frame single sheet welding system of claim 1, wherein: the positioner tool unit (4) comprises a main positioner (411), a slave positioner (412) and a tool clamp (42), wherein a workpiece is fixed on the tool clamp (42) and is installed between the main positioner (411) and the slave positioner (412), and the main positioner (411) and the slave positioner (412) adopt a speed reducer matched with a robot servo motor to drive the tool clamp (42) to rotate around a horizontal shaft.

8. The fully automatic steel frame single piece welding system of claim 7, wherein: frock clamp (42) are including backup pad (421), a plurality of locating piece (422), a plurality of locating pin (423) and a plurality of manual anchor clamps (424), main position changing machine (411) and carry on backup pad (421) from the position changing machine (412) centre, locating piece (422) and manual anchor clamps (424) are fixed on backup pad (421) through locating pin (423) and bolt, fix work piece (6) through locating piece (422), locating pin (423) and manual anchor clamps (424).

9. The fully automatic steel frame single sheet welding system of claim 1, wherein: the safety protection unit (5) comprises a safety door (51), a safety lock (52), a three-color lamp (53), a safety fence (54) and a shading curtain (55); a safety door (51) is arranged at a position corresponding to the safety fence (52), and the safety door (51) is provided with a safety lock (52) and a three-color lamp (53); when the safety door (51) is opened, the welding robot unit is informed to prepare for operation, after the safety door (51) is closed, the welding robot unit starts to operate, and the upper half part of the safety fence (54) is provided with a shading curtain (55).

10. The fully automatic steel frame single sheet welding system of claim 9, wherein: the safety fence (54) takes aluminum alloy as a frame and is filled with a steel wire mesh.