KR20190023370A - Automatic welding machine for muffler assembly - Google Patents

Abstract

The present invention provides an automatic welding machine for a muffler assembly, to automatically weld a muffler assembly welding material for connecting an outlet of an exhaust gas post-treatment apparatus with a muffler. To this end, according to the present invention, the automatic welding machine for a muffler assembly comprises: a head stock installed on one side on a table to rotate a first welding material (bellows pipe) by a rotating force of a motor while holding the first welding material with a holding jig; a tail stock installed on a table of an opposite side of the head stock to support a second member (functioning) inserted into a first member; a torch elevator loading a torch of a welder for welding the first and second members to be vertically elevated; a pair of sensor dogs attached to one surface of the holding jig at a predetermined interval; a pair of position sensors detecting the sensor dog to detect a rotating position of the holding jig; and a control unit to control rotation of the motor and operation of the welder in accordance with an output signal of the position sensor.

Description

[0001] AUTOMATIC WELDING MACHINE FOR MUFFLER ASSEMBLY [0002]

The present invention relates to an automatic welder for a muffler assembly, and more particularly to an arc welder capable of automatically producing a muffler assembly weldment for connecting a muffler with an exhaust port of an exhaust gas aftertreatment apparatus.

(CO), carbon dioxide (CO2), hydrocarbons (HC), nitrogen oxides (NOx), sulfurous acid gases (SOx), particulate matter (PM), graphite (Pb), soluble organic Exhaust gas of a three-way catalytic system, a diesel oxidation catalyst (DOC), and a diesel particulate filter trap (DPF) using a catalyst, a filter and a combustion technique in order to reduce harmful substances such as SOF The gas aftertreatment device is mounted on the vehicle.

This exhaust gas after-treatment apparatus connects the inlet to the internal combustion engine of the vehicle and connects the exhaust port to the muffler (muffler). In addition, when the exhaust gas after-treatment apparatus is further mounted on the existing vehicle, That is, a muffler assembly is required.

On the other hand, the muffler assembly for connecting the exhaust port of the exhaust gas after-treatment apparatus with the muffler has a flange joint with an exhaust port of the exhaust gas after-treatment apparatus on one side of the bellows pipe 1, Shaped elbow pipe 3 for connection with the muffler is formed on the other side (opposite side).

Since the bellows pipe 1, the flange 2, and the elbow pipe 3 are formed in different shapes, the muffler assembly A is difficult to be integrally formed. Therefore, after the bellows pipe 1 is formed into a separate member, And each welding angle and horizontal angle are accurately positioned and maintained while being manually welded and integrated.

That is, the muffler assembly A is made of a welded assembly (welding material) for assembling various members by welding.

However, when the muffler assembly (A) is manually welded and integrated by welding, the welding defect rate and the production efficiency are largely dependent on the skill and sincerity of the welding operator, and the labor cost and the working time are long, There is a problem of deterioration.

In addition, there is considerable difficulty and limitation in maintaining the position defined by the welded joint, such as the exact connection angle and horizontal angle between the bellows pipe 1, the flange 2 and the elbow pipe 3 alone, There is a labor and a trouble to weld while maintaining the welding posture using a positioner or the like after measuring the angle and the horizontal state.

In other words, precision and machining quality must be changed according to the competence of a welder, so that it is difficult to secure a uniform quality, and there is also a risk of occurrence of a safety accident.

Herein, the background art or the prior art described above is only intended to help understand the technical significance of the present invention as information acquired by the present inventor or derived from the present invention, It does not mean that it is widely known in the field.

KR10-1041280 B1 (June 7, 2011) KR10-0778794 B1 (November 16, 2007) KR10-0785483 B1 (2007.12.06)

Accordingly, the present inventor has intensively focused on solving the limitations and problems of the conventional method of manufacturing muffler assembly welding by taking into account the above-mentioned matters in a comprehensive manner, and by semi-automating the process of manufacturing the muffler assembly welding material, As a result, the inventors of the present invention have invented the present invention as a result of intensive efforts to develop an automatic welding machine capable of improving the efficiency and productivity of the worker by reducing manpower and work time and ensuring the uniformity of the quality.

SUMMARY OF THE INVENTION Accordingly, the present invention has been made keeping in mind the above problems occurring in the prior art, and it is an object of the present invention to provide an automatic welding machine capable of quickly and easily producing a muffler assembly workpiece in a semi-automatic manner.

Herein, the technical object and object to be solved by the present invention are not limited to the technical object and purpose mentioned above, and another technical object and purpose not mentioned can be understood by those skilled in the art from the following description.

According to an aspect of the present invention, there is provided a method of manufacturing a bellows pipe, comprising the steps of: providing a bellows pipe supporting a first welding material (bellows pipe) with a holding jig, A tailstock for supporting a second member (flange) provided on the table opposite to the headstock and fitted to the first member, a torch for welding the first member and the second member, A first and a second position sensor for sensing the rotational position of the holding jig by sensing the sensor dog, and a second and a third position sensor for sensing the rotational position of the holding jig, And a control unit for controlling the rotation of the electric motor and the operation of the welding machine according to an output signal of the 2-position sensor The automatic welding machine is proposed.

Thus, the present invention makes it possible to produce the muffler assembly welding material quickly, easily and precisely. That is, it is possible to reduce the labor required for welding and shorten the working time, thereby improving the efficiency and productivity of the work, and also the welding and assembling of the muffler assembly members can be accurately carried out, so that uniform and good quality can be always obtained irrespective of the skill of the worker.

According to a preferred embodiment of the present invention, the holding jig includes: a rotating shaft fixed to a transmission shaft of the motor and having the pair of sensor dogs attached to one surface thereof; A first jig formed so as to surround one half of the first jig, a second jig formed so as to surround the other half of the first jig, The second jig having the latch bolt mounted on the opposite end of the hinge and the first jig adjacent to the latch bolt to rotate the second jig about the hinge and maintain the open and closed state with the first jig, And a latch fork, which is connected to one end of the latch bolt to lock the latch bolt when the latch is rotated about the pin, It jig is free to prevent the rotation accuracy of the welding position between the first member and the second member, and reliably match can be made cleaner and more robust weld.

According to a preferred embodiment of the present invention, the tailstock further comprises: a swivel head which supports the end portion of the second member and is freely rotatable; and an actuator installed on the table to move the swivel head forward and backward So that it is prevented that the first member and the second member are tilted to one side during the rotation, so that the welding can be performed more uniformly and efficiently.

According to a preferred embodiment of the present invention, the control unit operates the first position sensor only in response to the switch operation to operate the welding machine while rotating the electric motor of the electric motor by one rotation to rotate the first member and the second member Or both of the first and second position sensors are operated to operate the welding machine while rotating the electric motor shaft of the electric motor within a predetermined angular range to weld only a part of the first member and the third member (elbow pipe) have.

An embodiment of the present invention having the means and construction for solving the above object and the technical object of the present invention is characterized in that the welding position between the first and second members by the organic stable operation of the headstock, The welding angle can be more precisely and accurately welded.

Therefore, it is possible to manufacture the muffler assembly welding materials faster and easier and more precisely compared to the manual work, and the labor and time required for the welding work can be greatly reduced, and the efficiency and productivity are greatly improved due to the simplification and the half automation of the mass production .

In addition, all processes can be accurately and stably welded, unlike the conventional one, which depends on the handwork of the welder, so that uniform and good quality can be obtained at all times irrespective of the technical manpower or proficiency, thereby reducing the welding defect rate and minimizing the loss cost can do.

Here, the effects of the present invention are not limited to the effects mentioned above, and other effects not mentioned can be clearly understood by those skilled in the art from the description of the claims.

1 is an exemplary view showing a conventional muffler assembly.
2 is a side view showing an automatic welder according to an embodiment of the present invention.
3 is a plan view of a head stock in an automatic welder according to an embodiment of the present invention.
FIG. 4 and FIG. 5 are side structural views illustrating an operation state of an automatic welding machine according to an embodiment of the present invention.

Hereinafter, embodiments according to the present invention will be described more specifically with reference to the accompanying drawings.

Prior to this, the following terms are defined in consideration of the functions of the present invention, and they are to be construed to mean concepts that are consistent with the technical idea of the present invention and interpretations that are commonly or commonly understood in the technical field of the present invention.

In the following description, well-known functions or constructions are not described in detail to avoid obscuring the subject matter of the present invention.

BRIEF DESCRIPTION OF THE DRAWINGS The accompanying drawings, which are included to provide a further understanding of the invention and are incorporated in and constitute a part of this specification, illustrate embodiments of the invention and, together with the description, serve to explain the principles of the invention.

In addition, when a part includes an element, it does not exclude other elements unless specifically stated otherwise, but may include other elements.

In addition, the meaning of the terms "part" and "unit" means a unit or module type that processes at least one function or operation, and may be implemented by hardware or software or a combination of hardware and software.

2 to 5, an automatic welder according to an embodiment of the present invention includes a table 100, a head stock 200, a tail stock 300, a torch elevator 400, and a control unit 500 .

The table 100 has a structure in which a head stock 200 and a tail stock 300 are positioned and maintained at a predetermined height on the ground surface for the sake of convenience of welding work and a frame of a plurality of steel bars, They are fixed in a fixed form and are stably fixed on the floor while keeping their level.

The head stock 200 supports the first member (bellows pipe) and transmits power for rotation. The head stock 200 is installed on one side (left side) of the table 100.

That is, the head stock 200 has a built-in electric motor 200, and a holding jig 210 is fixed to the transmission shaft of the electric motor 200 to hold the first member firmly so as to prevent the first member from moving out of the supporting position. The first member (bellows pipe) is inserted and rotated together with the tailstock 300 by the rotational driving force of the electric motor 200. [

The holding jig 210 includes a rotating shaft 212 fixed to the transmission shaft of the electric motor 200 with a sensor dog 211 attached to one side thereof and a pair of upper and lower A first jig 213 which is formed so as to surround one part of the first member and is fixed to the other (opposite) surface of the rotating drum 212, and a second jig 213 which is formed so as to surround the remaining one- The second jig 214 and the second jig 214 are connected to one end of the first jig 213 by a hinge 215 and the latch bolt 216 is mounted on the opposite end of the hinge 215. [ A pin 218 is provided at one end of the first jig 213 adjacent to the latch bolt 216 to rotate the hinge 215 about the hinge 215 and maintain the open and closed state with the first jig 213. [ And a latch (not shown) which is configured to lock or unlock the latch bolt 216 when it is rotated about the pin 218, And a fork 217.

That is, the first and second jigs 213 and 214 are each formed in a semicylindrical shape so as to enclose one-half of the upper and lower parts of the first member, respectively, so that the first and second jigs 213 and 214 can be opened and closed One end of which is connected to the other by a hinge 215 and the other end of the other end of the hinge 215 is locked and unlocked by a locking device.

The sensor detects the sensor dog 211 attached to the turntable 212 to detect the rotation reference position and the rotation angle of the turntable 212 and transmits a signal for controlling the operation of the motor 220 and the welding machine to the controller The first and second position sensors 231 and 232 are mounted on the head stock 200 at regular intervals.

That is, when the sensor dog 211 rotated by the electric motor 220 approaches within a certain distance range, the first position sensor 231 detects it as an operation time point, And the second position sensor 232 detects the operation end point of the sensor dog 211 which is continuously rotated by the electric motor 220 within a certain distance range and controls the operation of the welding machine to the control part 500 And transmits it as an electrical signal to terminate.

The first and second position sensors 231 and 232 can be fixed by bolts using a separate bracket or the like so that the position can be changed.

That is, a slot hole is formed for bolting the first and second position sensors 231 and 232 in the longitudinal direction of the bracket, and the first and second position sensors 231 and 232 are respectively fastened with bolts The first and second position sensors 231 and 232 relative to the bracket can be moved and changed freely according to the welding position and range between the first and second members Can be fixed.

Here, the first and second position sensors 231 and 232 include a high-frequency oscillation circuit in which a switching operation is performed while an oscillation frequency or oscillation amplitude of an oscillation circuit connected to the detection coil is changed by an electromagnetic induction action when a metal object approaches the detection coil A capacitive sensor using a phenomenon in which the capacitance of the sensor portion greatly changes when the object to be detected approaches the detecting portion having a conductor or a conductor electrode, or an optical fiber proximity sensor detecting the position of the object in a noncontact manner . In addition, a limit switch may be employed in which an object is brought into contact with a contact portion to operate the built-in switch, or when the contact point is switched, the position of the object is detected to open and close.

The electric motor 220 is provided with a built-in motor (not shown) which can reduce the noise and vibration by removing the separate power transmission means for transmitting the rotational force to the rotary shaft 212 of the holding jig, It is preferable to use a built-in motor spindle or an induction motor that operates by a rotational force generated by an interaction between a rotating magnetic field generated by an alternating current flowing in the servo motor and an induction current generated in the rotor portion And a geared motor including a speed reducer which adjusts the speed of the motor to be controlled so that the speed of the motor is reduced to a value required for driving.

Here, the head stock 200 is provided with a conversion device for adjusting the rotation speed of the electric motor, and the rotation speed of the head stock 200 can be controlled by controlling the switch of the controller 500.

The tail stock 300 supports the second member (flange) fitted to the first member (bellows pipe) and is provided on the table 100 opposite to the head stock 200.

That is, the tailstock 300 includes a swivel head 310 which is freely rotatable while closely supporting an end portion of a second member (flange) fitted to the first member, and a swivel head 310 fixedly installed on the upper portion of the table 100 And an actuator 320 for moving the swivel head 310 forward and backward under the control of the control unit 500.

It is needless to say that a bearing that smoothly rotates can be mounted on the rotating shaft of the swivel head 310. [

As the actuator 320, a control signal is transmitted to a driving source such as a compressor according to opening and closing of a switch, and when the cylinder rod is operated by hydraulic pressure or air pressure, the second member is pressed forward or backward, Conventional actuator mechanisms and devices can be employed.

The torch elevator 400 has a torch T for welding a first member and a second member (or a third member) to vertically mount the torch. The torch T Can be raised and lowered on the upper side of the table 100 in accordance with the control signal of the control unit 500. [

Here, the torch elevator 400 transmits a control signal to a driving source of a compressor or the like in response to opening and closing of a switch so that the torch position of the welding torch can be freely moved by a stretching and contracting action, Or a conventional hydraulic cylinder or actuator mechanism or apparatus of a structure that operates while descending can be adopted.

The control unit 500 controls the operation of the electric motor 220, the actuator 320 and the torch elevator 400 in the first half of the operation along with the operation of the welding machine. In particular, the control unit 500 controls the operation of the first and second position sensors 231 and 232 And controls the rotation of the electric motor 220 and the operation of the welding machine according to the output signal.

That is, the control unit 500 determines the time required for one rotation of the rotating disk 212, the time required for the movement and travel of the tail stock 300 and the torch elevator 400, Ratio, and rotation ratio, so that each component is controlled so as to alternately and smoothly operate organically without any operation interference or collision.

In addition, the controller 500 operates the first position sensor 231 in response to the switch operation of the operator to operate the welding machine while rotating the motor shaft of the electric motor 220 by one turn, so that the first member and the second member can be completely welded Or both of the first and second position sensors 231 and 232 operate to operate the welder while rotating the motor shaft of the electric motor 220 within a predetermined angular range so that a part of the first member and the third member Only welding can be performed.

Here, the control unit 500 further includes a direction switching switch for changing the rotating direction of the electric motor 220 to the forward / reverse direction, so that the holding jig 210 can be rotated in the forward or reverse direction as necessary, .

The main operation principle of the automatic welder according to the embodiment of the present invention will be described as follows.

4, the first member (bellows pipe) is inserted into the first jig 213 of the holding jig 210, the second jig 214 is closed, and the latch bolt 216 and the latch fork 217), the second member (flange) is inserted into the open side of the first member, and the second member (flange) is pressed by the tailstock 300 so as to be immovable, So that uniform and stable welding can be achieved.

At this time, since the tailstock 300 has a structure in which the swivel head 310 rotates freely while supporting the end portion of the second member, the tailstock 300 can be rotated together with the first member in a natural manner without interfering with the rotation by the holding jig 210 It can rotate smoothly.

5, when the movable power source is applied while the operation of the second position sensor 232 is stopped by the operation of a switch or the like, the control unit 500 determines that the torch elevator 400 is in the first and second And controls the electric motor 220 to rotate the rotating plate 212 and the holding jig 210. At this time, the first position sensor The welding position and the welding angle between the first and second members are further precisely and precisely controlled by controlling the operation of the electric motor 200 and the welding machine by receiving the detection signal of the sensor dog 211 outputted by the controller 200 But a solid weld can be achieved.

In addition, the first member (the bellows 210) in which the second member (flange) is welded to one side of the first jig 213 of the holding jig 210 and the third member (elbow pipe) The second jig 214 is closed and fixed with the latch bolt 216 and the latch fork 217 so as not to be separated from the lock, The control unit 500 controls the motor 220 to rotate the rotating plate 212 and the holding jig 210 when the operation of the second position sensor 232 is canceled by the operation of the second position sensor 232, The control unit 500 controls the motor 200 to start the operation of the welder and the second position sensor 232 outputs the detection signal of the sensor dog 211 outputted from the first position sensor 231 The control unit 500 receives the detection signal of the sensor dog 211 and stops the operation of the electric motor 200 and the welding machine It can be controlled.

Accordingly, it is possible to reduce the work force and time required for the rotation adjustment so that the welding position between the torch (T) of the welding machine and the welding position between the first and third members coincide with each other, Uniform and good welding quality can be always obtained regardless of the skill level of the operator while minimizing the occurrence of safety accidents.

While the present invention has been particularly shown and described with reference to exemplary embodiments thereof, it is to be understood that the invention is not limited to the disclosed exemplary embodiments or constructions. Various changes and substitutions may be made without departing from the spirit and scope of the invention. It will be obvious to those skilled in the art that the present invention can be widely applied to other embodiments.

Therefore, it is to be understood that modifications and variations of the features of the present invention are intended to be included within the spirit and scope of the present invention.

100: Table 200: Headstock
210: holding jig 211: sensor dog
212: Rotor 213: 1st jig
214: second jig 215: hinge
216: latch bolt 217: latch fork
218: pin 220: electric motor
231: first position sensor 232: second position sensor
300: Tailstock 310: Swivel head
320: Actuator 400: Torch Elevator
500:
A: muffler assembly T: torch

Claims (4)

table;
A head stock installed on one side of the table for rotating the first member (bellows pipe) by the rotational driving force of the electric motor while holding the first member (bellows pipe) with the holding jig;
A tailstock installed on a table opposite to the headstock and supporting a second member (flange) fitted to the first member;
A torch elevator for vertically mounting a torch of a welding machine for welding the first member and the second member;
A sensor dog attached to one side of the holding jig;
First and second position sensors mounted at regular intervals on the headstock and sensing the rotational position of the holding jig by sensing the sensor dog;
A controller for controlling the rotation of the electric motor and the operation of the welder according to output signals of the first and second position sensors;
The automatic welder.
The method according to claim 1,
The holding jig includes: a rotary shaft fixed to a transmission shaft of the electric motor and having the sensor dog attached to one side thereof;
A first jig which is fixed to the other side of the rotation shaft and surrounds the upper and lower half portions of the first member;
A second jig formed to surround the remaining one-half of the first member, the second jig being connected to one end of the first jig by a hinge and having a latch bolt mounted on the opposite end of the hinge; And
The second jig is connected to one end of the first jig adjacent to the latch bolt by a pin joint to rotate the second jig around the hinge and maintain the open and closed state with the first jig, A latch fork configured to lock the latch bolt by locking the latch bolt when the latch is rotated;
The automatic welder.
3. The method according to claim 1 or 2,
Wherein the tail stock comprises: a swivel head supporting an end portion of the second member and capable of freely rotating;
An actuator installed on the table for advancing and retracting the swivel head;
The automatic welder.
The method according to claim 1,
The control unit operates the first position sensor only in response to the switch operation to operate the welding machine while rotating the electric shafts of the electric motor one rotation to completely weld the first member and the second member, And the second position sensor operates to rotate the electric motor shaft of the electric motor within a predetermined angular range while operating the welder to weld only a part of the first member and the third member (elbow pipe).

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