KR20240054095A - Automatic Welding Equipment and Method of Welding using the same - Google Patents

Abstract

The present invention relates to an automatic welding device and a welding method using the same. The automatic welding device of the present invention includes a running rail fixed to the upper surface of a corrugated plate material; A carriage that moves along the longitudinal direction of the running rail and can move along the weld line of the corrugated plate material; A welding header coupled to the carriage and equipped with a welding torch; a traveling axis (X-axis) driving unit provided on the carriage and moving the carriage along the traveling rail; A welding header/torch height axis (Y-axis) drive unit provided on the carriage and simultaneously adjusting the height of the welding header and the gap between the welding torch and the corrugated plate; a welding header/torch rotation axis (R-axis) drive unit provided on the carriage and controlling an inclination of the welding header with respect to the traveling direction of the carriage; a welding line tracking axis (Z-axis) drive unit provided on the welding header and controlling a position of the welding torch in the width direction of the welding line; and a weaving axis (W-axis) drive unit provided in front of the welding torch mounted on the welding header and controlling the position of the welding line tracking axis drive unit.

Description

Automatic welding equipment and method of welding using the same}

The present invention relates to an automatic welding device and a welding method using the same.

Among membrane-type LNG cargo holds, a structure consisting of a primary barrier and a secondary barrier is widely used. Here, metal materials such as corrugated sheet Invar or stainless steel are mainly used as the primary and secondary barriers.

Therefore, the core production technology for these metal barriers is the technology of welding the thin corrugated membrane sheet installed on the barrier. Therefore, in the production of these LNG cargo holds, automatic welding technology for overlapping corrugated membrane sheets that absorb thermal stress is an important factor in determining production productivity.

Meanwhile, the membrane sheet used as a barrier for this LNG cargo hold may be a protruding pleated membrane sheet with wrinkles protruding upward or a depressed pleated membrane sheet with wrinkles recessed toward the bottom. Here, the wrinkles of the membrane sheet are generally formed in a grid shape.

Meanwhile, recently, LNG cargo holds are being developed and constructed in which the primary barrier is composed of a protruding corrugated membrane sheet and the secondary barrier is composed of a recessed corrugated membrane sheet.

The existing automatic membrane sheet welding device is configured to adjust the degree of the There was a problem of low adaptability to various types of wrinkles formed on the sheet.

Accordingly, the present applicant applied for an automatic welding device for corrugated plates that is highly adaptable to various types of wrinkles formed on the membrane sheet on May 13, 2016, and received patent registration as Patent No. 10-1874943.

The automatic welding device for corrugated plates of Patent No. 10-1874943 relates to the structure of an automatic welding device for corrugated plates used in MLNC cargo holds. As shown in Figure 19, the automatic welding device for corrugated plates includes a carriage and a welding torch that move along the welding line of the corrugated plates. Equipped with a welding header, a running axis (X-axis) that moves along the rail, a height axis (Y-axis) that controls the height of the welding header, a rotation axis (R-axis) that controls the inclination of the welding header, and a welding machine that controls the arc length of the welding torch. It consists of the torch height axis (AC axis) and the weld line tracking axis (Z axis), which controls the position of the weld line width direction.

However, in the automatic welding device for corrugated sheets of Patent No. 10-1874943, the drive shaft that controls the position of the welding torch is separately composed of a welding header height axis (Y-axis) and a welding torch height axis (AC-axis). Since the welding header height axis is controlled by the displacement amount of contact displacement sensor No. 3, and the welding torch height axis is separately controlled by the displacement amount of contact displacement sensor No. 3, the drive shaft and sensor configuration is complicated, resulting in high manufacturing and maintenance costs. It was discovered. In addition, the automatic welding device for corrugated sheets of Patent No. 10-1874943 did not have an automatic weld line tracking function, so weld line tracking was performed manually by the welder, which required a lot of welding man-hours.

Domestic Registered Patent Publication No. 10-1874943 (Announcement date: June 29, 2018)

The present invention was created to solve the problems of the prior art as described above. The purpose of the present invention is to replace the existing analog type contact displacement sensor (LVDT), which is vulnerable to welding noise, with a digital encoder type linear displacement sensor, and to replace the existing analog type contact displacement sensor (LVDT), which is vulnerable to welding noise. By integrating the welding header height axis (Y-axis) and welding torch height axis (AC-axis) to control the welding header and welding torch height simultaneously on one axis, welding quality is improved by improving the precision of the control algorithm compared to the existing system. The goal is to provide an automatic welding device and a welding method using the same that can not only improve the technology, but also reduce equipment manufacturing and maintenance costs due to the complexity of the existing drive shaft and sensor configuration.

In addition, the purpose of the present invention is to build a system that can perform a welding start position detection algorithm, a curved surface tracking algorithm, and a welding line tracking algorithm to clearly distinguish between the welding line and the welding bead, thereby tracking the welder's manual welding line compared to the existing automatic welding device. To provide an automatic welding device and a welding method using the same that can eliminate welding work man-hours and dramatically improve welding productivity.

An automatic welding device according to one aspect of the present invention includes a running rail fixed to the upper surface of a corrugated plate material; A carriage that moves along the longitudinal direction of the running rail and can move along the weld line of the corrugated plate material; A welding header coupled to the carriage and equipped with a welding torch; a traveling axis (X-axis) driving unit provided on the carriage and moving the carriage along the traveling rail; A welding header/torch height axis (Y-axis) drive unit provided on the carriage and simultaneously adjusting the height of the welding header and the gap between the welding torch and the corrugated plate; a welding header/torch rotation axis (R-axis) drive unit provided on the carriage and controlling an inclination of the welding header with respect to the traveling direction of the carriage; a welding line tracking axis (Z-axis) drive unit provided on the welding header and controlling a position of the welding torch in the width direction of the welding line; and a weaving axis (W-axis) drive unit provided in front of the welding torch mounted on the welding header and controlling the position of the welding line tracking axis drive unit.

Specifically, the welding header/torch height axis driving unit includes a first ball screw member having a screw shaft and a lifting nut that is coupled to the welding header/torch rotation axis driving unit and moves up and down as the screw shaft rotates; a lifting drive motor connected to the screw shaft through a power transmission belt to rotate the screw shaft; Lifting guide rails provided on both sides of the carriage and supporting the lifting and lowering movement of the welding header; and a height axis support LM block that is fixedly connected to the welding header/torch rotation axis driving unit, is provided at a position corresponding to the lifting guide rail, and slides along the lifting guide rail.

Specifically, the welding header/torch rotation axis driving unit includes a lifting frame that is fixedly connected to the height axis support LM block and enables the welding header on which the welding torch is mounted to be raised and lowered; A rotation drive motor provided on one side of the lifting frame; a rotation link structure rotatably connected to one side of the lifting frame and receiving rotational force from the rotation drive motor to rotate the welding header on which the welding torch is mounted; and is slidably connected to the other side of the lifting frame, and when the rotation link structure rotates by the rotation drive motor and adjusts the rotation angle of the welding torch mounted on the welding header, the welding torch is moved without change in the welding point. It may include a horizontal/vertical adjustment unit that maintains a horizontal and vertical state with respect to a flat or curved surface.

Specifically, the welding line tracking axis driving unit includes a torch tracking axis LM block that is provided to be horizontally movable in the width direction of the welding line and is coupled to the welding torch so that its behavior is consistent; a tracking drive unit that horizontally moves the torch tracking axis LM block in the width direction of the weld line; and a torch horizontal rail that maintains the movement trajectory of the torch tracking axis LM block.

Specifically, the weaving shaft driving unit includes a housing coupled to the welding line tracking axis driving unit; A weaving drive unit installed in the housing; A bracket on which a laser displacement sensor is installed, connected to the weaving drive unit, and weaving the laser displacement sensor along a W-axis (weaving axis) perpendicular to the welding progress direction; and a position adjusting device installed in the housing and connected to the bracket to adjust the position of the bracket.

Specifically, it is provided on the welding header, detects the shape of the corrugated sheet by contacting the surface of the corrugated sheet, and controls the welding header/torch height axis driver based on the detected height value of the corrugated sheet to control the welding torch. A first contact-type displacement sensor that adjusts the height and consists of a linear encoder digital displacement sensor; It is provided on the welding header, detects the shape of the corrugated sheet by contacting the surface of the corrugated sheet, and controls the welding header/torch rotation axis drive unit based on the detected inclination value of the corrugated sheet to change the posture of the welding torch to the welding surface. a second contact-type displacement sensor that is maintained perpendicular to and is made of a linear encoder digital displacement sensor; a laser displacement sensor provided in the weaving shaft drive unit to detect a weld line position while performing a weaving operation, and control the weld line tracking axis drive unit based on the detected weld line position value to adjust the position of the weld line tracking axis drive unit; And it is provided in the header unit of the welding header, detects the curved shape of the corrugated sheet material by irradiating light on the surface of the corrugated sheet material, and based on the detected shape information of the corrugated sheet material, the welding header/torch height axis driving unit and the welding unit. It may include a curved surface detection sensor that controls the header/torch rotation shaft drive unit.

A welding method using an automatic welding device according to another aspect of the present invention is a welding method using an automatic welding device according to claim 1, wherein the welding header/torch height axis drive unit is operated to lower the welding header to the welding start position. The first step is to do; A second step of determining whether the first height value of the corrugated plate detected by the first contact displacement sensor provided in the welding header is '0' or more; In the second step, if it is determined that the first height value is not '0' or more, it is determined whether the current height axis (Y-axis) position of the welding header/torch height axis driver is greater than the first height value, If it is not large, it returns to the first step, and if it is large, a third step of generating a fixed error signal of the first contact-type displacement sensor to end welding; In the second step, if it is determined that the first height value is '0' or more, the first height is determined based on the set height value of the first contact displacement sensor and the first height value at the rotation center of the welding torch. A fourth step of calculating the amount of deviation; A fifth step of moving the Y-axis position by the first height deviation amount; A sixth step of initializing the position of the weaving shaft driving unit and storing the initial value of the laser displacement sensor provided in the weaving shaft driving unit; A seventh step of scanning the weaving axis (W axis) with the laser displacement sensor by operating the weaving axis driving unit to detect the step difference; An eighth step of determining whether the first displacement difference value obtained by subtracting the first previous displacement value from the first current displacement value is greater than the detected step difference multiplied by 0.7; In the eighth step, when the first displacement difference value is large, a ninth step of calculating a first position deviation amount based on the first current position value of the W axis obtained by step detection and the set position value of the weld line; A tenth step of aligning the Z-axis of the weld line by adjusting the position of the weld line tracking axis drive unit (Z-axis position adjustment) using the first position deviation amount; and an 11th step of waiting for the automatic welding start operation and completing the welding start position detection algorithm.

Specifically, in the eighth step, if the first displacement difference value is not large, it is determined whether the step detection operation has exceeded a predetermined number of times, and if the predetermined number of times has been exceeded, a start weld line detection error signal is generated to end welding. Step 12; And in the twelfth step, if the predetermined number of times is not exceeded, a thirteenth step of operating the traveling shaft drive unit to move the position of the traveling shaft (X-axis) forward and returning to the sixth step. .

Specifically, the rotation angle of the welding header/torch rotation axis drive unit starts automatic welding from the 11th step and adjusts the rotation axis (R axis) obtained by the second contact-type displacement sensor and curved surface detection sensor provided in the welding header. A 14th step of determining whether it is a curved welding section based on the value; In the 14th step, in the case of the curved surface welding section, a 15th step of calculating and outputting speed values of each of the Y-axis, X-axis, and R-axis and completing the curved surface tracking algorithm; In the 14th step, if the curved welding section is not a section, it is judged to be flat and a 16th step of traveling on the X-axis at a set welding speed; A 17th step of calculating a second height deviation amount based on the set height value of the first contact-type displacement sensor and the second height value of the corrugated plate detected by the first contact-type displacement sensor while driving; and an 18th step of moving the Y-axis position by the second height deviation amount and completing the curved surface tracking algorithm.

Specifically, in the case of the curved surface welding section, the 15th step of calculating and outputting the speed values of each of the Y-axis, Step 15-1 of calculating a third height deviation amount based on the third height value of the corrugated plate detected by the displacement sensor while driving; Step 15-2 of calculating and outputting a speed value of the welding header/torch height axis (Y-axis) driving unit; Step 15-3 of measuring the rotation angle of the rotation axis (R-axis) using the rotary drive motor encoder value of the welding header/torch rotation axis (R-axis) drive unit; Step 15-4 of calculating and outputting the speed value of the traveling axis (X-axis) driving unit; 15-5 for calculating a fourth height deviation amount based on the third height value of the first contact-type displacement sensor and the height value of the second contact-type displacement sensor disposed ahead of the first contact-type displacement sensor. step; Step 15-6 of calculating and outputting a speed value of the welding header/torch rotation axis (R axis) driving unit; By operating the rotation link structure and the horizontal/vertical adjustment unit with the rotation drive motor of the welding header/torch rotation axis (R axis) drive unit, the welding torch can maintain a horizontal and vertical state with respect to a flat or curved surface without changing the welding point. Step 15-7; And a 15-8 step of performing a welding operation while the welding torch rotated by the welding header is maintained perpendicular to the welding surface.

Specifically, in the 15th or 18th step, a 19th step of initializing the position of the weaving shaft driver and storing an initial value of the laser displacement sensor; A 20th step of scanning the weaving axis (W axis) with the laser displacement sensor by operating the weaving axis driver to detect the step difference; Step 21 of determining whether the second displacement difference value obtained by subtracting the second previous displacement value from the second current displacement value is greater than the detected step difference multiplied by 0.7; In the 21st step, if the second displacement difference value is large, a 22nd step of calculating a second position deviation amount based on the second current position value of the W axis obtained through step detection and the set position value of the weld line; A 23rd step of determining whether the second displacement difference value obtained by subtracting the second previous displacement value from the second current displacement value is greater than an allowable deviation amount; In the 23rd step, when the second displacement difference value is large, the Z-axis of the weld line is aligned by adjusting the position of the weld line tracking axis drive unit (Z-axis position adjustment) using the second position deviation amount, and running the weld line tracking algorithm. Step 24 to complete; and a 25th step of checking whether there is a stop command for welding work, returning to step 14 if it is not a stop command, and ending the welding work if it is a stop command.

Specifically, in the 21st step, if the second displacement difference value is not large, a 26th step of recognizing and counting as a weld bead; And it is determined whether the number of counts recognized as a weld bead exceeds the predetermined number of times. If it does not exceed the predetermined number of times, it is judged to be a weld bead and returns to step 14. If the number exceeds the predetermined number of times, it is recognized as a weld end point and A 27th step of stopping and ending welding may be included.

Specifically, in the 23rd step, if the second displacement difference value is not large, a 28th step of counting an error in excess of the allowable deviation amount; And it is determined whether the number of error counting exceeding the allowable deviation amount exceeds a predetermined number of times. If it does not exceed the predetermined number of times, it is judged as noise and returns to the 14th step. If it exceeds the predetermined number of times, the upper surface of the corrugated plate material is determined. It may include a 29th step of terminating the welding in anticipation of an installation error in the running rail fixed to or an uneven weld line.

The automatic welding device and welding method using the same according to the present invention replace the existing analog type contact displacement sensor (LVDT), which is vulnerable to welding noise, with a digital encoder type linear displacement sensor, and replace the existing welding header height axis (Y axis) with a digital encoder type linear displacement sensor. By integrating the welding torch height axis (AC axis) and controlling the welding header and welding torch height simultaneously on one axis, not only can welding quality be improved by improving the precision of the control algorithm compared to the existing one, but also the existing welding torch height axis (AC axis) is integrated. Equipment manufacturing and maintenance costs due to complex drive shaft and sensor configuration can be reduced.

In addition, the automatic welding device and the welding method using the same according to the present invention construct a system that can perform a welding start position detection algorithm, a curved surface tracking algorithm, and a welding line tracking algorithm to clearly distinguish between the weld line and the weld bead, Compared to automatic welding equipment, the welder's manual welding line tracking can be eliminated, reducing welding man-hours and dramatically improving welding productivity.

In addition, the automatic welding device and the welding method using the same according to the present invention configure the welding header/torch rotation axis drive unit to directly connect the motor power transmission shaft and the link drive shaft through a link, and the driving algorithm of the welding header/torch rotation shaft drive unit ( By building a system that can perform a curved surface tracking algorithm, the shaking and clearance phenomenon of the welding torch can be improved compared to existing automatic welding devices that connect the motor power transmission shaft and the link drive shaft through a timing belt or gear, and welding The motion control performance and durability of the torch can be improved, the quality of welding equipment can be improved, and equipment maintenance costs can be dramatically reduced.

1 is a perspective view of an automatic welding device according to an embodiment of the present invention.
Figure 2 is a front view of an automatic welding device according to an embodiment of the present invention.
Figure 3 is a bottom view of an automatic welding device according to an embodiment of the present invention.
Figure 4 is a perspective view for explaining an automatic welding device according to an embodiment of the present invention.
Figure 5 is a perspective view showing the driving shaft driving part in Figure 4.
FIG. 6 is a perspective view showing the manual travel clutch of the drive shaft drive unit in FIG. 4.
Figure 7 is a perspective view showing the welding line tracking axis driving part and the weaving axis driving part in Figure 4.
Figure 8 is a rear perspective view showing the weaving shaft driving part in Figure 7.
Figures 9 and 10 are perspective views showing the welding header/torch rotation shaft drive unit in Figure 4.
FIG. 11 is an exploded perspective view of the welding header/torch rotation shaft drive unit shown in FIG. 10.
Figures 12 (a) to (d) are diagrams showing the left and right rotational movement of the welding torch by the welding header/torch rotation axis drive unit shown in Figure 9.
Figure 13 is a diagram for explaining the welding algorithm of the automatic welding device according to an embodiment of the present invention.
Figures 14 (a) and (b) are drawings for explaining weld lines and weld beads.
15 to 17 are flowcharts for explaining a welding method using an automatic welding device according to an embodiment of the present invention.
FIG. 18 is a flowchart for explaining the curved surface tracking algorithm in the case of the curved welding section in FIG. 16.
Figure 19 is a perspective view of an automatic welding device according to the prior art.

The objectives, specific advantages and novel features of the present invention will become more apparent from the following detailed description and preferred embodiments taken in conjunction with the accompanying drawings. In this specification, when adding reference numbers to components in each drawing, it should be noted that identical components are given the same number as much as possible even if they are shown in different drawings. Additionally, in describing the present invention, if it is determined that a detailed description of related known technologies may unnecessarily obscure the gist of the present invention, the detailed description will be omitted.

Hereinafter, preferred embodiments of the present invention will be described in detail with reference to the attached drawings.

First, with reference to FIGS. 1 to 3, the overall configuration of the automatic welding device 1 according to an embodiment of the present invention will be described.

Figure 1 is a perspective view of an automatic welding device according to an embodiment of the present invention, Figure 2 is a front view of an automatic welding device according to an embodiment of the present invention, and Figure 3 is an automatic welding device according to an embodiment of the present invention. This is a bottom view of .

As shown in FIGS. 1 to 3, the automatic welding device 1 according to an embodiment of the present invention includes a running rail 11, a carriage 2, a welding header 3, and a welding torch 4. can do.

The running rail 11 may be fixed to the upper surface of the corrugated plate material (CP), which is the welding target of the automatic welding device 1 according to an embodiment of the present invention.

The running rail 11 may be composed of a straight beam and may be installed parallel to the weld line (WL) of the corrugated plate (CP).

The running rail 11 may be provided with a rack gear 12 in the center along the longitudinal direction. This rack gear 12 may be engaged with the pinion gear 55 of the traveling shaft drive unit 5, which will be described later.

The carriage (2) can move along the longitudinal direction of the running rail (11) and move along the weld line (WL) of the corrugated plate (CP), and is provided in the automatic welding device (1) according to an embodiment of the present invention. It corresponds to the main body where various mechanical components are installed.

The welding header 3 is coupled to one side of the carriage 2 and can move in the longitudinal direction of the running rail 11 as the carriage 2 moves along the running rail 11. The header unit 31 of the welding header 3 includes a weld line tracking axis drive unit 8, a weaving axis drive unit 9, a first contact displacement sensor DS1, a second contact displacement sensor DS2, and a laser, which will be described later. A displacement sensor (LS) and a curved surface sensor (CS) may be provided.

The welding torch 4 is a device that generates an arc to perform welding of a corrugated plate material (CP), and can be provided so that its behavior matches the welding header 3. In one embodiment, the welding torch 4 may be coupled to the torch mounting portion 41 provided on the welding header 3. The corrugated sheet (CP) may be a membrane sheet with protruding or recessed corrugations (CG).

The automatic welding device (1) according to an embodiment of the present invention having such a configuration travels along the running rail (11) installed on the corrugated plate (CP) and uses a welding torch (4) to weld the corrugated plate (CP). can be welded.

In addition, the automatic welding device 1 according to an embodiment of the present invention is connected to the running axis (X-axis) moving along the running rail 11 and the protruding or recessed wrinkles (CG) of the corrugated plate material (CP). The height axis (Y-axis) of the welding header (3), which adjusts the arc length by simultaneously adjusting the height of the welding header (3) and the welding torch (4), and the rotation angle of the welding header (3) and the welding torch (4) The rotation axis (R axis) of the welding header (3), which adjusts the position of the welding torch (4) in the width direction of the welding line (WL) of the welding torch (4) so that the welding torch (4) tracks the welding line (WL). It is configured so that a total of 5 axes can be adjusted, including the tracking axis (Z-axis), the weaving axis (W-axis) that detects steps by weaving the laser displacement sensor (LS) to detect the weld line (WL), and various types of wrinkles ( Corrugated sheet material (CP) with CG) can be welded.

For this purpose, the automatic welding device (1) according to an embodiment of the present invention includes a traveling axis driving unit (5) for controlling the /It includes a torch rotation axis drive unit (7), a welding line tracking axis drive unit (8) that controls the Z axis, and a weaving axis drive unit (9) that controls the W axis.

In addition, the automatic welding device (1) according to an embodiment of the present invention includes a traveling axis driving unit (5), a welding header/torch height axis driving unit (6), a welding header/torch rotation axis driving unit (7), and a welding line tracking axis driving unit ( 8), it may include a control unit (not shown) that controls the weaving shaft drive unit 9.

Hereinafter, with reference to FIGS. 4 to 14, the structure in which the five axes of the automatic welding device 1 according to an embodiment of the present invention are driven will be described.

Figure 4 is a perspective view for explaining an automatic welding device according to an embodiment of the present invention, Figure 5 is a perspective view showing the driving shaft driving part in Figure 4, and Figure 6 is a manual driving clutch of the driving shaft driving part in Figure 4. It is a perspective view, and FIG. 7 is a perspective view showing the welding line tracking shaft drive unit and the weaving shaft drive unit in FIG. 4, FIG. 8 is a rear perspective view showing the weaving shaft drive unit in FIG. 7, and FIGS. 9 and 10 are in FIG. 4. It is a perspective view showing the welding header/torch rotation axis drive unit, Figure 11 is an exploded perspective view of the welding header/torch rotation axis drive unit shown in Figure 10, and Figures 12 (a) to (d) are the welding header/torch shown in Figure 9. It is a diagram showing the left and right rotational movement of the welding torch by the torch rotation shaft drive unit, and Figure 13 is a diagram for explaining the welding algorithm of the automatic welding device according to an embodiment of the present invention, and Figures 14 (a) and (b) ) are drawings to explain weld lines and weld beads.

The traveling shaft drive unit 5 is provided on the carriage 2 and can move the carriage 2 along the traveling rail 11. The traveling shaft driving unit 5 may be controlled by a control unit according to measured values of the first contact-type displacement sensor DS1 and the second contact-type displacement sensor DS2, which will be described later.

As shown in Figures 4 to 6, the traveling shaft drive unit 5 includes a base frame 51, a traveling roller 52, a rail clamp 53, a tightening screw 54, a pinion gear 55, and a traveling drive. It may include a motor 56, a manual travel clutch 57, and a hinge shaft 58.

The base frame 51 may be provided at the bottom of the carriage 2.

The traveling roller 52 is provided at the bottom of the base frame 51, and the base frame 51 can be movably mounted on the traveling rail 11.

In one embodiment, a plurality of traveling rollers 52 may be provided in a symmetrical form on both sides of the base frame 51 to grip both ends of the traveling rail 11, but the present invention is not limited thereto.

In addition, in one embodiment, the traveling roller 52 is configured to contact the inclined surfaces or bottom surfaces of both ends of the traveling rail 11, as shown in FIGS. 1 to 3, so that the base frame 51 and the carriage 2 It is possible to prevent derailment from the traveling rail (11) while driving.

The rail clamp 53 can press the traveling roller 52 to the traveling rail 11 so that the traveling roller 52 is firmly in close contact with the traveling rail 11.

To this end, in one embodiment, the rail clamp 53 adjusts the position of the traveling roller 52 by pushing the traveling roller 52 provided on one side among the traveling rollers 52 provided on both sides of the base frame 51. It can be configured to do so.

This rail clamp 53 can be operated through a tightening screw 54 that can apply pressure to the traveling roller 52 and constrain the position of the traveling roller 52, as shown in FIG. 5.

The automatic welding device 1 according to an embodiment of the present invention having this configuration has the advantage of being configured to adjust the position of the traveling roller 52 and being applicable to traveling rails 11 of various sizes.

The tightening screw 54 can apply pressure to the traveling roller 52 and restrict the position of the traveling roller 52.

The pinion gear 55 is rotatably coupled to the base frame 51 and may be engaged with the rack gear 12 provided on the running rail 11.

The travel drive motor 56 is provided on the base frame 51 and can rotate the pinion gear 55. In one embodiment, the travel drive motor 56 may be configured to transmit rotational force to the pinion gear 55 through a reducer (not shown).

The control unit can control the travel speed (welding speed) of the automatic welding device 1 by controlling the travel drive motor 56 and the reducer.

The manual travel clutch 57 can move and fix the position of the pinion gear 55 in the width direction of the travel rail 11.

In one embodiment, the manual travel clutch 57 supports the travel drive motor 56 and the pinion gear 55, as shown in FIG. 6, and rotates on the hinge shaft 58 provided on the base frame 51. Possibly combined, the base frame 51 may be rotatable in the width direction of the running rail 11.

This manual travel clutch 57 rotates to engage or disengage the pinion gear 55 from the rack gear 12 of the travel rail 11.

Therefore, the user operates the manual travel clutch 57 to manually adjust the position of the automatic welding device 1 in a state in which the pinion gear 55 is separated from the rack gear 12 of the travel rail 11, or manually adjusts the position of the automatic welding device 1. Welding work can be performed.

In addition, the manual travel clutch 57 can be rotated around the hinge axis 58 and then fix the position of the pinion gear 55 by tightening the bolt provided at the end. Through this function of adjusting the position of the pinion gear 55 of the manual traveling clutch 57, the automatic welding device 1 according to an embodiment of the present invention is capable of operating various types of traveling rails with different positions of the rack gear 12. 11) has the advantage of being applicable.

The welding header/torch height axis drive unit 6 is provided on the carriage 2 and can simultaneously adjust the height of the welding header 3 and the gap between the welding torch 4 and the corrugated plate material (CP).

As shown in Figures 4 and 13, the welding header/torch height axis drive unit 6 includes a first ball screw member 61, a lifting drive motor 62, a power transmission belt 63, and a lifting guide rail 64. ), and may include a height axis support LM (Linear Motion) block 65.

The first ball screw member 61 may include a screw shaft 611 and a lifting nut 612 that moves up and down as the screw shaft 611 rotates.

The lifting nut 612 can lift the welding header (3) and the welding torch (4). In one embodiment, the lifting nut 612 may be connected to the welding header/torch rotation axis drive unit 7 coupled to the welding header 3.

The lifting drive motor 62 is connected to the screw shaft 611 through a power transmission belt 63 and can rotate the screw shaft 611, but is not limited to this. The lifting drive motor 62 and the screw shaft 611 may be configured as gears for power transmission.

This lifting drive motor 62 can be driven by a control unit.

The lifting guide rail 64 is provided in a long direction perpendicular to the carriage 2 and can support the lifting movement of the welding header 3 and the welding torch 4.

In one embodiment, the lifting guide rail 64 may be composed of a rail member that is fastened to the height axis support LM block 65 and allows the welding header/torch rotation axis drive unit 7 to slide. This lifting guide rail (64) performs the function of maintaining the vertical lifting trajectory so that it does not rock or tilt in the horizontal direction during the lifting operation of the welding header (3) while fastened to the height axis support LM block (65). You can.

Additionally, as an example, lifting guide rails 64 may be provided on both sides of the carriage 2.

The height axis support LM block 65 is provided at a position corresponding to the lifting guide rail 64 and can slide along the lifting guide rail 64.

This height axis support LM block 65 can be fixedly coupled to the lifting frame 71 of the welding header/torch rotation axis drive unit 7, and the lifting force of the welding header/torch height axis drive unit 6 is applied to the welding header/torch. It can be transmitted to the welding header (3) and the welding torch (4) through the rotating shaft drive unit (7).

In this way, the lifting guide rails 64 provided on both sides of the carriage 2 support both sides of the lifting frame 71 of the welding header/torch rotation axis drive unit 7 through the height axis support LM block 65, thereby enabling welding. The header (3) and welding torch (4) can be stably raised and lowered in the vertical direction without being distorted.

As shown in FIGS. 4 and 9 to 13, the welding header/torch rotation axis drive unit 7 is provided on the carriage 2, and the traveling direction of the carriage 2 of the welding header 3 and the welding torch 4 The slope can be adjusted. The welding header/torch rotation axis drive unit 7 can rotate the welding header 3 and the welding torch 4 coupled thereto in the direction in which the carriage 2 travels and in the direction opposite to the direction in which the carriage 2 travels.

The welding header/torch rotation axis driver 7 can adjust the rotation angle of the welding torch 4 without changing the welding point based on the measured values of the first contact displacement sensor DS1 and the second contact displacement sensor DS2, which will be described later. It may be configured to do so and may include a lifting frame 71, a rotation drive motor 72, a reducer 73, a rotation link structure 74, and a horizontal/vertical adjustment unit 75.

The lifting frame 71 is fixedly connected to the height axis support LM block 65 of the welding header/torch height axis driving unit 6 to enable the welding header 3 on which the welding torch 4 is mounted to be raised and lowered.

The lifting frame 71 may be provided to fixedly couple the height axis support LM block 65, which is slidably coupled to the lifting guide rails 64 provided on both sides of the carriage 2.

The lifting frame 71 may be rotatably connected to the hinge link 741 of the rotary link structure 74 on one side, and the horizontal rail 752 of the horizontal/vertical adjustment unit 75 may be mounted on the other side.

The rotation drive motor 72 is provided on one side of the lifting frame 71 and can generate power so that the rotation link structure 74 rotates. The rotational drive motor 72 may be configured to transmit rotational force to the hinge link 741 of the rotation link structure 74 through the reducer 73.

The rotation drive motor 72 and the reducer 73 rotate forward or reverse according to the measured values of the first contact displacement sensor DS1 and the second contact displacement sensor DS2, which will be described later, to form the rotation link structure 74. ), the rotation angle of the welding torch (4) mounted on the welding header (3) can be adjusted. The operation of the rotation drive motor 72 and the reducer 73 can be controlled by the control unit.

The rotation link structure 74 is rotatably connected to one side of the lifting frame 71 so that the welding header 3 on which the welding torch 4 is mounted can be rotated by receiving the rotational force of the rotation drive motor 72. It may include a hinge link 741, a slide hinge 742, a first rotation hinge 743, a second rotation hinge 744, a first link bar 745, and a second link bar 746. You can.

The hinge link 741 may be rotatably connected to one side of the lifting frame 71 and may be a power transmission shaft that transmits the power of the rotation drive motor 72 to the welding header 3 on which the welding torch 4 is mounted. there is.

The hinge link 741 may have one end connected to the rotation axis of the rotation drive motor 72 and the other end connected to the first rotation hinge 743.

The slide hinge 742 may be configured to slide up and down, and includes a hinge bar 7421 having a certain length, a first insertion hole 7422 provided at one end of the hinge bar 7421, and a hinge bar ( It may be composed of a second insertion hole 7423 provided at the other end of 7421).

The slide hinge 742 can slide up and down by the rotation link support LM block 754 and the vertical rail 755 of the horizontal/vertical adjustment unit 75, which will be described later, which will be understood later.

A vertical rail 755 of the horizontal/vertical adjustment unit 75, which will be described later, may be mounted on one side of the hinge bar 7421.

The first insertion hole 7422 may be formed so that the first hinge pin 7431 of the first rotation hinge 743 can be inserted and rotated.

The second insertion hole 7423 may be formed so that the second hinge pin 7441 of the second rotation hinge 744 can be inserted and rotated.

The first rotation hinge 743 may be a rotation axis that is forced to rotate by power transmitted from the hinge link 741.

The first rotation hinge 743 may be connected to the other end of the hinge link 741 while rotatably inserted into the first insertion hole 7422 of the slide hinge 742, and may be connected to the first hinge pin 7431 and the first hinge pin 7431. 1 It may consist of a hinge head 7432.

The first hinge pin 7431 is rotatably inserted into the first insertion hole 7422 of the slide hinge 742, the other end of the hinge link 741 is connected to one end, and the first hinge head 7432 is connected to the other end. It can be configured to provide.

The first hinge head 7432 may be provided at the other end of the first hinge pin 7431, and each end of the first link bar 745 and the second link bar 746 may be configured to be rotatably connected. there is.

The first hinge head 7432 may have a plate shape and may be composed of an outer plate and an inner plate. At this time, the outer plate may be provided at the end of the first hinge pin 7431, and the inner plate may be provided at the first hinge pin 7431 at a position spaced a certain distance away from the outer plate. The gap between the outer plate and the inner plate may be a distance at which one end of each of the first link bar 745 and the second link bar 746 can be inserted and rotated.

The second rotation hinge 744 may be a rotation axis that freely rotates by the rotation force transmitted through the first link bar 745 and the second link bar 746, which are rotatably connected to the first rotation hinge 743. , It is also fixedly coupled to the header unit 31 of the welding header 3 to transmit rotational force to the welding header 3 to adjust the rotation angle of the welding torch 4.

The second rotation hinge 744 may be rotatably inserted and connected to the second insertion hole 7423 of the slide hinge 742, and may be composed of a second hinge pin 7441 and a second hinge head 7442. .

The second hinge pin 7441 may be configured such that one end is rotatably inserted and connected to the second insertion hole 7423 of the slide hinge 742, and a second hinge head 7442 is provided at the other end.

The second hinge head 7442 may be provided at the other end of the second hinge pin 7441, and the other ends of each of the first link bar 745 and the second link bar 746 may be configured to be rotatably connected. there is.

The second hinge head 7442 may have a plate shape and may be composed of an outer plate and an inner plate. At this time, the outer plate may be provided at the end of the second hinge pin 7441, and the inner plate may be provided at the second hinge pin 7441 at a position spaced a certain distance away from the outer plate. The gap between the outer plate and the inner plate may be a distance at which the second link bar 746 and the other end of each of the second link bars 746 can be inserted and rotated.

Additionally, the outer plate of the second hinge head 7442 can be fixedly coupled to the header unit 31 of the welding header 3, thereby allowing the rotation angle of the welding torch 4 to be adjusted.

The first link bar 745 and the second link bar 746 may be installed between the first rotation hinge 743 and the second rotation hinge 744.

One end of the first link bar 745 is rotatably connected to one side of the first hinge head 7432 with respect to the first hinge pin 7431, and the other end is connected to the second hinge head 7432 with respect to the second hinge pin 7441. It can be rotatably connected to one side of the hinge head 7442.

The second link bar 746 has one end rotatably connected to the other side of the first hinge head 7432 with respect to the first hinge pin 7431, and the other end with the second hinge pin 7441 as the basis. It can be rotatably connected to the other side of the hinge head 7442.

As described above, each of the first link bar 745 and the second link bar 746 is connected to the first rotation hinge 743 and the second rotation hinge 744, so that the rotational force of the first rotation hinge 743 Can be transmitted to the second rotation hinge 744.

The horizontal/vertical adjustment unit 75 is slidably connected to the other side of the lifting frame 71, and the rotary link structure 74 rotates by the rotary drive motor 72 and a welding torch mounted on the welding header 3 ( When adjusting the rotation angle of 4), the welding torch (4) can be configured to maintain a horizontal and vertical state with respect to a flat or curved surface without changing the welding point, and the installation plate (751), horizontal rail (752), and rotation axis It may include a support LM block 753, a rotary link support LM block 754, and a vertical rail 755.

The installation plate 751 may be configured so that the rotation axis support LM block 753 and the rotation link support LM block 754 can be fixedly installed.

The installation plate 751 may be composed of a first plate 7511 on which the rotation axis support LM block 753 is installed and a second plate 7512 on which the rotation link support LM block 754 is installed. In this case, the first plate 7511 and the second plate 7512 may be coupled by a coupling means. In one embodiment, the installation plate 751 is described as being made of a first plate 7511 and a second plate 7512, but of course, it is not limited to this and can be formed as an integrated piece.

The horizontal rail 752 may be mounted on the other side of the lifting frame 71.

A pair of horizontal rails 752 may be provided horizontally at regular intervals on the lifting frame 71, and the rotation axis support LM block 753 may be coupled to be slidable in the horizontal direction.

The rotation axis support LM block 753 may be slidably coupled to the horizontal rail 752 and may be fixedly installed on the first plate 7511 of the installation plate 751.

The horizontal rail 752 and the rotation axis support LM block 753 have a rotation link structure 74 connected to a rotation drive motor 72 to adjust the rotation angle of the welding torch 4 mounted on the welding header 3. When rotating at a certain angle in the traveling direction or in the opposite direction, the rotation axis support LM block (753) moves horizontally on the horizontal rail (752) in the traveling direction or in the opposite direction, and the welding torch (4) remains horizontal without changing the welding point. Allows the status to be maintained.

The rotation link support LM block 754 may be fixedly installed on the second plate 7512 of the installation plate 751, and may be configured to be slidably coupled to the vertical rail 755.

The vertical rail 755 can be mounted on the slide hinge 742 of the rotary link structure 74 and can be slidably coupled to the rotary link support LM block 754.

As described above, the rotary link support LM block 754 is fixedly installed on the second plate 7512 of the installation plate 751, and the vertical rail 755 is mounted on the slide hinge 742 of the rotary link structure 74. By being installed in a sliding manner, the rotation link structure 74 is moved in the traveling direction or in the opposite direction by the rotation drive motor 72 in order to adjust the rotation angle of the welding torch 4 mounted on the welding header 3. When rotating at a certain angle, the slide hinge 742 on which the vertical rail 755 is mounted moves vertically upward or downward, allowing the welding torch 4 to maintain a vertical state without changing the welding point.

The horizontal/vertical adjustment unit 75 configured as described above is supported by a welding torch ( The welding point of 4) is maintained in a horizontal state, and the welding torch ( By maintaining the horizontal state with respect to the welding point of 4), when adjusting the rotation angle of the welding torch (4) mounted on the welding header (3) as shown in (a) to (d) of Figure 12, welding The torch (4) can rotate left and right without changing the welding point, thereby improving welding quality.

The weld line tracking axis driving unit 8 may be provided in the welding header 3.

The welding line tracking axis driving unit 8 adjusts the width direction position of the welding line (WL) of the welding torch (4), so that the welding torch (4) performs welding along the welding line (WL) in the horizontal direction. can be adjusted.

The welding line tracking axis driving unit 8 can automatically adjust the position of the welding torch 4 and control its deviation from the welding line WL according to the welding line position value detected by the laser displacement sensor LS, which will be described later, and can be controlled by the control unit. It can operate automatically.

As shown in FIG. 7, the welding line tracking axis driving unit 8 may include a torch tracking axis LM block 81, a tracking driving unit 82, and a torch horizontal rail 83.

The torch tracking axis LM block 81 is provided to be horizontally movable in the width direction of the weld line WL, and the welding torch 4 can be combined with the welding torch 4 in a consistent manner.

The tracking drive unit 82 can horizontally move the torch tracking axis LM block 81 in the width direction of the weld line WL. For example, the tracking drive unit 82 includes a second ball screw member 821 to which the torch tracking axis LM block 81 is coupled and a belt pulley 822 connected to the second ball screw member 821. It may be configured, but is not limited to this.

The welding line tracking shaft drive unit 8 can transmit power from the tracking drive unit 82 to the second ball screw member 821 and the torch tracking shaft LM block 81 through the belt pulley 822.

The torch horizontal rail (83) is fixed to the header unit (31) of the welding header (3), and is a rail member to which the torch tracking axis LM block (81) is coupled so that it can move horizontally in the width direction of the welding line (WL). It can perform the function of maintaining the movement trajectory of the torch tracking axis LM block (81) so that the tracking axis LM block (81) can move stably without shaking or being removed.

The weaving axis driving unit 9 may be provided in front (direction of progress) of the welding torch 4, and weaves a laser displacement sensor (LS) for detecting the weld line along the weaving axis (W axis) perpendicular to the direction of welding. By weaving, the laser displacement sensor (LS) can be configured to detect the step.

The weaving axis drive unit 9 can perform weld line tracking by adjusting the position of the weld line tracking axis drive unit 8 (Z-axis position adjustment) based on the position where the step is detected, and can be automatically operated by the control unit. .

As shown in FIGS. 7 and 8, the weaving shaft drive unit 9 may include a housing 91, a weaving drive unit 92, a bracket 93, and a position adjusting device 94.

The housing 91 may be coupled to the weld line tracking axis drive unit 8.

The weaving drive unit 92 can be installed in the housing 91, and the bracket 93 on which the laser displacement sensor LS is installed can be weaved along the W axis (weaving axis) perpendicular to the welding progress direction. . For example, the weaving drive unit 92 includes a third ball screw member 921 to which the bracket 93 is coupled and a power transmission gear 922 that transmits power to the third ball screw member 921. It may be possible, but it is not limited to this.

The bracket 93 can be equipped with a laser displacement sensor (LS) and is connected to the weaving drive unit 92 so that the laser displacement sensor (LS) is weaved along the W axis (weaving axis) perpendicular to the welding progress direction. You can.

The position adjusting device 94 is installed in the housing 91 and connected to the bracket 93 to adjust the position of the bracket 93. That is, the position adjusting device 94 can adjust the position of the laser displacement sensor LS.

The automatic welding device 1 according to an embodiment of the present invention includes a first contact displacement sensor (DS1), a second contact displacement sensor (DS2), a laser displacement sensor (LS), and a curved surface detection sensor (CS). can do.

The first contact displacement sensor DS1 and the second contact displacement sensor DS2 may be linear encoder digital displacement sensors and may be provided in the welding header 3.

The first contact displacement sensor DS1 and the second contact displacement sensor DS2 can detect the shape of the corrugated sheet CP by contacting the surface of the corrugated sheet CP during welding.

As shown in FIGS. 2 and 3, the first contact-type displacement sensor DS1 may be disposed rearward than the second contact-type displacement sensor DS2 based on the traveling direction of the carriage 2.

In this configuration, the first contact displacement sensor DS1 and the second contact displacement sensor DS2 can detect the height of the corrugated plate CP or the inclination of the corrugated plate CP.

The second contact-type displacement sensor (DS2) detects the shape of the corrugated plate (CP) ahead of the first contact-type displacement sensor (DS1) when the carriage (2) travels, and detects the corrugated part of the corrugated plate (CP) formed in the welding direction. The slope can be detected first.

Meanwhile, the control unit operates the traveling axis driving unit 5 and the welding header/torch height axis based on the shape information of the corrugated plate (CP) detected by the first contact displacement sensor (DS1) and the second contact displacement sensor (DS2). The driving unit 6 and the welding header/torch rotation axis driving unit 7 can be controlled.

In one embodiment, the control unit calculates the running speed of the carriage 2 through the first contact displacement sensor DS1 and/or the second contact displacement sensor DS2, and compares it with a preset reference welding speed to determine whether the carriage The traveling speed of (2) can be calculated in real time and the traveling shaft drive unit 5 can be controlled based on the calculated traveling speed.

The laser displacement sensor (LS) can be installed on the bracket 93 of the weaving axis drive unit 9, and can be weaved along the W axis (weaving axis) perpendicular to the welding progress direction to detect the welding line (WL). .

The laser displacement sensor (LS) can transmit data about the weld line (WL) and weld bead (WB) to the control unit according to a distance data analysis algorithm while performing a weaving operation.

Meanwhile, the control unit may control the weld line tracking axis driving unit 8 based on the weld line position value detected by the laser displacement sensor LS.

For example, the control unit automatically adjusts the position of the welding torch (4) by controlling the welding line tracking axis driving unit (8) based on the welding line position value detected by the laser displacement sensor (LS). Leaving the weld line (WL) can be controlled.

The laser displacement sensor (LS) may be a distance sensor using a point laser, but is not limited to this and may include various sensors capable of measuring distance, such as a distance sensor using a line laser and a distance sensor using light. am.

In the above, the laser displacement sensor LS may have a weaving width range of 10 mm, but is not limited thereto. In addition, when the laser displacement sensor (LS) is a distance sensor using a point laser, the measurement range may be 8 mm to 10 mm, the frequency may be 2 Hz to 3 Hz, and the wave form may be a square pulse, but it is not limited thereto.

The curved surface detection sensor (CS) is provided in the header unit 31 of the welding header 3, and can detect the curved shape of the corrugated sheet (CP) by irradiating light to the surface of the corrugated sheet (CP).

Here, the control unit can control the welding header/torch height axis driving unit 6 and the welding header/torch rotation axis driving unit 7 based on shape information of the corrugated plate (CP) from the curved surface detection sensor (CS).

For example, the control unit receives the shape information of the corrugated plate (CP) detected by the curved surface detection sensor (CS), and the welding torch measured by the first contact displacement sensor (DS1) and the second contact displacement sensor (DS2) ( Based on the rotation angle information in 4), the welding conditions (peak, welding current, welding pulse frequency, pilot gas amount, current pulse width, etc.) for each section of the wrinkle section can be adjusted to suit the welding characteristics in each section of the wrinkle section. .

Meanwhile, the automatic welding device 1 according to an embodiment of the present invention includes a corrugated plate (CP) having protruding wrinkles (CG) shown in FIG. 13 as well as a corrugated plate (CP) having recessed wrinkles (CG). It can be used for all welding, and accordingly, although not specifically described in this embodiment, it may include a clamp member and a rail fixing unit for fixing the running rail 11 to the corrugated plate material CP.

As shown in FIG. 13, the automatic welding device 1 of the present invention is configured such that the welding torch 4 is tilted by the welding header/torch rotation axis drive unit 7 on the corrugated plate CP having wrinkles CG. Welding can be performed while moving along the weld line (WL) in a state perpendicular to the welding surface (flat or curved) of the corrugated plate (CG), and the welding torch (4) can be used on the flat part of the corrugated plate (CP) Of course, welding is performed while moving along the weld line (WL) in a state perpendicular to the welding surface.

Hereinafter, the welding method using the automatic welding device 1 of the present invention described above will be described with reference to FIGS. 15 to 18.

Figures 15 to 17 are flowcharts for explaining a welding method using an automatic welding device according to an embodiment of the present invention. Figure 15 is a flowchart for the welding start position detection algorithm, and Figure 16 is a flowchart for the curved surface tracking algorithm. , FIG. 17 is a flowchart for the weld line tracking algorithm, and FIG. 18 is a flowchart for explaining the curved surface tracking algorithm in the case of a curved welding section in FIG. 16.

The welding method using an automatic welding device in one embodiment of the present invention may be comprised of the welding start position detection algorithm shown in FIG. 15, the curved surface tracking algorithm shown in FIG. 16, and the weld line tracking algorithm shown in FIG. 17.

In order to perform welding work, the welding start position must be reviewed, which will be explained with reference to FIGS. 13 and 15.

The automatic welding device (1) is positioned at the welding start position, and the welding header/torch height axis drive unit (6) is operated to lower the welding header (3) to the welding start position (S1).

With the welding header (3) lowered, it is determined whether the first height value of the corrugated plate (CP) detected by the first contact displacement sensor (DS1) provided in the welding header (3) is '0' or more ( S2).

In step S2, if it is determined that the first height value is not '0' or more, it is determined whether the current height axis (Y-axis) position of the welding header/torch height axis driver 6 is greater than the first height value, If it is not large, the process returns to step (S1), and if it is large, a fixed error signal of the first contact-type displacement sensor (DS1) is generated to end welding (S3).

In step S2, if it is determined that the first height value is '0' or more, the first height value is set at the rotation center of the welding torch 4 based on the set height value and the first height value of the first contact displacement sensor DS1. 1 Calculate the height deviation amount (S4), and move the Y-axis position by the first height deviation amount (S5).

In a state where the Y-axis position is moved, the position of the weaving shaft driver 9 is initialized, the initial value of the laser displacement sensor LS provided in the weaving shaft driver 9 is stored (S6), and the step is detected. The weaving axis driving unit (9) is operated to scan the weaving axis (W axis) with the laser displacement sensor (LS) (S7).

While scanning the weaving axis (W axis), it is determined whether the first displacement difference value obtained by subtracting the first previous displacement value from the first current displacement value is greater than the detected step difference multiplied by 0.7 (S8).

In step S8, when the first displacement difference value is large, the first position deviation amount is calculated based on the first current position value of the W axis obtained by step detection and the set position value of the weld line WL (S9), 1 Align the Z-axis of the weld line (WL) by adjusting the position of the weld line tracking axis drive unit 8 (Z-axis position control) using the position deviation amount (S10).

As the Z-axis of the weld line (WL) is aligned, the welding start position detection algorithm is completed and the automatic welding start operation standby state is maintained (S11).

In the above step (S8), if the first displacement difference value is not large, it is determined whether the step detection operation has exceeded a predetermined number of times (e.g., 3 step detection operations), and if the predetermined number of steps has been exceeded, a start weld line detection error is performed. A signal is generated to end welding (S12).

In step S12, if the predetermined number of times is not exceeded, the traveling shaft driving unit 5 is operated to move the position of the traveling shaft (X-axis) forward and the process returns to step S6 (S13).

The welding start position can be detected by performing step S13 from step S1 described above.

After the welding start position detection algorithm is performed as described above, the curved surface tracking algorithm and the welding line tracking algorithm are performed.

The curved surface tracking algorithm will be described with reference to FIG. 16.

First, automatic welding starts from step S11 and the welding header / welding header / It is determined whether it is a curved welding section based on the rotation angle value of the torch rotation shaft drive unit 7 (S14).

In step S14, in the case of a curved welding section, the speed values of each of the Y-axis, X-axis, and R-axis are calculated and output, and the curved surface tracking algorithm is completed (S15).

In step S14, if it is not a curved welding section, it is judged to be flat and travels along the X-axis at the set welding speed (S16), and the set height value of the first contact displacement sensor DS1 ) Calculate the second height deviation amount based on the second height value of the corrugated plate (CP) detected while driving (S17).

The curved surface tracking algorithm is completed by moving the Y-axis position by the calculated second height deviation amount (S18).

In the above, in the case of a curved welding section, the step (S15) of calculating and outputting the speed values of each of the Y-axis, X-axis, and R-axis may include the following steps, which will be described with reference to FIG.

Step (S15) determines the third height based on the set height value of the first contact-type displacement sensor (DS1) and the third height value of the corrugated plate (CP) detected by the first contact-type displacement sensor (DS1) while driving. Calculate the amount of deviation (S15-1), calculate and output the speed value of the welding header/torch height axis (Y axis) drive unit (6) (S15-2), and calculate and output the speed value of the welding header/torch rotation axis (R axis) drive unit (S15-2). Measure the rotation angle of the rotation axis (R axis) using the encoder value of the rotation drive motor 72 in 7) (S15-3), calculate and output the speed value of the driving axis (X axis) drive unit 5 ( S15-4), based on the third height value of the first contact-type displacement sensor (DS1) and the height value of the second contact-type displacement sensor (DS2) disposed ahead of the first contact-type displacement sensor (DS1) 4 Calculate the height deviation amount (S15-5), calculate and output the speed value of the welding header/torch rotation axis (R axis) drive unit (7) (S15-6), and calculate the speed value of the welding header/torch rotation axis (R axis) drive unit (S15-6). By operating the rotation link structure 74 and the horizontal/vertical adjustment unit 75 with the rotation drive motor 72 of (7), the welding torch 4 maintains a horizontal and vertical state with respect to a flat or curved surface without changing the welding point. (S15-7), and the welding work is performed with the welding torch (4) rotated by the welding header (3) maintained perpendicular to the welding surface (S15-8).

The weld line tracking algorithm will be described with reference to FIG. 17.

First, in step S15 or step S18, the position of the weaving shaft driver 9 is initialized, the initial value of the laser displacement sensor LS is stored (S19), and the weaving shaft driver 9 is installed to detect the step. ) to scan the weaving axis (W axis) with the laser displacement sensor (LS) (S20).

While scanning the weaving axis (W axis), it is determined whether the second displacement difference value obtained by subtracting the second previous displacement value from the second current displacement value is greater than the detected step difference multiplied by 0.7 (S21).

In step S21, if the second displacement difference value is large, the second position deviation amount is calculated based on the second current position value of the W axis obtained by step detection and the set position value of the weld line WL (S22), 2 It is determined whether the second displacement difference value obtained by subtracting the second previous displacement value from the current displacement value is greater than the allowable deviation amount (S23).

In step S23, when the second displacement difference value is large, the position of the weld line tracking axis drive unit 8 is adjusted (Z-axis position adjustment) using the second position deviation amount to align the Z axis of the weld line WL to track the weld line. Complete the algorithm (S24).

Afterwards, it is checked whether there is a stop command for welding work. If it is not a stop command, the process returns to step S14. If it is a stop command, the welding work is terminated (S25).

In the above step (S21), if the second displacement difference value is not large, it is recognized and counted as a weld bead (WB) (S26).

It is determined whether the number of counts recognized as a weld bead (WB) exceeds the scheduled number (for example, 5 weld bead counting times), and if it does not exceed the scheduled number, it is judged as a weld bead (WB) in step S14. It returns to , and if the scheduled number of times is exceeded, it is recognized as the end point of welding and stops to complete welding (S27).

In the above step (S23), if the second displacement difference value is not large, an error exceeding the allowable deviation amount is counted (S28).

It is determined whether the number of errors exceeding the allowable deviation amount exceeds a predetermined number (for example, 10 errors exceeding the allowable deviation amount), and if it does not exceed the predetermined number, it is determined to be noise and returns to step S14. , if the scheduled number of times is exceeded, the welding is terminated in anticipation of an installation error in the running rail 11 fixed to the upper surface of the corrugated plate (CP) or an unevenness of the weld line (WL) (S29).

In the above, the present invention has been described focusing on the embodiments of the present invention, but this is only an example and does not limit the present invention, and those of ordinary skill in the field to which the present invention pertains will not deviate from the essential technical content of the present embodiments. It will be appreciated that various combinations, modifications, and applications not illustrated in the examples are possible within the scope. Accordingly, technical details related to modifications and applications that can be easily derived from the embodiments of the present invention should be construed as included in the present invention.

1: Automatic welding device 11: Running rail
12: Rack gear 2: Carriage
3: Welding header 31: Header unit
4: Welding torch 41: Torch mounting part
5: Driving shaft driving part 51: Base frame
52: Travel roller 53: Rail clamp
54: Tightening screw 55: Pinion gear
56: Travel drive motor 57: Manual travel clutch
58: Hinge axis 6: Welding header/torch height axis driving unit
61: first ball screw member 611: screw shaft
612: Lifting nut 62: Lifting drive motor
63: Power transmission belt 64: Elevating guide rail
65: Height axis support LM block 7: Welding header/torch rotation axis drive unit
71: Elevating frame 72: Rotation drive motor
73: Reducer 74: Rotating link structure
741: Hinge link 742: Slide hinge
7421: Hinge bar 7422: First insertion hole
7423: second insertion hole 743: first rotation hinge
7431: first hinge pin 7432: first hinge head
744: second rotation hinge 7441: second hinge pin
7442: second hinge head 745: first link bar
746: second link bar 75: horizontal/vertical adjustment unit
751: Installation plate 7511: First plate
7512: second plate 752: horizontal rail
753: Rotation shaft support LM block 754: Rotation link support LM block
755: vertical rail 8: weld line tracking axis drive unit
81: Torch tracking axis LM block 82: Tracking drive unit
821: Second ball screw member 822: Belt pulley
83: Torch horizontal rail 9: Weaving shaft driving unit
91: Housing 92: Weaving drive unit
921: Third ball screw member 922: Power transmission gear
93: Bracket 94: Position adjusting device
DS1: First contact displacement sensor DS2: Second contact displacement sensor
LS: Laser displacement sensor CS: Curved surface detection sensor
CP: corrugated board CG: corrugated
WL: Weld line WB: Weld bead

Claims (13)

A running rail fixed to the upper surface of the corrugated plate;
A carriage that moves along the longitudinal direction of the running rail and can move along the weld line of the corrugated plate material;
A welding header coupled to the carriage and equipped with a welding torch;
a traveling axis (X-axis) driving unit provided on the carriage and moving the carriage along the traveling rail;
A welding header/torch height axis (Y-axis) drive unit provided on the carriage and simultaneously adjusting the height of the welding header and the gap between the welding torch and the corrugated plate;
a welding header/torch rotation axis (R-axis) drive unit provided on the carriage and controlling an inclination of the welding header with respect to the traveling direction of the carriage;
a welding line tracking axis (Z-axis) drive unit provided on the welding header and controlling a position of the welding torch in the width direction of the welding line; and
An automatic welding device comprising a weaving axis (W-axis) drive unit provided in front of the welding torch mounted on the welding header and controlling the position of the welding line tracking axis drive unit. According to paragraph 1,
The welding header/torch height axis driving unit,
A first ball screw member having a screw shaft and a lifting nut that is coupled to the welding header/torch rotation shaft drive unit and moves up and down as the screw shaft rotates;
a lifting drive motor connected to the screw shaft through a power transmission belt to rotate the screw shaft;
Lifting guide rails provided on both sides of the carriage and supporting the lifting and lowering movement of the welding header; and
An automatic welding device comprising a height axis support LM block that is fixedly connected to the welding header/torch rotation axis drive unit, is provided at a position corresponding to the lifting guide rail, and slides along the lifting guide rail. According to paragraph 2,
The welding header/torch rotation axis driving unit,
A lifting frame fixedly connected to the height axis support LM block to enable the welding header on which the welding torch is mounted to be raised and lowered;
A rotation drive motor provided on one side of the lifting frame;
a rotation link structure rotatably connected to one side of the lifting frame and receiving rotational force from the rotation drive motor to rotate the welding header on which the welding torch is mounted; and
It is slidably connected to the other side of the lifting frame, and when the rotation link structure rotates by the rotation drive motor and adjusts the rotation angle of the welding torch mounted on the welding header, the welding torch is flat without changing the welding point. Or, an automatic welding device including a horizontal/vertical control unit that maintains the horizontal and vertical state with respect to the curved surface. According to paragraph 1,
The welding line tracking axis driving unit,
A torch tracking axis LM block is provided to be horizontally movable in the width direction of the welding line and is coupled to the welding torch in a consistent manner.
a tracking drive unit that horizontally moves the torch tracking axis LM block in the width direction of the weld line; and
An automatic welding device comprising a torch horizontal rail that maintains the movement trajectory of the torch tracking axis LM block. According to paragraph 1,
The weaving shaft driving unit,
A housing coupled to the weld line tracking axis driving unit;
A weaving drive unit installed in the housing;
A bracket on which a laser displacement sensor is installed, connected to the weaving drive unit, and weaving the laser displacement sensor along a W-axis (weaving axis) perpendicular to the welding progress direction; and
An automatic welding device comprising a position control device installed in the housing and connected to the bracket to adjust the position of the bracket. According to paragraph 1,
It is provided on the welding header, detects the shape of the corrugated sheet by contacting the surface of the corrugated sheet, and controls the welding header/torch height axis driver based on the detected height value of the corrugated sheet to adjust the height of the welding torch. A first contact displacement sensor consisting of a linear encoder digital displacement sensor; and
It is provided on the welding header, detects the shape of the corrugated sheet by contacting the surface of the corrugated sheet, and controls the welding header/torch rotation axis drive unit based on the detected inclination value of the corrugated sheet to change the posture of the welding torch to the welding surface. A second contact displacement sensor is maintained perpendicular to and is made of a linear encoder digital displacement sensor;
a laser displacement sensor provided in the weaving shaft drive unit to detect a weld line position while performing a weaving operation, and control the weld line tracking axis drive unit based on the detected weld line position value to adjust the position of the weld line tracking axis drive unit; and
It is provided in the header unit of the welding header, detects the curved shape of the corrugated sheet material by irradiating light on the surface of the corrugated sheet material, and based on the detected shape information of the corrugated sheet material, the welding header/torch height axis driver and the welding header /Automatic welding device including a curved surface detection sensor that controls the torch rotation axis driving unit. A welding method using an automatic welding device according to paragraph 1,
A first step of lowering the welding header to the welding start position by operating the welding header/torch height axis driving unit;
A second step of determining whether the first height value of the corrugated plate detected by the first contact displacement sensor provided in the welding header is '0' or more;
In the second step, if it is determined that the first height value is not '0' or more, it is determined whether the current height axis (Y-axis) position of the welding header/torch height axis driver is greater than the first height value, If it is not large, it returns to the first step, and if it is large, a third step of generating a fixed error signal of the first contact-type displacement sensor to end welding;
In the second step, if it is determined that the first height value is '0' or more, the first height is determined based on the set height value of the first contact displacement sensor and the first height value at the rotation center of the welding torch. A fourth step of calculating the amount of deviation;
A fifth step of moving the Y-axis position by the first height deviation amount;
A sixth step of initializing the position of the weaving shaft driving unit and storing the initial value of the laser displacement sensor provided in the weaving shaft driving unit;
A seventh step of scanning the weaving axis (W axis) with the laser displacement sensor by operating the weaving axis driving unit to detect the step difference;
An eighth step of determining whether the first displacement difference value obtained by subtracting the first previous displacement value from the first current displacement value is greater than the detected step difference multiplied by 0.7;
In the eighth step, when the first displacement difference value is large, a ninth step of calculating a first position deviation amount based on the first current position value of the W axis obtained by step detection and the set position value of the weld line;
A tenth step of aligning the Z-axis of the weld line by adjusting the position of the weld line tracking axis drive unit (Z-axis position adjustment) using the first position deviation amount; and
An 11th step of waiting for the automatic welding start operation and completing the welding start position detection algorithm. A welding method using an automatic welding device comprising a. In clause 7,
In the eighth step, if the first displacement difference value is not large, it is determined whether the step detection operation has exceeded a predetermined number of times, and if the predetermined number of times has been exceeded, a start weld line detection error signal is generated to terminate the welding. step; and
In the twelfth step, if the predetermined number of times is not exceeded, a thirteenth step of operating the traveling shaft drive unit to move the position of the traveling shaft (X-axis) forward and returning to the sixth step is an automatic welding device comprising a. Welding method using. In clause 7,
Automatic welding starts from the 11th step and the curved surface is set to the rotation angle value of the welding header/torch rotation axis drive unit that controls the rotation axis (R axis) obtained by the second contact-type displacement sensor and curved surface detection sensor provided in the welding header. A 14th step of determining whether it is a welding section;
In the 14th step, in the case of the curved surface welding section, a 15th step of calculating and outputting speed values of each of the Y-axis, X-axis, and R-axis and completing the curved surface tracking algorithm;
In the 14th step, if the curved welding section is not a section, it is judged to be flat and a 16th step of traveling on the X-axis at a set welding speed;
A 17th step of calculating a second height deviation amount based on the set height value of the first contact-type displacement sensor and the second height value of the corrugated plate detected by the first contact-type displacement sensor while driving; and
An 18th step of moving the Y-axis position by the second height deviation amount and completing the curved surface tracking algorithm. A welding method using an automatic welding device comprising a. According to clause 9,
The 15th step of calculating and outputting the speed values of each of the Y-axis, X-axis, and R-axis in the case of the curved surface welding section,
Step 15-1 of calculating a third height deviation amount based on the set height value of the first contact-type displacement sensor and the third height value of the corrugated plate detected by the first contact-type displacement sensor while driving;
Step 15-2 of calculating and outputting a speed value of the welding header/torch height axis (Y-axis) driving unit;
Step 15-3 of measuring the rotation angle of the rotation axis (R-axis) using the rotary drive motor encoder value of the welding header/torch rotation axis (R-axis) drive unit;
Step 15-4 of calculating and outputting the speed value of the traveling axis (X-axis) driving unit;
15-5 for calculating a fourth height deviation amount based on the third height value of the first contact-type displacement sensor and the height value of the second contact-type displacement sensor disposed ahead of the first contact-type displacement sensor. step;
Step 15-6 of calculating and outputting a speed value of the welding header/torch rotation axis (R axis) driving unit;
The rotation link structure and the horizontal/vertical adjustment unit are operated by the rotation drive motor of the welding header/torch rotation axis (R axis) drive unit so that the welding torch can maintain a horizontal and vertical state with respect to a flat or curved surface without changing the welding point. Step 15-7; and
A welding method using an automatic welding device comprising a step 15-8 of performing a welding operation while the welding torch rotated by the welding header is maintained perpendicular to the welding surface. According to clause 9,
In the 15th step or the 18th step, a 19th step of initializing the position of the weaving shaft driver and storing an initial value of the laser displacement sensor;
A 20th step of scanning the weaving axis (W axis) with the laser displacement sensor by operating the weaving axis driver to detect the step difference;
Step 21 of determining whether the second displacement difference value obtained by subtracting the second previous displacement value from the second current displacement value is greater than the detected step difference multiplied by 0.7;
In the 21st step, if the second displacement difference value is large, a 22nd step of calculating a second position deviation amount based on the second current position value of the W axis obtained through step detection and the set position value of the weld line;
A 23rd step of determining whether the second displacement difference value obtained by subtracting the second previous displacement value from the second current displacement value is greater than an allowable deviation amount;
In the 23rd step, when the second displacement difference value is large, the Z-axis of the weld line is aligned by adjusting the position of the weld line tracking axis drive unit (Z-axis position adjustment) using the second position deviation amount, and running the weld line tracking algorithm. Step 24 to complete; and
A welding method using an automatic welding device comprising a 25th step of checking whether there is a stop command for the welding operation, returning to the 14th step if it is not a stop command, and ending the welding operation if it is a stop command. According to clause 11,
In the 21st step, if the second displacement difference value is not large, a 26th step of recognizing and counting as a weld bead; and
It is determined whether the number of counts recognized as a weld bead exceeds the predetermined number of times. If it does not exceed the predetermined number of times, it is judged to be a weld bead and returns to step 14. If the number exceeds the predetermined number of times, it is recognized as the end point of the weld and stops. A welding method using an automatic welding device including a 27th step of completing welding. According to clause 11,
In the 23rd step, if the second displacement difference value is not large, a 28th step of counting an error in excess of the allowable deviation amount; and
It is determined whether the error counting number of the allowable deviation exceeds the predetermined number of times. If it does not exceed the predetermined number of times, it is judged as noise and returns to the 14th step. If it exceeds the predetermined number of times, the number is A welding method using an automatic welding device comprising a 29th step of terminating welding in anticipation of installation errors in the fixed running rail or unevenness of the weld line.

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