WO2021248646A1 - 一种用于石油钻井设备钻头火焰喷焊硬面工艺的自动化工作站及其工作方法 - Google Patents

一种用于石油钻井设备钻头火焰喷焊硬面工艺的自动化工作站及其工作方法 Download PDF

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Publication number
WO2021248646A1
WO2021248646A1 PCT/CN2020/104622 CN2020104622W WO2021248646A1 WO 2021248646 A1 WO2021248646 A1 WO 2021248646A1 CN 2020104622 W CN2020104622 W CN 2020104622W WO 2021248646 A1 WO2021248646 A1 WO 2021248646A1
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WO
WIPO (PCT)
Prior art keywords
welding
unit
block
welding torch
robot
Prior art date
Application number
PCT/CN2020/104622
Other languages
English (en)
French (fr)
Inventor
孙雪雁
张弛
程远
徐楠华
孙志成
张考
王小满
顾江
孙桂圆
Original Assignee
南京英尼格玛工业自动化技术有限公司
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Filing date
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Application filed by 南京英尼格玛工业自动化技术有限公司 filed Critical 南京英尼格玛工业自动化技术有限公司
Publication of WO2021248646A1 publication Critical patent/WO2021248646A1/zh

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K3/00—Tools, devices, or special appurtenances for soldering, e.g. brazing, or unsoldering, not specially adapted for particular methods
    • B23K3/04—Heating appliances
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K3/00—Tools, devices, or special appurtenances for soldering, e.g. brazing, or unsoldering, not specially adapted for particular methods
    • B23K3/04—Heating appliances
    • B23K3/043—Flame-heated appliances
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K3/00—Tools, devices, or special appurtenances for soldering, e.g. brazing, or unsoldering, not specially adapted for particular methods
    • B23K3/06—Solder feeding devices; Solder melting pans
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K3/00—Tools, devices, or special appurtenances for soldering, e.g. brazing, or unsoldering, not specially adapted for particular methods
    • B23K3/06—Solder feeding devices; Solder melting pans
    • B23K3/0607—Solder feeding devices

Definitions

  • the invention relates to an automated workstation used for the flame spray welding hard surface process of a petroleum drilling equipment drill bit, in particular to an automated workstation used for the flame spray welding hard surface process of a petroleum drilling equipment drill bit and a working method thereof.
  • An automated workstation used for the flame spray welding hard surface process of a drill bit of an oil drilling equipment and a working method thereof are used to solve the above-mentioned problems existing in the prior art.
  • An automated workstation used for the flame spray welding hard surface process of oil drilling equipment drill bits including;
  • a welding unit a control unit connected with the welding unit, a detection auxiliary unit connected with the control unit, a safety protection unit arranged in the circumferential direction of the welding unit, and the control unit is arranged at the safety
  • the outer side of the protection unit is a pipeline unit that is laid on the inner side of the safety protection unit and connected to the control unit.
  • the welding unit includes a type A positioner for random displacement arranged inside the safety protection unit, and a type A positioner arranged on the type A positioner for clamping a workpiece
  • the welding fixture assembly is fixedly installed on the base for carrying the robot on the right side of the A-type positioner, the robot fixedly installed on the robot base, and the quick change unit arranged on the sixth axis of the robot, A welding torch unit arranged on the right side of the robot, an ignition unit for welding torch ignition arranged in the first direction of the welding torch unit, and a gun cleaning unit arranged in the first direction of the ignition unit for cleaning residual powder of the welding gun , A powder feeder connected with the welding torch unit through a pipeline to provide powder for the welding torch, and a water cooler connected with the welding fixture assembly through a pipeline to cool the welding fixture assembly ;
  • the welding torch unit includes a quick-change bracket, a first welding torch unit and a second welding torch unit arranged on the bracket, and a height that is arranged on the bracket and located in the middle of the first welding torch unit and the second welding torch unit Detection unit.
  • the quick-change unit is in the form of one-to-three, including one quick-change male head and at least 3 quick-change female heads, wherein the quick-change male head is installed on the sixth axis of the robot At the end position, 3 quick-change female heads are respectively installed on the first welding torch unit, the second welding torch unit and the height detection unit.
  • control unit includes a master control machine, a robot control cabinet connected with the robot to control anti-robot actions, and a touch controller for automated control of the workstation connected in communication with the master control cabinet. Display screen.
  • the detection auxiliary unit includes an image detection unit, a height detection unit provided on the quick-change bracket, and an auxiliary heating unit provided in the first direction of the image detection unit;
  • the image detection unit includes an image detection bracket set at a preset position, an image detection instrument screwed on the image detection bracket, and a protective cover fixedly installed on the image detection bracket for protecting the image detection instrument.
  • the detection auxiliary unit further includes a temperature detection unit arranged in a symmetrical direction of the image detection unit;
  • the temperature detection unit includes an L-shaped temperature detection bracket, a cross module arranged on the temperature detection bracket that can move in two directions, and a temperature detection bracket arranged on the cross module. Temperature detector
  • the auxiliary heating unit includes a sliding rail assembly, an auxiliary heating bracket arranged on the sliding rail assembly, a lifting cylinder fixedly installed on the auxiliary heating bracket for driving the heating gun to move up and down, and is arranged on the lifting
  • the heating gun above the cylinder is provided with an igniter used to ignite the heating gun on the side of the heating gun, and a protective assembly fixedly installed on the slide rail assembly.
  • the welding fixture assembly includes a turntable, a first fixture, a second fixture, and a third fixture that are arranged on the turntable and are used to clamp the workpiece, and the welding fixture assembly is arranged on the turntable for Two-axis servo displacement device for switching the welding posture of the workpiece;
  • the first clamp, the second clamp, and the third clamp have the same structure and are evenly distributed on the turntable at 120° between the three;
  • the first clamp includes a blocking and pressing mechanism provided on the turntable, a positioning mechanism fixedly installed on the turntable, and a support assembly screwed on the turntable;
  • the shielding and pressing mechanism includes two linear bearing fixing blocks fixedly mounted on the turntable, a guide shaft mounted on the linear bearing fixing block with interference fit, and a first fixedly mounted on the end of the guide shaft.
  • a guide fixing block, a cylinder mounting plate that is fixedly mounted on the turntable and on the same horizontal line as the guide shaft, and a strong clamping cylinder mounted on the cylinder mounting plate is fixed to the strong clamping cylinder
  • the upper clamping arm is a support block fixedly installed on the turntable and located on the side of the cylinder mounting plate, a limit block fixedly installed on the support block, and a fixed installation block on the limit block.
  • the connecting block, the side stopper fixedly installed on the connecting block, the shielding baffle fixedly installed on the side stopper, the shielding block fixedly installed on the first guide fixing block, and one side is fixedly installed on the
  • the second guide fixing block on the upper side of the blocking block and the other side connected with the guide shaft is fixedly installed on the turntable and the telescopic cylinder whose telescopic end is connected with the second guide block is arranged on the Cylinder protective cover on the connecting block;
  • the shielding and pressing mechanism is also provided with a water-cooling system on the upper surface, and the water-cooling system includes a first water-cooling pipe with one end connected to the shielding block and the other end connected to the side stopper. A second water-cooling tube connected to the connecting block at the other end, a third water-cooling tube connected to the side block at one end and connected to the connecting block at the other end, and A water cooler in which the first water-cooling pipe and the third water-cooling pipe are connected together.
  • the protection unit includes a welding protection room, safety gratings arranged at the upper and lower sides of the welding protection room are arranged at the entrance and exit of the welding protection room, and the inspection door unit is arranged in the welding protection room.
  • a camera monitoring unit on the protective room for remotely monitoring the internal working conditions of the workstation, a three-color lamp electrically connected to the camera monitoring unit, and a three-color lamp arranged inside the welding protective room for detecting dangerous gases inside the workstation Concentration sensor unit.
  • the piping unit includes a hard pipe unit laid inside the welding protection room and surrounding the installation frame inside the workstation, and a line used to connect electrical circuits arranged inside the welding protection room. groove.
  • Step 1 Place the correspondences of the three different workpieces in the first fixture, the second fixture and the third fixture;
  • the safety grating starts to work.
  • the safety grating is installed at the upper and lower parts of the welding protection room.
  • the workstation starts welding work.
  • the maintenance door unit includes the maintenance door and the safety door lock. It is used for workers to enter the workstation for debugging and maintenance; a safety door lock is installed on the inspection door, and the workstation can only work when the safety door lock is closed to ensure the safety of workers.
  • the camera monitoring unit is used to remotely monitor the internal working conditions of the workstation.
  • Step 3 When the safety grating starts, and the external robot places the workpiece on the welding jig, the image detection unit judges the position of the workpiece by taking pictures and image processing. If it is judged that the workpiece is already in place, the welding jig starts to clamp operate;
  • Step 4 the welding fixture clamps the workpiece, the bottom of the welding fixture is fixedly connected with the flange of the A-type positioner, and then the A-type positioner completes the movement in two directions to the spray welding position of the workpiece;
  • Step 5 When the A-type positioner drives the workpiece to the preset position, the robot carries the quick-change male head to match the first welding torch unit or the second welding torch unit according to the needs of different stages of the spray welding process, and then the robot carries it.
  • the first welding torch unit or the second welding torch unit ignites to the ignition unit, and then moves to the welding work area;
  • Step 6 After moving to the welding work area, the powder feeder starts to feed powder and the spray welding process starts;
  • Step 7 After the welding is completed, the robot takes the welding torch to the gun cleaning unit to clean the residual powder of the gun head, and then places the welding torch on the quick-change bracket, the quick-change male and female heads are disconnected, the spray welding process is completed, and the water cooler and welding The fixture is connected, and the water cooler is connected with the welding torch unit.
  • the water cooler works at the same time to reduce the temperature of the welding fixture and the welding torch to achieve the purpose of protection;
  • Step 8 The welding is completed, the welding torch unit returns to the initial position, and the welding is finished.
  • the invention discloses an automated workstation for the flame spray welding hard surface process of oil drilling equipment drill bits.
  • This workstation can realize the fully automated production of the flame spray welding hard surface process of oil drilling equipment drill bits. Compared with manual spray welding, it is not only greatly Improved work efficiency, stable welding gun posture and moving speed; at the same time, the detection auxiliary unit can ensure the spray welding process conditions, especially the spray welding layer height, and the workpiece temperature is stable and controllable, so that the spray welding quality and consistency of the workpiece can be effectively guaranteed .
  • Figure 1 is a schematic diagram of the various components of the workstation
  • FIG. 2 is a schematic diagram of the welding unit of the present invention.
  • Figure 3 is a top view of the workstation and a schematic diagram of the control unit
  • Figure 4 is a schematic diagram of the detection auxiliary unit of the present invention.
  • FIG. 5 is a schematic diagram of the structure of the welding fixture assembly of the present invention.
  • Figure 6 is a structural schematic diagram 1 of the shielding and pressing mechanism of the present invention.
  • FIG. 7 is a schematic diagram 2 of the structure of the blocking and pressing mechanism of the present invention.
  • Figure 8 is a schematic structural diagram 3 of the blocking and pressing mechanism of the present invention.
  • Fig. 9 is a structural schematic diagram 4 of the blocking and pressing mechanism of the present invention.
  • Figure 10 is a schematic diagram of the structure of the side stopper of the present invention.
  • Figure 11 is a schematic diagram of the structure of the blocking block of the present invention.
  • Figure 12 is a schematic diagram of the structure of the safety protection unit of the present invention.
  • Figure 13 is a schematic diagram of the structure of the quick change unit of the present invention.
  • Fig. 14 is a schematic diagram of the structure of the temperature detection unit of the present invention.
  • the reference signs are: turntable 1, first clamp 2, second clamp 3, third clamp 4, two-axis servo displacement device 5, protective cover 501, solenoid valve group 502, manifold block 503, pagoda joint 504, shield Clamping mechanism 21, linear bearing fixed block 2101, guide shaft 2102, first guide fixed block 2103, cylinder mounting plate 2104, strong clamping cylinder 2105, clamping arm 2106, support block 2107, limit block 2108, connecting block 2109 , Side block 2110, shielding baffle 2111, shielding block 2112, second guide fixing block 2113, telescopic cylinder 2114, cylinder guard 2115, first water-cooling pipe 2117, second water-cooling pipe 2118, third water-cooling pipe 2119, water cooler 2120, water cooling hole 2121, positioning mechanism 22, first positioning block 2201, second positioning block 2202, positioning pin 2203, diamond pin 2204, support assembly 23, base 2301, spacer block 2302, welding unit 60, control unit 70, total Control machine 70-1, robot control cabinet 70-2, touch screen 70-3
  • the prior art process uses high-temperature spray welding to integrate the diamond and the drill bit.
  • the welding torch posture, workpiece temperature and material feeding amount need to be strictly controlled.
  • manual welding takes a long time, spray welding height, welding gun attitude, and workpiece temperature are difficult to control, which makes it difficult to guarantee product quality, consistency and pass rate.
  • the specific scheme of the automated workstation for the hard surface process is as follows.
  • an automated workstation for the flame spray welding hard surface process of oil drilling equipment drill bits includes a turntable 1, a first fixture 2, a second fixture 3, a third fixture 4, a two-axis servo displacement device 5, Protective cover 501, solenoid valve group 502, manifold block 503, pagoda joint 504, blocking and pressing mechanism 21, linear bearing fixing block 2101, guide shaft 2102, first guide fixing block 2103, cylinder mounting plate 2104, powerful clamping cylinder 2105, clamping arm 2106, support block 2107, limit block 2108, connecting block 2109, side stop block 2110, shielding baffle 2111, shielding block 2112, second guide fixing block 2113, telescopic cylinder 2114, cylinder guard 2115, first A water cooling pipe 2117, a second water cooling pipe 2118, a third water cooling pipe 2119, a water chiller 2120, a water cooling hole 2121, a positioning mechanism 22, a first positioning block 2201, a second positioning block 2202, a positioning pin 2203,
  • the welding unit 60 as shown in FIG. 2, the control unit 70 and the welding unit 60 are connected together, the detection auxiliary unit 80 and the control unit 70 are connected together, and the safety protection unit 90 is arranged at The circumference of the welding unit 60 and the control unit 70 are arranged on the outside of the safety protection unit 90, and the pipeline unit 100 is laid on the inside of the safety protection unit 90 and is connected to the control unit 70.
  • the AA type positioner 701 is arranged inside the safety protection unit 90, the welding jig assembly 702 is arranged on the AA type positioner 701, and the welding jig assembly 702 is used for To clamp the workpiece, the base 703 is fixedly installed on the right side of the AA-type positioner 701, the robot 704 is fixedly installed on the base 703 of the robot 704, and the quick change unit 705 is arranged on the robot 704 above the sixth axis, the welding torch unit 706 is arranged on the right side of the robot 704, the ignition unit 707 is arranged in the first direction of the welding torch unit 706, and the gun cleaning unit 708 is arranged on the In the first direction of the ignition unit 707, the powder feeder 709 and the welding torch unit 706 are connected together by a pipeline, and the water cooler is connected with the welding fixture assembly 702 by a pipeline.
  • the quick change The bracket 705-1 is fixedly installed at a designated position, the first welding torch unit 705-2 and the second welding torch unit 705-3 are arranged on the quick-change bracket 705-1, and the height detection unit 80-2 is arranged On the upper side of the bracket, located in the middle position of the first welding torch unit 705-2 and the second welding torch unit 705-3, wherein the turntable 1 is set at a preset position, and the first clamp 2 is fixedly installed at On the top of the turntable 1, the second clamp 3 is fixedly installed on the top of the turntable 1 and adjacent to the first clamp 2, and the third clamp 4 is fixedly installed on the top of the turntable 1, And located between the first clamp 2 and the second clamp 3, the first clamp 2, the second clamp 3 and the third clamp 4 have the same structure and are 120° evenly distributed on the turntable 1 Above, by setting up three stations, and the three stations are evenly distributed on the circular turntable 1, it can meet the welding requirements of three different types of workpieces.
  • a visual inspection function is set up to identify the type of the workpiece. Switch the welding station, and you can judge whether the positioning status of the workpiece is normal and whether it can be welded.
  • the model of the workpiece can be identified through the visual camera detection, and then the corresponding station can be switched to. It can meet the welding requirements of three kinds of workpieces with different shapes. Compared with manual welding, the welding efficiency and beat are greatly improved.
  • the turntable 1 is arranged in a circular shape. At the same time, in order to reduce the weight of the turntable 1, the turntable 1 is further designed to resemble a windmill shape, and excess materials are removed.
  • the shielding and pressing mechanism 21 is arranged on the turntable 1, the positioning mechanism 22 is arranged on the turntable 1 and at the bottom of the shielding and pressing mechanism 21, and the support assembly 23 is arranged on the top of the turntable 1.
  • the support assembly 23 is arranged on the top of the turntable 1.
  • the shielding and pressing mechanism 21 is provided on the top of each fixture, only the area of the workpiece that needs spray welding is exposed, and the area that does not need to be spray welded is shielded to ensure the welding quality of the workpiece.
  • the linear bearing is fixed.
  • the block 2101 is fixedly installed on the upper surface of the turntable 1, the guide shaft 2102 is installed on the linear bearing fixed block 2101 by interference fit, and the first guide fixed block 2103 is fixedly installed on the end of the guide shaft 2102.
  • the cylinder mounting plate 2104 is fixedly installed on the top of the turntable 1 and on the same horizontal line as the guide shaft 2102
  • the strong clamping cylinder 2105 is fixedly mounted on the cylinder mounting plate 2104
  • the clamping arm 2106 is arranged on the strong clamping cylinder 2105
  • the support block 2107 is fixedly installed on the turntable 1 and located on the side of the cylinder mounting plate 2104
  • the limit block 2108 is fixed Installed on the supporting block 2107
  • the connecting block 2109 is fixedly installed on the limiting block 2108
  • the side stop 2110 is fixedly installed on the connecting block 2109
  • the shielding plate 2111 is fixed Installed on the top of the side block 2110
  • the shielding block 2112 is fixedly installed on the top of the first
  • a water cooling system is also provided on the shield pressing mechanism 21.
  • One end of the first water cooling pipe 2117 is connected to the shield block 2112, and the other end is connected to the side stop block 2110.
  • one end of the second water-cooling pipe 2118 is connected to the blocking block 2112, the other end is connected to the connecting block 2109, and one end of the third water-cooling pipe 2119 is connected to the side block 2110.
  • the other end is connected with the connecting block 2109.
  • the water cooler 2120 is connected with the first water-cooling pipe 2117 and the third water-cooling pipe 2119.
  • the blocking block 2112 is provided with a water-cooling hole 2121, the water-cooling hole 2121 and the first water-cooling tube 2117 and the second water-cooling tube 2118
  • the water in the water cooler 2120 can flow into the shield block 2112 through the water cooling holes 2121 in the shield block 2112, in the form of a cyclic loop, by allowing the water in the water cooler 2120 to flow into the shield block 2112
  • a circular loop is formed, which can absorb the heat of the welding torch flame through the thermal barrier coating, and effectively protect the blocking block 2112.
  • the first positioning block 2201 and the second positioning block 2202 are respectively fixed on the top of the turntable 1, and the first positioning block 2201 and the second positioning block 2202 are on the same horizontal line, and the first positioning pin 2203 has an interference fit Installed on the top of the first positioning block 2201, the diamond-shaped pin 2204 is installed on the second positioning block 2202 with interference fit, in order to facilitate the clamping of the workpiece, one end of the diamond-shaped pin 2204 is rounded, When the workpiece is clamped and positioned, it first passes through the rounded end of the diamond pin 2204. The rounded corner provides a guide for positioning and assembly, and then enters the diamond part through the rounded end to accurately position the workpiece.
  • the base 2301 is fixedly installed on the top of the turntable 1, the support plates are respectively screwed on the base 2301, the spacers 2302 are screwed on both ends of the support plate, and are located on the shielding and pressing
  • the inner side of the mechanism 21 is respectively screwed to the support plate on the base 2301, and the two pads 2302 at both ends of the support plate are screwed.
  • the length of the base 2301 is provided with a water cooling hole 2121, and the two bases The water cooling holes 2121 of 2301 are connected together by a fourth water cooling pipe.
  • the protective cover 501 is fixedly installed at the bottom of the turntable 1
  • the solenoid valve group 502 is fixedly installed at the bottom of the turntable 1 inside the protective cover 501
  • the manifold block 503 is arranged on the On the top of the turntable 1
  • the pagoda joint 504 is screwed on the manifold block 503
  • at least four pagoda joints 504 on each manifold block 503 are used for the first water-cooling pipe 2117 and the second water-cooling
  • the tube 2118, the third water-cooling tube 2119 and the fourth water-cooling tube are made by bending copper tubes.
  • the first water-cooling tube 2117, the second water-cooling tube 2118, the third water-cooling tube 2119 and the fourth water-cooling tube are connected to the manifold block 503, respectively.
  • the connected pagoda joints 504 are connected together, and the water is passed through the first water-cooling pipe 2117, the second water-cooling pipe 2118, and the third water-cooling pipe 2119 through the water-cooling machine 2120 to pass water through the water-cooling pipes in the shielding baffle 2111 and the side block 2110
  • the upper surface of the first clamp 2, the second clamp 3 and the third clamp 4 are respectively provided with a blocking and pressing mechanism 21, a positioning mechanism 22 and a supporting assembly 23.
  • the blocking and pressing mechanism 21 is clamped by two powerful cylinders 2105. Complete a 90° rotation and compaction action to press the workpiece to prevent the workpiece from moving. After compaction, the telescopic cylinder 2114 extends forward to drive the 6 push and shield mechanism to move forward and push the front end of the workpiece.
  • the mechanism realizes the functions of positioning, supporting, pressing and shielding, ensuring that the spray welding material is only sprayed on the area that needs to be welded during spray welding.
  • the specific working principle of the welding fixture assembly put the corresponding three different workpieces in the first fixture 2, the second fixture 3 and the third fixture 4.
  • a powerful clamping cylinder 2105 completes a 90° rotation and compaction action, pressing the workpiece to prevent the workpiece from moving.
  • the telescopic cylinder 2114 starts to work, and the telescopic cylinder 2114 extends forward to drive the shielding baffle. 2111 moves forward to push the front end of the workpiece tightly.
  • the equipment starts spray welding, and then the water cooling system starts to work, so that the water in the water cooler 2120 can flow into the blocking block 2112, forming a cycle
  • the circuit can absorb the heat of the welding torch flame through the thermal barrier coating to effectively protect the blocking block 2112.
  • the welding fixture assembly 702 is used to clamp the workpiece, and its bottom is fixedly connected with the flange of the AA-type positioner 701, and can move in two directions with the positioner's mechanical arm to meet the requirements of the spray welding position and posture of the workpiece.
  • the quick-change unit 705 is a one-to-three form, including one quick-change male 705-5 and three quick-change female 705-6, of which the quick-change male 705-5 is installed on the sixth axis of the robot 704, 3
  • the two female heads are respectively installed in the first welding torch unit 705-2, the second welding torch unit 705-3 and the height detecting unit 80-2.
  • the first welding torch unit 705-2 and the second welding torch unit 705-3 respectively include a welding torch body, a connecting bracket and a quick-change female head 705-6, which are fixedly connected.
  • the robot 704 is installed on the human base 703, and its sixth axis flange is installed with a quick-change male head 705-5. After the spray welding program is started, the robot 704 will carry the quick-change male head 705-5 and the first welding torch unit 705-2 quick-change female head 705-6 or the second welding torch unit 705-3 quick-change female head according to the needs of different stages of the spray welding process.
  • the robot 704 After the 705-6 is matched and connected, the robot 704 carries the welding torch to the ignition gun unit to ignite, and then moves to the welding work area, the powder feeder starts to feed powder, and the spray welding process starts; after the welding is completed, the robot 704 carries the welding torch to the gun cleaning unit 708 for cleaning After leaving the powder on the gun head, place the welding torch on the quick-change bracket 705-1), the quick-change male 705-5 female head is disconnected, and the spray welding process is completed. Further, the water cooler is in communication with the welding jig assembly 702, and the water cooler is in communication with the second welding torch unit 705-3. During the period from the beginning to the end of the welding procedure, the water cooler works to reduce the temperature of the welding jig and the welding torch for protection purposes.
  • the master control machine 70-1 is connected to the welding unit 60
  • the robot 704 control cabinet 70-2 is connected to the robot 704
  • the touch display screen 70-3 is communicatively connected to the master control cabinet. Together for automatic control of workstations.
  • the image detection unit 80-1 is arranged at a preset position
  • the height detection unit 80-2 is arranged on the quick-change bracket 705-1
  • the auxiliary heating unit 80-3 is arranged on the image detection unit 80 -1 in the first direction
  • the image detection bracket 80-11 is set at a preset position
  • the image detector 80-12 is screwed on the image detection bracket 80-11
  • the protective cover 80- 13 is fixedly installed on the image detection bracket 80-11.
  • the temperature detection unit 80-4 is arranged in a symmetrical direction of the image detection unit 80-1, and the temperature detection bracket 80 -5 is designed in an L shape, the cross module 80-6 is arranged on the temperature detection bracket 80-5 and can move in two directions, and the temperature detector 80-16 is arranged on the cross module 80 -6 is used to detect temperature, the slide rail assembly 80-7 is set at a preset position, the auxiliary heat support 80-8 is provided on the slide rail assembly 80-7, and the lifting cylinder 80 -9 is fixedly installed on the auxiliary heating bracket 80-8 to facilitate the up and down movement of the heating gun 80-10, and drive the heating gun 80-10 to the corresponding position.
  • the igniter 80-14 is located in the heating gun
  • the side surface of the 80-10 is convenient for igniting the heating gun 80-10.
  • the protective assembly 80-15 is fixedly installed on the slide rail assembly 80-7.
  • the protective assembly 80-15 includes a first protective member and For the second protective part, the two protective parts are spliced together to form an internal hollow space.
  • the sliding rail assembly 80-7 is inside the hollow space.
  • the protective assembly 80-15 secures the sliding components together, which prevents dust from working. The materials enter the slide rail group together, affecting the efficiency of sliding.
  • the detection auxiliary unit 80 is shown in FIG. 4, the image detection unit 80-1 includes an image detection bracket 80-11, an image detector 80-12, and a protective cover 80-13, which are fixedly connected and used to position the workpiece. Perform identification and judgment; when the external robot 704 places the workpiece on the welding fixture, the image detection unit 80-1 judges the position of the workpiece by taking pictures and image processing. If it is judged that the workpiece has been placed in place, the welding fixture starts to perform the clamping operation .
  • the height detection unit 80-2 includes a height detector, a connecting bracket and a female head of the quick-change unit 705, all of which are fixedly connected.
  • the temperature detection unit 80-4 includes a temperature detector 80-16, a cross module 80-6 and a temperature detection bracket 80-5: the detector is connected to the cross module 80-6 and can move in two directions, the cross module The 80-6 is fixedly connected to the temperature detection bracket 80-5, which can perform multi-directional real-time temperature monitoring of the workpiece.
  • the auxiliary heating unit 80-3 includes an igniter 80-14, a heating gun 80-10, a jacking cylinder, a slide rail assembly 80-7, a bracket and a protection assembly 80-15: the heating gun 80-10 is connected to the water cooler, The igniter 80-14 and the heating gun 80-10 are connected to the movable end of the jacking cylinder through a bracket, and can move up and down; the jacking cylinder is installed on the slide rail and can move horizontally and left and right as a whole.
  • the igniter 80-14 ignites the heating gun 80-10, and the water cooler is turned on to protect the heating gun 80-10; the jacking cylinder drives the igniter 80-14 and the heating gun 80- 10 Ascend to a suitable position, the slider assembly starts to move horizontally to the left and right to evenly replenish heat to the workpiece.
  • the welding protection room is arranged in the circumferential direction of the workstation, the safety gratings are arranged at the upper and lower sides of the welding protection room, and the inspection door unit is arranged at the entrance and exit of the welding protection room.
  • the camera monitoring unit is set on the welding protection room for remote monitoring of the internal conditions of the workstation, the three-color light is electrically connected to the camera monitoring unit, and the sensor unit is set in the welding protection room. Internally, it is used to detect the concentration of dangerous gases inside the workstation.
  • the safety protection unit 90 is used to ensure the safety of the workstation. Further, the safety grating is installed at the upper and lower parts of the welding protection room.
  • the inspection door unit includes an inspection door and a safety door lock for workers to enter the workstation for debugging and maintenance; a safety door lock is installed on the inspection door, and the workstation can work only when the safety door lock is closed to ensure worker safety.
  • the camera monitoring unit is used to remotely monitor the internal working conditions of the workstation.
  • the sensor unit is used to detect the concentration of dangerous gas in the workstation. When the concentration exceeds the standard, the workstation will alarm and power off, and the three-color light will alarm.
  • the pipe unit 100 includes a hard pipe unit, a hose unit, a wire duct, and pipe accessories.
  • the pipeline unit 100 is used to provide required gas, waterway, and circuit for each system.
  • the trunking is used for the connection of electrical circuits.
  • Piping accessories include joints, pressure regulators, balance cranes, etc.
  • the rigid pipe unit is installed with a frame around the inside of the workstation, and is connected to each unit through a joint adapter hose at a position adjacent to each functional unit.
  • the hoses connected to the first welding torch unit 705-2, the second welding torch unit 705-3 and the height detection unit 80-2 placed on the quick-change bracket 705-1 need to be connected to the hard pipe interface through a balance crane to ensure The cable has enough space for movement and does not hinder the movement of the robot 704.
  • a working method of an automated workstation for the flame spray welding hard surface process of a drill bit of an oil drilling equipment includes the following steps:
  • Step 1 Place the correspondences of the three different workpieces in the first fixture, the second fixture and the third fixture;
  • the safety grating starts to work.
  • the safety grating is installed at the upper and lower parts of the welding protection room.
  • the workstation starts the welding work.
  • the maintenance door unit includes the maintenance door and the safety door. Locks are used for workers to enter the workstation for debugging and maintenance; a safety door lock is installed on the inspection door, and the workstation can only work when the safety door lock is closed to ensure worker safety.
  • the camera monitoring unit is used to remotely monitor the internal working conditions of the workstation;
  • Step 3 When the safety grating is activated and the external robot 704 places the workpiece on the welding jig, the image detection unit 80-1 judges the position of the workpiece by taking pictures and image processing. If it is judged that the workpiece has been put in place, then the welding jig Start the clamping operation;
  • Step 4 the welding fixture clamps the workpiece, the bottom of the welding fixture is fixedly connected with the flange of the AA type positioner 701, and then the AA type positioner 701 completes the movement in two directions to the spray welding position of the workpiece;
  • Step 5 When the AA type positioner 701 drives the workpiece to the preset position, the robot 704 carries the quick change male head 705-5 and the first welding torch unit 705-2 or the second according to the needs of different stages of the spray welding process.
  • the welding torch unit 705-3 is connected, and then the robot 704 carries the first welding torch unit 705-2 or the second welding torch unit 705-3 to the ignition unit 707 to ignite, and then moves to the welding work area;
  • Step 6 After moving to the welding work area, the powder feeder starts to feed powder and the spray welding process starts;
  • Step 7 After the welding is completed, the robot 704 carries the welding torch to the gun cleaning unit 708 to clean the residual powder of the gun head, and then places the welding torch on the quick-change bracket 705-1, the quick-change male connector 705-5 female connector is disconnected, and the spray welder
  • the sequence is completed, at the same time the water cooler is connected with the welding fixture, and the water cooler is connected with the welding torch unit 706.
  • the water cooler works at the same time to reduce the temperature of the welding fixture and the welding torch to achieve the purpose of protection;
  • Step 8 The welding is completed, the welding torch unit 706 returns to the initial position, and the welding ends.

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Abstract

用于石油钻井设备钻头火焰喷焊硬面工艺的自动化工作站及其工作方法，该工作站可实现石油钻井设备钻头火焰喷焊硬面工艺的全自动化生产，焊枪姿态、运动速度稳定；同时检测辅助单元（80）能够保障喷焊工艺条件尤其是喷焊层高度、工件温度稳定可控，从而使工件的喷焊质量、一致性能够得到有效保障。

Description

一种用于石油钻井设备钻头火焰喷焊硬面工艺的自动化工作站及其工作方法 技术领域
本发明涉及一种用于石油钻井设备钻头火焰喷焊硬面工艺的自动化工作站，具体是一种用于石油钻井设备钻头火焰喷焊硬面工艺的自动化工作站及其工作方法。
 背景技术
随着科学技术发展，新工艺、新技术不断涌现。在石油钻井设备研发改进过程中，一种自动化火焰喷焊硬面工艺被应用到钻头的加工设计中。该工艺采用高温喷焊的方法将金刚石与钻头融为一体，在焊接不同阶段的时候，焊枪的焊枪姿态、工件温度及材料送粉量的需要严格的控制。而人工焊接耗时长、喷焊高度、焊枪姿态、工件温度都难以控制，造成产品的质量、一致性以及合格率难以保障。
 技术问题
一种用于石油钻井设备钻头火焰喷焊硬面工艺的自动化工作站及其工作方法，以解决现有技术存在的上述问题。
 技术解决方案
一种用于石油钻井设备钻头火焰喷焊硬面工艺的自动化工作站，包括；
焊接单元，与所述焊接单元连接在一起的控制单元，与所述控制单元连接在一起的检测辅助单元，设置在所述焊接单元周向的安全防护单元，所述控制单元设置在所述安全防护单元的外侧，铺设在所述安全防护单元内侧的、并且与所述控制单元连接在一起的管路单元。
在进一步实施例中，所述焊接单元，包括设在所述安全防护单元内部的用于随机变位的A型变位机，设置在所述A型变位机上面的用于夹持工件的焊接夹具组件，固定安装在所述A型变位机右侧的用于承载机器人的底座，固定安装在所述机器人底座上面的机器人，设置在所述机器人的第六轴上面的快换单元，设置在所述机器人右侧的焊枪单元，设置在所述焊枪单元的第一方向处用于焊枪点火的点火单元，设置在所述点火单元第一方向的用于清理焊枪残留粉末的清枪单元，与所述焊枪单元通过管路连接在一起的用于为焊枪提供粉料的送粉机，通过管路与所述焊接夹具组件连接在一起的用于为所述焊接夹具组件降温的水冷机；
所述焊枪单元包括快换支架，设置在所述支架上面的第一焊枪单元和第二焊枪单元，设置在所述支架上面的、位于所述第一焊枪单元和第二焊枪单元中间位置的高度检测单元。
在进一步实施例中，所述快换单元为一拖三的形式，包括一个快换公头和至少3个快换母头，其中所述快换公头安装在所述机器人的第六轴的端部位置，3个快换母头分别安装在第一焊枪单元、第二焊枪单元和高度检测单元的上面。
在进一步实施例中，所述控制单元，包括总控机，与机器人连接在一起的控制防机器人动作的机器人控制柜，与所述总控柜通信连接在一起的用于工作站的自动化控制的触摸显示屏。
在进一步实施例中，所述检测辅助单元，包括图像检测单元，设置在快换支架上面的高度检测单元，设置在所述图像检测单元的第一方向处的辅热单元；
所述图像检测单元包括设置在预设位置的图像检测支架，螺接在所述图像检测支架上面的图像检测仪，固定安装在所述图像检测支架上面的用于防护图像检测仪的防护罩。
在进一步实施例中，所述检测辅助单元还包括设置在所述图像检测单元对称方向的温度检测单元；
所述温度检测单元，包括设计呈L型的温度检测支架，设置在所述温度检测支架上面的能够进行两个方向运动的十字模组，设置在所述十字模组上面的用于检测温度的温度检测仪；
所述辅热单元，包括滑轨组件，设置在所述滑轨组件上面的辅热支架，固定安装在所述辅热支架上面的用于带动加热枪上下动作的升降气缸，设置在所述升降气缸上面的加热枪，设中在所述加热枪侧面的用于为加热枪点火的点火器，以及固定安装在所述滑轨组件上面的防护组件。
在进一步实施例中，所述焊接夹具组件包括转台，设置在所述转台上面的用于将夹紧工件的第一夹具、第二夹具和第三夹具，以及设置在所述转台上面的用于切换工件焊接姿态的两轴伺服变位装置；
所述第一夹具、第二夹具和第三夹具结构相同并且三者之间呈120°均布在所述转台的上面；
所述第一夹具，包括设置在所述转台上面的遮挡压紧机构，固定安装在所述转台上面的定位机构，以及螺接在所述转台上面的支撑组件；
所述遮挡压紧机构包括固定安装在所述转台上面的两个直线轴承固定块，过盈配合安装在所述直线轴承固定块上面的导向轴，固定安装在所述导向轴端部的第一导向固定块，固定安装在所述转台上面的、和所述导向轴在同一水平线上面的气缸安装板，固定安装在所述气缸安装板上面的强力夹紧气缸，设置在所述强力夹紧气缸上面的夹紧臂，固定安装在所述转台上面的、并且位于所述气缸安装板侧面的支撑块，固定安装在所述支撑块上面的限位块，固定安装在所述限位块上面的连接块，固定安装在所述连接块上面的侧挡块，固定安装在所述侧挡块上面的遮挡板，固定安装在所述第一导向固定块上面的遮挡块，一面固定安装在所述遮挡块上面的、另一面与所述导向轴连接在一起的第二导向固定块，固定安装在所述转台上面的、并且伸缩端与第二导向块连接在一起的伸缩气缸，设置在所述连接块上面的气缸防护罩；
所述遮挡压紧机构的上面还设有水冷系统，所述水冷系统，包括一端与所述遮挡块连接在一起、另一端与侧挡块连接在一起的第一水冷管，一端与所述遮挡块连接在一起、另一端与所述连接块连接在一起的第二水冷管，一端与所述侧挡块连接在一起、另一端与所述连接块连接在一起的第三水冷管，以及与所述第一水冷管和第三水冷管连接在一起的水冷机。
在进一步实施例中，所述防护单元，包括焊接防护房，设置在所述焊接防护房上下两侧位置的安全光栅，设置在所述焊接防护房进出口处检修门单元，设置在所述焊接防护房上面的用于远程监控工作站内部工作情况的摄像监控单元，与所述摄像监控单元电性连接在一起的三色灯，以及设置在所述焊接防护房内部的用于检测工作站内部危险气体浓度的传感器单元。
在进一步实施例中，所述管路单元，包括铺设在焊接防护房内部的围绕在工作站内部安装构架上面的硬管单元，设置在所述焊接防护房内部的用于为电气线路的联通的线槽。
在进一步实施例中，包括如下步骤：
步骤1、将三种不同的工件的对应放在第一夹具、第二夹具和第三夹具中；
步骤2、然后安全光栅启动工作，安全光栅安装于焊接防护房上下件处，当安全光栅检测到外部机器人手臂已离开上下件区域，工作站方开始焊接工作，其中检修门单元包含检修门和安全门锁，用于工人进入工作站调试、维护；检修门上安装有安全门锁，只有当安全门锁闭合时，工作站才能进行工作，以保障工人安全，摄像监控单元用于远程监控工作站内部工作情况，
步骤3、当安全光栅启动时，同时外部机器人将工件放置于焊接夹具上后，图像检测单元通过拍照图像处理，对工件进行到位判断，如判断工件已经放置到位后，则焊接夹具开始进行夹持操作；
步骤4、然后焊接夹具夹持工件，焊接夹具的底部与A型变位机法兰固定连接在一起，然后A型变位机完成两个方向的运动至工件喷焊位置；
步骤5、当A型变位机带动工件至预设的位置时，机器人根据喷焊的工艺不同阶段的需要携着快换公头与第一焊枪单元或者第二焊枪单元配合连接，之后机器人携第一焊枪单元或者第二焊枪单元至点火单元点火，之后运动至焊接工作区;
步骤6、移动至焊接工作区之后，送粉器开始送粉，喷焊工序开始；
步骤7、焊接完成后，机器人携焊枪至清枪单元清理枪头残留粉末，之后将焊枪放置至快换支架上，快换公头母头断开连接，喷焊工序完成，同时水冷机与焊接夹具连通，水冷机与焊枪单元连通，当焊接程序开始到结束期间，水冷机同时工作，降低焊接夹具与焊枪温度以达到保护目的；
步骤8、焊接完成，焊枪单元回到初始位置，焊接结束。
 有益效果
本发明公开了一种用于石油钻井设备钻头火焰喷焊硬面工艺的自动化工作站，本工作站可实现油钻井设备钻头火焰喷焊硬面工艺的全自动化生产，相较于人工喷焊，不仅大大提高的工作效率，且焊枪姿态、运动速度稳定；同时检测辅助单元能够保障喷焊工艺条件尤其是喷焊层高度、工件温度稳定可控，从而使工件的喷焊质量、一致性能够得到有效保障。
 附图说明
图1为本工作站各组成单元示意图；
图2为本发明的焊接单元的示意图；
图3为本工作站俯视图及控制单元示意图；
图4为本发明检测辅助单元示意图；
图5为本发明焊接夹具组件的结构示意图；
图6为本发明遮挡压紧机构的结构示意图1；
图7为本发明挡压紧机构的结构示意图2；
图8为本发明挡压紧机构的结构示意图3；
图9为本发明挡压紧机构的结构示意图4；
图10为本发明侧挡块的结构示意图；
图11为本发明遮挡块的结构示意图；
图12为本发明安全防护单元的结构示意图；
图13为本发明快换单元的结构示意图；
图14为本发明温度检测单元的结构示意图。
附图标记为：转台1、第一夹具2、第二夹具3、第三夹具4、两轴伺服变位装置5、防护罩501、电磁阀组502、歧管块503、宝塔接头504、遮挡压紧机构21、直线轴承固定块2101、导向轴2102、第一导向固定块2103、气缸安装板2104、强力夹紧气缸2105、夹紧臂2106、支撑块2107、限位块2108、连接块2109、侧挡块2110、遮挡板2111、遮挡块2112、第二导向固定块2113、伸缩气缸2114、气缸防护罩2115、第一水冷管2117、第二水冷管2118、第三水冷管2119、水冷机2120、水冷孔2121、定位机构22、第一定位块2201、第二定位块2202、定位销2203、菱形销2204、支撑组件23、底座2301、垫块2302、焊接单元60、控制单元70、总控机70-1、机器人控制柜70-2、触摸显示屏70-3、检测辅助单元80、图像检测单元80-1、图像检测支架80-11、图像检测仪80-12、防护罩80-13、高度检测单元80-2、辅热单元80-3、温度检测单元80-4、温度检测支架80-5、十字模组80-6、温度检测仪80-16、滑轨组件80-7、辅热支架80-8、升降气缸80-9、加热枪80-10、点火器80-14、防护组件80-15、安全防护单元90、管路单元100、A型变位机701、焊接夹具组件702、底座703、机器人704、快换单元705、快换支架705-1、第一焊枪单元705-2、第二焊枪单元705-3、高度检测单元705-4、快换公头705-5、快换母头705-6、焊枪单元706、点火单元707、清枪单元708、送粉机709。
 本发明的实施方式
经过申请人的研究分析，现有技术的工艺采用高温喷焊的方法将金刚石与钻头融为一体，在焊接不同阶段的时候，焊枪的焊枪姿态、工件温度及材料送粉量的需要严格的控制。而人工焊接耗时长、喷焊高度、焊枪姿态、工件温度都难以控制，造成产品的质量、一致性以及合格率难以保障根据这些问题，申请人提出了一种用于石油钻井设备钻头火焰喷焊硬面工艺的自动化工作站，具体方案如下。
如附图所示，一种用于石油钻井设备钻头火焰喷焊硬面工艺的自动化工作站包括转台1、第一夹具2、第二夹具3、第三夹具4、两轴伺服变位装置5、防护罩501、电磁阀组502、歧管块503、宝塔接头504、遮挡压紧机构21、直线轴承固定块2101、导向轴2102、第一导向固定块2103、气缸安装板2104、强力夹紧气缸2105、夹紧臂2106、支撑块2107、限位块2108、连接块2109、侧挡块2110、遮挡板2111、遮挡块2112、第二导向固定块2113、伸缩气缸2114、气缸防护罩2115、第一水冷管2117、第二水冷管2118、第三水冷管2119、水冷机2120、水冷孔2121、定位机构22、第一定位块2201、第二定位块2202、定位销2203、菱形销2204、支撑组件23、底座2301、垫块2302、焊接单元60、控制单元70、总控机70-1、机器人控制柜70-2、触摸显示屏70-3、检测辅助单元80、图像检测单元80-1、图像检测支架80-11、图像检测仪80-12、防护罩80-13、高度检测单元80-2、辅热单元80-3、温度检测单元80-4、温度检测支架80-5、十字模组80-6、温度检测仪80-6、滑轨组件80-7、辅热支架80-8、升降气缸80-9、加热枪80-10、点火器80-14、防护组件80-15、安全防护单元90、管路单元100、A型变位机701、焊接夹具组件702、底座703、机器人704、快换单元705、快换支架705-1、第一焊枪单元705-2、第二焊枪单元705-3、高度检测单元705-4、快换公头705-5、快换母头705-6、焊枪单元706、点火单元707、清枪单元708、送粉机709。
其中所述焊接单元60，如图2所示，所述控制单元70与焊接单元60连接在一起，所述检测辅助单元80与所述控制单元70连接在一起，所述安全防护单元90设置在所述焊接单元60的周向、并且所述控制单元70设置在所述安全防护单元90的外侧，所述管路单元100铺设在所述安全防护单元90内侧的、并且与所述控制单元70连接在一起，所述AA型变位机701设置在所述安全防护单元90的内部，所述焊接夹具组件702设置在所述AA型变位机701的上面，所述焊接夹具组件702用于夹持工件，所述底座703固定安装在所述AA型变位机701的右侧，所述机器人704固定安装在所述机器人704底座703的上面，所述快换单元705设置在所述机器人704第六轴的上面，所述焊枪单元706设置在所述机器人704的右侧，所述点火单元707设置在所述焊枪单元706的第一方向处，所述清枪单元708设置在所述点火单元707的第一方向处，所述送粉机709与所述焊枪单元706通过管路连接在一起，所述水冷机通过管路与所述焊接夹具组件702连接在一起，所述快换支架705-1固定安装在指定的位置，所述第一焊枪单元705-2和第二焊枪单元705-3设置在所述快换支架705-1的上面，所述高度检测单元80-2设置在所述支架的上面、位于所述第一焊枪单元705-2和第二焊枪单元705-3中间位置，其中，所述转台1设置在预设的位置，所述第一夹具2固定安装在所述转台1的上面，所述第二夹具3固定安装在所述转台1的上面、并且和所述第一夹具2相邻，所述第三夹具4固定安装在所述转台1的上面、并且位于所述第一夹具2和第二夹具3之间，所述第一夹具2、第二夹具3和第三夹具4结构相同并且三者之间呈120°均布在所述转台1的上面，通过设在三个工位，并且三个工位均布在圆形的转台1上面，可以满足三种不同型号的工件焊接要求，同时设置了视觉检测功能，可以识别工件的型号，以切换焊接工位，并且可以判断工件的定位状态是否正常，能否进行焊接，通过三工位旋转台1设计，通过视觉相机检测可以识别工件的型号，从而切换到对应的工位。可以满足三种不同外形工件的焊接要求，相比人工焊接，极大的提高了焊接的效率和节拍。
具体的，所述转台1设置呈圆形，同时为了减轻转台1的自身重量，进一步的转台1设计呈类似风车形状，将多余的材料去除，
所述遮挡压紧机构21设置在所述转台1的上面，所述定位机构22设置在所述转台1的上面、并且位于所述遮挡压紧机构21的底部，所述支撑组件23设置在所述转台1的上面，工作时工件全部暴露在焊枪的高温火焰下，喷焊材料的会无差别的喷焊到工件的各个表面，影响工件的质量，也给后期的修整带来了难度，所以在每个夹具的上面都设置了所述遮挡压紧机构21，只露出工件需要喷焊的区域，将不需要被喷焊的地方遮挡起来，保证了工件的焊接质量，其中所述直线轴承固定块2101固定安装在所述转台1的上面，所述导向轴2102过盈配合安装在所述直线轴承固定块2101的上面，所述第一导向固定块2103固定安装在所述导向轴2102的端部，所述气缸安装板2104固定安装在所述转台1的上面、并且和所述导向轴2102在同一水平线上，所述强力夹紧气缸2105固定安装在所述气缸安装板2104的上面，所述夹紧臂2106设置在所述强力夹紧气缸2105的上面，所述支撑块2107固定安装在所述转台1上面的、并且位于所述气缸安装板2104的侧面，所述限位块2108定安装在所述支撑块2107的上面，所述连接块2109固定安装在所述限位块2108的上面，所述侧挡块2110固定安装在所述连接块2109的上面，所述遮挡板2111固定安装在所述侧挡块2110的上面，所述遮挡块2112固定安装在所述第一导向固定块2103的上面，所述第二导向固定块2113的一面固定安装在所述遮挡块2112的上面、另一面与所述导向轴2102连接在一起，所述伸缩气缸2114固定安装在所述转台1的上面、并且伸缩端与第二导向块连接在一起，所述气缸防护罩501与所述连接块2109连接在一起。
为进一步的增加设备的寿命在所述遮挡压紧机构21的上面还设有水冷系统，所述第一水冷管2117一端与所述遮挡块2112连接在一起、另一端与侧挡块2110连接在一起，所述第二水冷管2118一端与所述遮挡块2112连接在一起、另一端与所述连接块2109连接在一起，所述第三水冷管2119一端与所述侧挡块2110连接在一起、另一端与所述连接块2109连接在一起，所述水冷机2120与所述第一水冷管2117和第三水冷管2119连接在一起，为了增加遮挡块2112与侧挡块2110的使用寿命，所述遮挡块2112与侧挡块2110的表面做喷涂热障涂层处理；所述遮挡块2112的内部设置有水冷孔2121，所述水冷孔2121与第一水冷管2117和第二水冷管2118相通，所述水冷机2120中的水能够通过所述遮挡块2112中的水冷孔2121流水到所述遮挡块2112中，形式一个循环的回路，通过使水冷机2120中的水可以流入遮挡块2112中，形成一个循环的回路，可以吸收焊枪火焰透过热障涂层的热量，有效保护遮挡块2112。
所述第一定位块2201和第二定位块2202分别固定在转台1的上面，并且所述第一定位块2201和第二定位块2202在同一水平线上，所述第一定位销2203过盈配合安装在所述第一定位块2201的上面，所述菱形销2204过盈配合安装在所述第二定位块2202的上面，为了方便工件的装夹，所述菱形销2204的一端倒圆角，工件装夹定位时先经过菱形销2204的倒圆角的一端，圆角为定位装配提供一个导向，依次经过圆角端进入到菱形部，进而为工件做精准的定位。
所述底座2301固定安装在转台1的上面，所述支撑板分别螺接在所述底座2301的上面，所述垫块2302螺接在所述支撑板的两端，并且位于所述遮挡压紧机构21的内侧，分别螺接在所述底座2301上面的支撑板，螺接在所述支撑板两端的两个垫块2302，所述底座2301的长度设置有水冷孔2121，所述两个底座2301的水冷孔2121通过第四水冷管连接在一起。
所述防护罩501固定安装在所述转台1的底部，所述电磁阀组502固定安装在所述转台1底部的、位于所述防护罩501的内部，所述歧管块503设置在所述转台1的上面，所述宝塔接头504螺接在所述歧管块503的上面，所述每个歧管块503上面至少四个宝塔接头504，为了所述第一水冷管2117、第二水冷管2118、第三水冷管2119和第四水冷管选用紫铜管折弯制作完成，第一水冷管2117、第二水冷管2118、第三水冷管2119和第四水冷管分別和歧管块503连接在一起的宝塔接头504连接在一起，通过水冷机2120将水经过第一水冷管2117、第二水冷管2118、第三水冷管2119为遮挡板2111和侧挡块2110中的水冷管通水为两者冷却，通过为两者降温，进一步的保护了遮挡板2111和侧挡块2110，提高了他们的使用寿命。
具体的，第一夹具2、第二夹具3和第三夹具4的上面，分别设置有遮挡压紧机构21、定位机构22和支撑组件23，遮挡压紧机构21通过两个强力夹紧气缸2105完成一个90°的旋转压紧动作，压住工件，防止工件窜动，压紧之后，伸缩气缸2114向前伸出，带动⑥推紧遮挡机构向前移动，推紧工件前端。该机构实现定位支撑压紧以及遮挡的功能，保证喷焊时喷焊材料只喷焊在需要焊接的区域，该机构为遮挡机构的水冷系统，遮挡块2112表面做喷涂热障涂层处理，可以有效隔绝热量，防止焊枪的高温火焰使遮挡块2112发生形变或融化。同时在遮挡块2112内部有水冷孔2121，通过⑨水冷管路，使水冷机2120中的水可以流入遮挡块2112中，形成一个循环的回路，可以吸收焊枪火焰透过热障涂层的热量，有效保护遮挡块2112。
具体的焊接夹具组件的工作原理；将三种不同的工件的对应放在第一夹具2、第二夹具3和第三夹具4中，当工件放置好之后，然后遮挡压紧机构21中的两个强力夹紧气缸2105完成一个90°的旋转压紧动作，将工件压住，防止工件窜动，当工件压紧之后，伸缩气缸2114启动工作，伸缩气缸2114向前伸出，带动着遮挡板2111向前移动，推紧工件的前端，当工件完全固定推紧固之后，设备开始喷焊，然后水冷系统开始启动工作，使水冷机2120中的水可以流入遮挡块2112中，形成一个循环的回路，可以吸收焊枪火焰透过热障涂层的热量，有效保护遮挡块2112，喷焊结束之后各个装置与机构回到初始位置，同时水冷系统停止供水，工作停止。
所述焊接夹具组件702用于夹持工件，其底部和AA型变位机701法兰固连，可随变位机机械臂完成两方向运动，以满足工件喷焊位置姿态要求。所述快换单元705为一拖三形式，包含1个快换公头705-5和3个快换母头705-6，其中快换公头705-5安装于机器人704第六轴，3个母头分别安装于第一焊枪单元705-2、第二焊枪单元705-3和高度检测单元80-2。所述第一焊枪单元705-2和第二焊枪单元705-3分别包含焊枪本体，连接支架和快换母头705-6，三者固连。机器人704安装于人底座703上，其第六轴法兰安装快换公头705-5。喷焊程序启动后，机器人704根据喷焊工艺不同阶段需求，携快换公头705-5与第一焊枪单元705-2快换母头705-6或第二焊枪单元705-3快换母头705-6配合连接，之后机器人704携焊枪至点火枪单元点火，之后移动至焊接工作区，送粉器开始送粉，喷焊工序开始；焊接完成后，机器人704携焊枪至清枪单元708清理枪头残留粉末，之后将焊枪放置至快换支架705-1）上，快换公头705-5母头断开连接，喷焊工序完成。进一步的，所述水冷机与焊接夹具组件702连通，水冷机与第二焊枪单元705-3连通，当焊接程序开始到结束期间，水冷机工作，降低焊接夹具与焊枪温度以达到保护目的。
其中，所述总控机70-1与焊接单元60连接在一起，所述机器人704控制柜70-2与机器人704连接在一起，所述触摸显示屏70-3与所述总控柜通信连接在一起的用于工作站的自动化控制。
所述图像检测单元80-1设置在预设的位置，所述高度检测单元80-2设置在快换支架705-1的上面，所述辅热单元80-3设置在所述图像检测单元80-1的第一方向位置，所述图像检测支架80-11设置在预设位置，所述图像检测仪80-12螺接在所述图像检测支架80-11的上面，所述防护罩80-13固定安装在所述图像检测支架80-11的上为了保护图像检测仪80-12，所述温度检测单元80-4设置在所述图像检测单元80-1对称方向，所述温度检测支架80-5设计呈L型，所述十字模组80-6设置在所述温度检测支架80-5的上面能够进行两个方向运动，所述温度检测仪80-16设置在所述十字模组80-6上面的用于检测温度，所述滑轨组件80-7设置在预设的位置，所述辅热支架80-8设置在所述滑轨组件80-7的上面，所述升降气缸80-9固定安装在所述辅热支架80-8的上面便于带动加热枪80-10上下动作，带动加热枪80-10到达相应的位置，所述点火器80-14设中在所述加热枪80-10的侧面，便于为加热枪80-10点火，所述防护组件80-15固定安装在所述滑轨组件80-7的上面，所述防护组件80-15，包括第一防护件和第二防护件，两个防护件拼接在一起形成一个内部中空的空间，所述滑轨组件80-7在中空的空间内部，防护组件80-15将滑动组件保证一起，既防止了工作的粉料在一起进入到滑轨组间，影响滑动的效率。
所述检测辅助单元80如图4，所述图像检测单元80-1包含图像检测支架80-11、图像检测仪80-12、防护罩80-13，三者固连，用于对工件放置状态进行识别判断；当外部机器人704将工件放置于焊接夹具上后，图像检测单元80-1通过拍照图像处理，对工件进行到位判断，如判断工件已经放置到位后，则焊接夹具开始进行夹持操作。所述高度检测单元80-2包括高度检测仪，连接支架及快换单元705母头，三者固连。当焊接程序完成后，机器人704携快换公头705-5与高度检测单元80-2母头配合连接，之后携高度检测单元80-2至工件上方测量喷焊层高度：如喷焊层高度符合要求则工件下线，如喷焊层高度未达到工艺要求，则执行补焊程序，二次上粉。所述温度检测单元80-4包括温度检测仪80-16，十字模组80-6和温度检测支架80-5：检测仪与十字模组80-6相连，可进行两方向运动，十字模组80-6与温度检测支架80-5固连，可对工件进行多方位实时温度监控。所述辅热单元80-3包括点火器80-14，加热枪80-10，顶升气缸，滑轨组件80-7，支架及防护组件80-15：加热枪80-10与水冷机连接，点火器80-14与加热枪80-10通过支架连接于顶升气缸活动端，可进行升降运动；顶升气缸安装于滑轨滑块上，可整体水平左右运动。当温度检测组件反馈工件温度不足时，点火器80-14给加热枪80-10点火，同时水冷机接通，保护加热枪80-10；顶升气缸带动点火器80-14、加热枪80-10上升至合适位置，滑块组件开始左右水平运动，以给工件均匀补足热量。
其中，所述焊接防护房设置在工作站的周向，所述安全光栅，设置在所述焊接防护房的上下两侧位置，所述检修门单元设置在所述焊接防护房进出口处，所述摄像监控单设置在所述焊接防护房的上面，用于远程监控工作站内部情况，所述三色灯与所述摄像监控单元电性连接在一起，所述传感器单元设置在所述焊接防护房的内部，用于检测工作站内部危险气体浓度，通过所述安全防护单元90用于保障工作站使用安全，进一步的，安全光栅安装于焊接防护房上下件处，当安全光栅检测到外部机器人704手臂已离开上下件区域，工作站方开始焊接工作。所述检修门单元包含检修门和安全门锁，用于工人进入工作站调试、维护；检修门上安装有安全门锁，只有当安全门锁闭合时，工作站才能进行工作，以保障工人安全。摄像监控单元用于远程监控工作站内部工作情况。传感器单元用于检测工作站内危险气体浓度，当浓度超标时，工作站报警断电，三色灯报警。
管路单元100包括硬管单元，软管单元，线槽，管路附件。所述管路单元100用于给各系统提供所需气体、水路、电路。线槽用于电气线路的联通。管路附件包括接头，调压阀，平衡吊等。所述硬管单元围绕工作站内部安装构架，在各功能单元邻近位置通过接头转接软管连通到各单元上。进一步的，快换支架705-1上放置的第一焊枪单元705-2，第二焊枪单元705-3及高度检测单元80-2所连软管需通过平衡吊连接至硬管接口，以保证线缆有足够的运动空间且不妨碍机器人704运动。
具体的，一种用于石油钻井设备钻头火焰喷焊硬面工艺的自动化工作站的工作方法，包括如下步骤：
步骤1、将三种不同的工件的对应放在第一夹具、第二夹具和第三夹具中；
步骤2、然后安全光栅启动工作，安全光栅安装于焊接防护房上下件处，当安全光栅检测到外部机器人704手臂已离开上下件区域，工作站方开始焊接工作，其中检修门单元包含检修门和安全门锁，用于工人进入工作站调试、维护；检修门上安装有安全门锁，只有当安全门锁闭合时，工作站才能进行工作，以保障工人安全，摄像监控单元用于远程监控工作站内部工作情况；
步骤3、当安全光栅启动时，同时外部机器人704将工件放置于焊接夹具上后，图像检测单元80-1通过拍照图像处理，对工件进行到位判断，如判断工件已经放置到位后，则焊接夹具开始进行夹持操作；
步骤4、然后焊接夹具夹持工件，焊接夹具的底部与AA型变位机701法兰固定连接在一起，然后AA型变位机701完成两个方向的运动至工件喷焊位置；
步骤5、当AA型变位机701带动工件至预设的位置时，机器人704根据喷焊的工艺不同阶段的需要携着快换公头705-5与第一焊枪单元705-2或者第二焊枪单元705-3配合连接，之后机器人704携第一焊枪单元705-2或者第二焊枪单元705-3至点火单元707点火，之后运动至焊接工作区;
步骤6、移动至焊接工作区之后，送粉器开始送粉，喷焊工序开始；
步骤7、焊接完成后，机器人704携焊枪至清枪单元708清理枪头残留粉末，之后将焊枪放置至快换支架705-1上，快换公头705-5母头断开连接，喷焊工序完成，同时水冷机与焊接夹具连通，水冷机与焊枪单元706连通，当焊接程序开始到结束期间，水冷机同时工作，降低焊接夹具与焊枪温度以达到保护目的；
步骤8、焊接完成，焊枪单元706回到初始位置，焊接结束。以上结合附图详细描述了本发明的优选实施方式，但是，本发明并不限于上述实施方式中的具体细节，在本发明的技术构思范围内，可以对本发明的技术方案进行多种等同变换，这些等同变换均属于本发明的保护范围。

Claims (10)

  1. 一种用于石油钻井设备钻头火焰喷焊硬面工艺的自动化工作站，其特征在于，包括焊接单元，与所述焊接单元连接在一起的控制单元，与所述控制单元连接在一起的检测辅助单元，设置在所述焊接单元周向的安全防护单元，所述控制单元设置在所述安全防护单元的外侧，铺设在所述安全防护单元内侧的、并且与所述控制单元连接在一起的管路单元。
  2. 根据权利要求1所述的一种用于石油钻井设备钻头火焰喷焊硬面工艺的自动化工作站，其特征在于：所述焊接单元，包括设在所述安全防护单元内部的用于随机变位的A型变位机，设置在所述A型变位机上面的用于夹持工件的焊接夹具组件，固定安装在所述A型变位机右侧的用于承载机器人的底座，固定安装在所述机器人底座上面的机器人，设置在所述机器人的第六轴上面的快换单元，设置在所述机器人右侧的焊枪单元，设置在所述焊枪单元的第一方向处用于焊枪点火的点火单元，设置在所述点火单元第一方向的用于清理焊枪残留粉末的清枪单元，与所述焊枪单元通过管路连接在一起的用于为焊枪提供粉料的送粉机，通过管路与所述焊接夹具组件连接在一起的用于为所述焊接夹具组件降温的水冷机；
    所述焊枪单元包括快换支架，设置在所述快换支架上面的第一焊枪单元和第二焊枪单元，设置在所述支架上面的、位于所述第一焊枪单元和第二焊枪单元中间位置的高度检测单元。
  3. 根据权利要求2所述的一种用于石油钻井设备钻头火焰喷焊硬面工艺的自动化工作站，其特征在于，所述快换单元为一拖三的形式，包括一个快换公头和至少3个快换母头，其中所述快换公头安装在所述机器人的第六轴的端部位置，3个快换母头分别安装在第一焊枪单元、第二焊枪单元和高度检测单元的上面。
  4. 根据权利要求1所述的一种用于石油钻井设备钻头火焰喷焊硬面工艺的自动化工作站，其特征在于：所述控制单元，包括总控机，与机器人连接在一起的控制防机器人动作的机器人控制柜，与所述总控柜通信连接在一起的用于工作站的自动化控制的触摸显示屏。
  5. 根据权利要求1所述的一种用于石油钻井设备钻头火焰喷焊硬面工艺的自动化工作站，其特征在于：所述检测辅助单元，包括图像检测单元，设置在快换支架上面的高度检测单元，设置在所述图像检测单元的第一方向处的辅热单元；
    所述图像检测单元包括设置在预设位置的图像检测支架，螺接在所述图像检测支架上面的图像检测仪，固定安装在所述图像检测支架上面的用于防护图像检测仪的防护罩。
  6. 根据权利要求5所述的一种用于石油钻井设备钻头火焰喷焊硬面工艺的自动化工作站，其特征在于：所述检测辅助单元还包括设置在所述图像检测单元对称方向的温度检测单元；
    所述温度检测单元，包括设计呈L型的温度检测支架，设置在所述温度检测支架上面的能够进行两个方向运动的十字模组，设置在所述十字模组上面的用于检测温度的温度检测仪；
    所述辅热单元，包括滑轨组件，设置在所述滑轨组件上面的辅热支架，固定安装在所述辅热支架上面的用于带动加热枪上下动作的升降气缸，设置在所述升降气缸上面的加热枪，设中在所述加热枪侧面的用于为加热枪点火的点火器，以及固定安装在所述滑轨组件上面的防护组件。
  7. 根据权利要求2所述的一种用于石油钻井设备钻头火焰喷焊硬面工艺的自动化工作站，其特征在于：所述焊接夹具组件包括转台，设置在所述转台上面的用于将夹紧工件的第一夹具、第二夹具和第三夹具，以及设置在所述转台上面的用于切换工件焊接姿态的两轴伺服变位装置；
    所述第一夹具、第二夹具和第三夹具结构相同并且三者之间呈120°均布在所述转台的上面；
    所述第一夹具，包括设置在所述转台上面的遮挡压紧机构，固定安装在所述转台上面的定位机构，以及螺接在所述转台上面的支撑组件；
    所述遮挡压紧机构包括固定安装在所述转台上面的两个直线轴承固定块，过盈配合安装在所述直线轴承固定块上面的导向轴，固定安装在所述导向轴端部的第一导向固定块，固定安装在所述转台上面的、和所述导向轴在同一水平线上面的气缸安装板，固定安装在所述气缸安装板上面的强力夹紧气缸，设置在所述强力夹紧气缸上面的夹紧臂，固定安装在所述转台上面的、并且位于所述气缸安装板侧面的支撑块，固定安装在所述支撑块上面的限位块，固定安装在所述限位块上面的连接块，固定安装在所述连接块上面的侧挡块，固定安装在所述侧挡块上面的遮挡板，固定安装在所述第一导向固定块上面的遮挡块，一面固定安装在所述遮挡块上面的、另一面与所述导向轴连接在一起的第二导向固定块，固定安装在所述转台上面的、并且伸缩端与第二导向块连接在一起的伸缩气缸，设置在所述连接块上面的气缸防护罩；
    所述遮挡压紧机构的上面还设有水冷系统，所述水冷系统，包括一端与所述遮挡块连接在一起、另一端与侧挡块连接在一起的第一水冷管，一端与所述遮挡块连接在一起、另一端与所述连接块连接在一起的第二水冷管，一端与所述侧挡块连接在一起、另一端与所述连接块连接在一起的第三水冷管，以及与所述第一水冷管和第三水冷管连接在一起的水冷机。
  8. 根据权利要求1所述的一种用于石油钻井设备钻头火焰喷焊硬面工艺的自动化工作站，其特征在于：所述防护单元，包括焊接防护房，设置在所述焊接防护房上下两侧位置的安全光栅，设置在所述焊接防护房进出口处的检修门单元，设置在所述焊接防护房上面的用于远程监控工作站内部工作情况的摄像监控单元，与所述摄像监控单元电性连接在一起的三色灯，以及设置在所述焊接防护房内部的用于检测工作站内部危险气体浓度的传感器单元。
  9. 根据权利要求1所述的一种用于石油钻井设备钻头火焰喷焊硬面工艺的自动化工作站，其特征在于：所述管路单元，包括铺设在焊接防护房内部的围绕在工作站内部安装构架上面的硬管单元，设置在所述焊接防护房内部的用于为电气线路的联通的线槽。
  10. 一种用于石油钻井设备钻头火焰喷焊硬面工艺的自动化工作站的工作方法，其特征在于，包括如下步骤：
    步骤1、将三种不同的工件的对应放在第一夹具、第二夹具和第三夹具中；
    步骤2、然后安全光栅启动工作，安全光栅安装于焊接防护房上下件处，当安全光栅检测到外部机器人手臂已离开上下件区域，工作站方开始焊接工作，其中检修门单元包含检修门和安全门锁，用于工人进入工作站调试、维护；检修门上安装有安全门锁，只有当安全门锁闭合时，工作站才能进行工作，以保障工人安全，摄像监控单元用于远程监控工作站内部工作情况；
    步骤3、当安全光栅启动时，同时外部机器人将工件放置于焊接夹具上后，图像检测单元通过拍照图像处理，对工件进行到位判断，如判断工件已经放置到位后，则焊接夹具开始进行夹持操作；
    步骤4、然后焊接夹具夹持工件，焊接夹具的底部与A型变位机法兰固定连接在一起，然后A型变位机完成两个方向的运动至工件喷焊位置；
    步骤5、当A型变位机带动工件至预设的位置时，机器人根据喷焊的工艺不同阶段的需要携着快换公头与第一焊枪单元或者第二焊枪单元配合连接，之后机器人携第一焊枪单元或者第二焊枪单元至点火单元点火，之后运动至焊接工作区;
    步骤6、移动至焊接工作区之后，送粉器开始送粉，喷焊工序开始；
    步骤7、焊接完成后，机器人携焊枪至清枪单元清理枪头残留粉末，之后将焊枪放置至快换支架上，快换公头母头断开连接，喷焊工序完成，同时水冷机与焊接夹具连通，水冷机与焊枪单元连通，当焊接程序开始到结束期间，水冷机同时工作，降低焊接夹具与焊枪温度以达到保护目的；
    步骤8、焊接完成，焊枪单元回到初始位置，焊接结束。
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