WO2023005025A1 - 一种板材焊接用咬合结构、免拼点焊接装置及方法 - Google Patents

一种板材焊接用咬合结构、免拼点焊接装置及方法 Download PDF

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WO2023005025A1
WO2023005025A1 PCT/CN2021/126880 CN2021126880W WO2023005025A1 WO 2023005025 A1 WO2023005025 A1 WO 2023005025A1 CN 2021126880 W CN2021126880 W CN 2021126880W WO 2023005025 A1 WO2023005025 A1 WO 2023005025A1
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welding
occlusal
cutting
cutting mechanism
spot welding
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PCT/CN2021/126880
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English (en)
French (fr)
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纪昂
王灿
张立平
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江苏徐工工程机械研究院有限公司
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Publication of WO2023005025A1 publication Critical patent/WO2023005025A1/zh

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    • 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
    • B23K28/00—Welding or cutting not covered by any of the preceding groups, e.g. electrolytic welding
    • B23K28/02—Combined welding or cutting procedures or apparatus
    • 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
    • B23K26/00—Working by laser beam, e.g. welding, cutting or boring
    • B23K26/36—Removing material
    • B23K26/38—Removing material by boring or cutting
    • 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
    • B23K37/00—Auxiliary devices or processes, not specially adapted to a procedure covered by only one of the preceding main groups

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  • the invention relates to an articulation structure for plate welding, a joint-free spot welding device and a method, and belongs to the technical field of regular seam welding.
  • the straight arm structure is one of the common regular structural parts of construction machinery, and its connecting welds are generally long straight butt welds. Due to the large local stress and strain in the welding process, in order to ensure that the gap between the two plates remains consistent during the welding process, a large number of spot welds are required before welding to ensure the stability of the structure during the welding process.
  • the annular structure is also one of the common regular structural parts of construction machinery, and its connecting welds are generally annular butt welds. Since there are also very large local stresses and strains in the welding process, in order to avoid cracking of the weld seam during the welding process, a large number of spot welds are required before welding to ensure the stability of the structure during the welding process. In addition, because the ring structure is usually used for flat welding with a turntable, its welding process is similar to that of a straight weld.
  • the welding volume of the above two regular welds is huge, and the automatic welding method is generally used. Since the welding speed is generally set in advance, it is impossible to perform special treatment on spot welds like welders during the welding process. In order to avoid the formation of local bulges at the joints after welding and affect the appearance, it is usually necessary to manually polish the spot welds before welding, that is, the two plates are only connected and fixed through the roots of the welding joints.
  • the existing pre-welding process is as follows: (1) Put the bent plate into the joint tooling, and adjust the position between the two plates , to ensure that both ends are aligned and there is no wrong edge. The process is expected to take 20 minutes; (2) In the state of ensuring that the tooling is clamped, spot welding is performed in sequence. For example, 50 spot welds are required, and it is estimated to be 25 minutes; (3) Use an angle grinder to grind the spot welds, and the whole process is estimated to be 35 minutes; (4) Lift them to a special welding machine for welding, The welding process is estimated to be 30 minutes.
  • the object of the present invention is to provide an articulation structure for plate welding, a splicing-free spot welding device and method, to use a special path to cut the plate, so that after cutting, bending or rolling, the two plates can be fixed through the edge articulation structure.
  • Dimensional constraints so as to save the "point-grinding” process, and the formal welding process can be started after the direct alignment at the welding station, solving the "poor quality” and “high cost” caused by the spot welding seam " and "low efficiency”.
  • the present invention adopts the following technical solutions:
  • the present invention provides an engaging structure for plate welding, the engaging structure is located at the edge of two plates, and is used to constrain the mutual movement of the plates after the two plates are engaged.
  • the engaging structure includes mutually matching triangular, rectangular, trapezoidal, zigzag, and barb-shaped structures arranged on the edges of the two plates.
  • the engaging structure includes dovetail-shaped structures that cooperate with each other and are arranged on the edges of the two boards.
  • the occlusal structure also includes a rigid pad fixed on the back of the occlusal structure.
  • the rigid pad is fixed on the back of the occlusal structure by means of a clamp or a small amount of spot welding at the position where its edge contacts the occlusal structure.
  • small parameter spot welding is applied to the occlusal structure.
  • the width of the occlusal structure ranges from 0.5 to 6 mm.
  • the present invention provides a joint-free spot welding device, which includes a connecting bracket, a welding torch, and a cutting mechanism.
  • the welding torch is fixed on the connecting bracket, and the cutting mechanism is fixedly connected to the connecting bracket through a posture adjustment mechanism.
  • the cutting mechanism is used to remove the above-mentioned occlusal structure at the welding seam of the plate, and the welding torch is used to weld the unconnected area after the occlusal structure is removed.
  • the cutting mechanism includes a cutter body and a cutting piece, and the cutting piece is rotatably connected to the lower end of the cutter body.
  • the cutting mechanism is a laser cutting head.
  • the present invention provides a straight welding seam splicing-free spot welding method, which is carried out by using the aforementioned splicing-free spot welding device, the method comprising:
  • the cut plates are assembled and occluded, and fixed by spot welding at the end of the weld, or by random small-parameter spot welding at the occlusal structure, or, the rigid liner is passed through the clamp or in contact with the occlusal structure at its edge The position is fixed on the back of the occlusal structure by a small amount of spot welding;
  • the cutting mechanism and the welding torch are moved along the direction of the welding seam, the cutting mechanism removes the occlusal structure first, and the welding torch follows the cutting mechanism to weld the unconnected area after the occlusal structure is removed.
  • the cutting mechanism removes at least 80% of the width of the occlusal structure.
  • the cutting mechanism adopts the cutting machine body and the cutting piece, the lower edge of the cutting piece is not higher than the root of the welding seam.
  • the present invention provides a method for splicing-free spot welding of annular welds, which is carried out by using the aforementioned splicing-free spot welding device, the method comprising:
  • the plates after cutting and rolling are grouped and occluded, and a small amount of spot welding is randomly performed at the occlusal structure of the weld seam, or the circular or annular rigid liner is fixed by a small amount of spot welding at the contact position between the outer diameter edge and the occlusal structure.
  • the form is fixed on the back of the occlusal structure to obtain a ring structure;
  • the turntable drives the ring structure to rotate, the cutting mechanism removes the occlusal structure ahead, and the welding torch follows the cutting mechanism to weld the unconnected area after the occlusal structure is removed.
  • the cutting mechanism removes at least 80% of the width of the occlusal structure.
  • the rotation direction of the cutting piece is the direction in which the chips fly away from the welding torch.
  • the present invention gives full play to the advantages of the existing advanced laser cutting technology, adopts a special path to cut the plate and obtain the occlusal structure, thereby performing self-restraint in different dimensions, and then removes these constraints by cutting before welding, directly eliminating the need for "joint" Point-grinding" and other non-value-added processes have greatly increased the proportion of value-added time in the welding production of large and long ruled structural parts, and achieved complementary effects with efficient welding methods;
  • the present invention also provides three dimensional constrained occlusal structure forms, which can meet straight welds with different constrained requirements, and thus have high process integrity.
  • Fig. 1 is a schematic structural view of a splicing-free spot welding device according to an embodiment of the present invention
  • Fig. 2 is a schematic diagram of a triangular one-dimensional constrained occlusal structure
  • FIG. 3 is a schematic diagram of a rectangular one-dimensional constrained occlusal structure
  • Fig. 4 is a schematic diagram of a barb-shaped two-dimensional constrained occlusal structure
  • Fig. 5 is a schematic diagram of a dovetail-shaped two-dimensional constrained occlusal structure
  • Fig. 6 is a schematic diagram of three-dimensional constrained occlusal structure welding
  • Fig. 7 is a schematic structural view of a splicing-free spot welding device according to another embodiment of the present invention.
  • connection bracket 1 connection bracket; 2-1 welding torch; 2-2 welding wire; 3 posture adjustment mechanism; 4-1 cutting machine body; 4-2 cutting piece; 5-1 plate; Structure; 6 rigid pads; 7-1 laser cutting head; 7-2 laser.
  • the present invention provides a kind of joint-free spot welding device, as shown in Fig. Body 4-1, cutting piece 4-2, welded plate 5-1, weld 5-2, occlusal structure 5-3.
  • the connecting bracket 1 is fixed on the tool end of the welding robot or welding machine
  • the welding torch 2-1 is fixed on the connecting bracket
  • the cutting machine body 4-1 is fixedly connected with the connecting bracket 1 through the posture adjustment mechanism 3 .
  • the cutting piece 4-2 is located at the lower end of the cutting machine body 4-1, and the posture adjustment mechanism 3 can realize the adjustment of the position and posture of the cutting piece 4-2.
  • the welded plate 5-1 is provided with an occlusal structure 5-3, and after the two plates 5-1 are paired, multi-dimensional freedom constraints can be realized through the occluded structure 5-3.
  • the occlusal structure 5-3 can adopt a one-dimensional constraint form, such as a triangle or a rectangle, as shown in Figures 2 and 3, which can prevent the plates 5-1 on both sides of the weld from being displaced along the direction parallel to the weld during the welding process .
  • a one-dimensional constraint form such as a triangle or a rectangle, as shown in Figures 2 and 3, which can prevent the plates 5-1 on both sides of the weld from being displaced along the direction parallel to the weld during the welding process .
  • other structures such as trapezoids and zigzags can also be used.
  • the occlusal structure 5-3 can also adopt other two-dimensional constraint forms, such as the barb-shaped and dovetail-shaped structures shown in Figures 4 and 5, so that the plates 5-1 on both sides of the weld cannot move along the vertical direction of the weld during the welding process. Displacement occurs in and parallel directions.
  • the three-dimensional constraint form of the occlusal structure 5-3 can be realized by applying a rigid pad 6 and fixedly connecting it with two plates, as shown in FIG. 6 .
  • the rigid liner 6 can be fixed on the back of the weld seam of the two plates by a clamp to realize three-dimensional constraint.
  • the rigid pad 6 can be fixed on the back of the occlusal structure 5-3 by randomly performing a small amount of spot welding at the position where its edge contacts the occlusal structure 5-3. , so as to achieve three-dimensional constraints.
  • the rigid pad 6 can be fixed on the back of the weld of the two plates by a clamp to achieve three-dimensional constraints.
  • the rigid liner 6 can be fixed in the form of a small amount of random spot welding at the contact position between its edge and the occlusal structure 5-3. Occlusal structure 5-3 dorsal, thus achieving three-dimensional restraint.
  • grooves can be set on the rigid liner 6 to facilitate the molten pool to flow down.
  • the three-dimensional constraint can also be realized by random spot welding with small parameters and a small amount at the occlusal structure 5-3 of the above-mentioned one-dimensional constraint.
  • the three-dimensional constraint can also be realized by randomly performing spot welding with small parameters and a small amount at the above-mentioned two-dimensionally constrained occlusal structure 5-3 as shown in FIGS. 4 and 5 .
  • the occlusal structure 5-3 can adopt the one-dimensional and two-dimensional constraint forms as shown in Fig. 2-4.
  • the three-dimensional constraint can be realized by randomly performing a small amount of spot welding with small parameters at the occlusal structure 5-3 of the one-dimensional or two-dimensional constraint, or rigid pads can be used for fixing.
  • a rigid liner adopts a ring-shaped or circular liner, and the rigid liner is fixed on the back of the occlusal structure 5-3 by performing a small amount of spot welding at the contact position of its outer diameter edge with the occlusal structure 5-3 , so as to achieve three-dimensional constraints.
  • small parameter spot welding is used at the occlusal structure. When the occlusal structure is subsequently removed, the welding spots will be removed together with the occlusal structure.
  • the distribution of the occlusal structure 5-3 in the length direction of the weld can be adjusted according to the rigidity and process of the plate 5-1 structure.
  • the width of the occlusal structure 5-3 (that is, the height of the protrusion or the depth of the depression at the edge of the plate on one side) can be adjusted according to the process, and the width ranges from 0.5 to 6 mm.
  • the cutting piece 4-2 should be able to remove at least 80% of the width of the occlusal structure 5-3.
  • the present invention provides a method for splicing-free spot welding of straight welds, which is performed using the device shown in FIG. 1 .
  • the method includes:
  • the plates 5-1 Group and lock the plates 5-1 according to the form of the occlusal structure, and fix them by spot welding at the end of the weld, or randomly perform spot welding with small parameters at the occlusal structure, or use rigid pads 6 to fix them ; If the rigid liner 6 is used, it can be fixed on the back of the weld through a clamp or a small amount of spot welding of the rigid liner through the clamp or at the position where its edge contacts the occlusal structure;
  • the rotation direction of the cutting piece 4-2 needs to match the welding direction so that the chips fly away from the welding torch.
  • the cutting piece 4-2 and the welding torch 2-1 move along the welding seam direction driven by the welding robot or welding plane.
  • the occlusal structure 5-3 is removed one by one.
  • the welding torch 2-1 starts arcing when it reaches the beginning of the weld, and then the cutting piece 4-2 removes the occlusal structure 5-3 first, and the welding torch 2-1 -1 followed by normal welding;
  • the welding torch 2-1 turns off the arc after welding, and closes the cutting machine body 4-1.
  • the present invention provides a splicing-free spot welding method for annular welds, which is performed using the device shown in FIG. 1 .
  • the method includes:
  • the edge of the plate 5-1 can be cut according to the method shown in Figure 2-4 before rolling, or the edge of the plate 5-1 can be cut with the turntable after rolling;
  • the cutting machine body 4-1 is lifted, the welding torch 2-1 turns off the arc after completing the remaining welding, and the cutting machine body 4-1 is closed.
  • the laser cutting head 7-1 can also be used to replace the cutting machine body 4-1, and the laser cutting head 7-1 can realize straight line or swing cutting, as shown in Figure 7 As shown, laser cutting 7-2 is used to remove the occlusal structure 5-3. When the occlusal structure is wide, it can be cut with a scanning laser.
  • the present invention provides a method for splicing-free spot welding of straight welds, which is performed using the device shown in FIG. 7 .
  • the methods include:
  • the laser cutting head 7-1 and the welding torch 2-1 move along the welding seam direction driven by the welding robot or welding plane. After the laser cutting head 7-1 enters the plate, the occlusal structures 5-3 are removed one by one.
  • the welding torch 2-1 starts arcing when it reaches the beginning of the weld, and then the laser cutting head 7-1 removes the occlusal structures 5-3 first. Welding torch 2-1 performs normal welding at the back;
  • the welding torch 2-1 is turned off after welding, and the laser cutting head 7-1 is turned off.
  • the present invention provides a method for splicing-free spot welding of annular welds, which is performed using the device shown in Figure 7, and the method includes:
  • the edge of the plate 5-1 can be cut according to the method shown in Figure 2-4 before rolling, or the edge of the plate 5-1 can be cut with the turntable after rolling;
  • the laser cutting head 7-1 is raised, the welding torch 2-1 is turned off after the remaining welding is completed, and the laser cutting head 7-1 is turned off.

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Abstract

本发明提供了一种板材焊接用咬合结构、免拼点焊接装置及方法。装置包括连接支架、焊枪、切割机构，所述焊枪固定在连接支架上，所述切割机构通过位姿调整机构与连接支架固定连接。焊接板材上设有咬合结构，两块板材组对后，可以通过咬合结构实现多种维度的约束。焊接前，根据实际约束维度需求，将板材边缘按照咬合结构形式进行切割并组对咬合，在调整焊枪位置后，切割机构和焊枪在焊接机器人或者专机的带动下沿焊缝方向运动。切割机构在前负责去除咬合结构，焊枪在后进行正常焊接。本发明直接省去了"拼点-打磨"工序，提升了焊接效率和焊缝质量，节省了人力、物力成本。

Description

一种板材焊接用咬合结构、免拼点焊接装置及方法 技术领域
本发明涉及一种板材焊接用咬合结构、免拼点焊接装置及方法，属于规则焊缝焊接技术领域。
背景技术
直臂结构是工程机械常见规则结构件之一，其连接焊缝一般为长直对接焊缝。由于焊接过程存在较大的局部应力和应变，所以为了保证两板间隙在焊接过程中保持一致，长直焊缝在焊前需要通过大量的点固焊缝来保证焊接过程中结构的稳定性。
环形结构亦是工程机械常见规则结构件之一，其连接焊缝一般为环形对接焊缝。由于焊接过程同样存在非常大的局部应力和应变，所以为了避免焊缝在焊接过程中开裂，环形焊缝在焊前也需要通过大量的点固焊缝来保证焊接过程中结构的稳定性。另外，由于环形结构通常配合转台进行平焊，所以其焊接过程与直焊缝类似。
以上两种规则焊缝的焊接量巨大，一般采用自动化焊接方式。由于焊接速度一般提前设定，所以焊接过程中无法向焊工那样对点固焊缝进行特殊处理。为了避免焊后在拼点处形成局部凸起、影响外观，通常需要在焊前将点固焊缝人工打磨平整，即两板仅通过焊点根部进行连接固定。
以长为10m的“双C”型板对接直臂、单人操作为例，现有焊 接前期工序为：(1)将折弯后的板材放入拼点工装，调整两板之间的位置，保证两端对齐、无错边，该过程预计20min；(2)在保证工装夹紧的状态下，按顺序进行点焊，点固焊缝长50mm，点焊间距为200～500mm，以400mm为例，则需要50个点固焊缝、预估25min；(3)使用角磨机将点固的焊点进行打磨处理，整个过程预估35min；(4)吊送至焊接专机进行焊接，焊接过程预估30min。
现有技术方案在实施过程中存在以下缺点：(1)从价值流的角度来看，虽然很多高效焊接方法已经应用于该类大长规则焊缝的焊接过程，但是其前期“拼点-打磨”工序耗时严重(非增值时间)，既降低了整体的生产效率，也没有把应用高效焊接方法的优势完全发挥出来(增值时间)。所以“拼点-打磨”也成为了大长规则结构件焊接生产效率提升的一大痛点！(2)拼点工人的质量意识一般比较差，存在“盲焊”现象，导致点固焊缝经常出现根部未熔透以及焊接时开裂现象；(3)虽然采用大量的点固焊缝去拼接，但是起到实质作用的只有焊缝根部(上部都被打磨掉了)，因此造成大量的浪费；(4)需要配置专用的拼点工装，增加了机物料消耗成本。
发明内容
本发明的目的在于提供一种板材焊接用咬合结构、免拼点焊接装置及方法，以采用特殊路径切割板材，使其在切割、折弯或者卷圆后可以通过边缘的咬合结构实现两板一定维度上的约束，从而省去“拼点-打磨”工序，在焊接工位上直接组对咬合后便可以开始正式的焊接工序，解决由点固焊缝导致的“质量差”、“成本高”以及“效率低” 等问题。
为实现上述目的，本发明采用如下技术方案：
一方面，本发明提供了一种板材焊接用咬合结构，所述咬合结构位于两板材边缘处，用于在两板材组对咬合后约束板材的相互移动。
进一步地，所述咬合结构包括设置在两板材边缘的相互配合的三角形、矩形、梯形、锯齿形、倒钩形结构。
进一步地，所述咬合结构包括设置在两板材边缘的相互配合的燕尾形结构。
进一步地，所述咬合结构还包括固定在咬合结构背面的刚性衬垫。
进一步地，所述刚性衬垫通过夹具或者在其边缘与咬合结构接触位置进行少量点焊的形式固定在咬合结构背面。
进一步地，所述咬合结构上施加有小参数点焊。
进一步地，所述咬合结构的宽度范围为0.5～6mm。
另一方面，本发明提供了一种免拼点焊接装置，包括连接支架、焊枪、切割机构，所述焊枪固定在连接支架上，所述切割机构通过位姿调整机构与连接支架固定连接，所述切割机构用于去除板材焊缝处的前述的咬合结构，所述焊枪用于对去除咬合结构后的无连接区域进行施焊。
进一步地，所述切割机构包括切割机本体和切割片，所述切割片可旋转地连接于切割机本体的下端。
进一步地，所述切割机构为激光切割头。
另一方面，本发明提供了一种直焊缝免拼点焊接方法，其利用前述的免拼点焊接装置进行，所述方法包括：
将板材边缘按照前述咬合结构的形式进行切割；
将切割后的板材进行组对咬合，在焊缝端部进行点焊固定，或者在咬合结构处随机进行小参数点焊进行固定，或者，将刚性衬垫通过夹具或者在其边缘与咬合结构接触位置进行少量点焊的形式固定在咬合结构背面；
调整焊枪位置和切割机构位置，使焊枪和切割机构与焊缝中心对齐；
使切割机构和焊枪沿焊缝方向运动，切割机构在前将咬合结构去除，焊枪跟随切割机构对去除咬合结构后的无连接区域进行焊接。
进一步地，切割机构至少将咬合结构宽度的80％去除。
进一步地，当切割机构采用切割机本体和切割片时，所述切割片的下边沿不高于焊缝的根部。
进一步地，所述切割片旋转方向为切屑飞向远离焊枪的方向。另一方面，本发明提供了一种环形焊缝免拼点焊接方法，其利用前述的免拼点焊接装置进行，所述方法包括：
将板材边缘按照前述三角形、矩形、梯形、锯齿形、倒钩形等咬合结构的形式进行切割后再进行卷圆，或者将板材先进行卷圆后对板材边缘按照咬合结构的形式进行切割；
将切割卷圆后的板材进行组对咬合，在焊缝咬合结构处随机进行少量点焊固定，或者将圆形或环形刚性衬垫通过在其外径边缘与咬合 结构接触位置进行少量点焊的形式固定在咬合结构背面，得到环形结构件；
将环形结构件置于转台上，调整焊枪位置和切割机构位置，使焊枪和切割机构与焊缝中心对齐；
使切割机构和焊枪保持固定，转台带动环形结构件转动，切割机构在前将咬合结构去除，焊枪跟随切割机构对去除咬合结构后的无连接区域进行焊接。
进一步地，前述的一种环形焊缝免拼点焊接方法中，所述切割机构至少将咬合结构宽度的80％去除。
进一步地，前述的一种环形焊缝免拼点焊接方法中，当切割机构采用切割机本体和切割片时，所述切割片的下边沿不高于焊缝的根部。
进一步地，所述切割片旋转方向为切屑飞向远离焊枪的方向。本发明所达到的有益技术效果：
(1)本发明充分发挥了现有先进激光切割技术的优势，采用特殊路径去切割板材、获得咬合结构，从而进行不同维度的自我约束，焊前再通过切割去除这些约束，直接省去“拼点-打磨”等非增值工序，大大提升了大长规则结构件焊接生产中增值时间所占的比重，并获得与高效焊接方法相辅相成的效果；
(2)“拼点-打磨”等工序的省去也直接节省了人力、物力成本；
(3)由于咬合结构在焊前会被去除，所以提供一个良好的间隙，可以有效保证焊缝根部的熔透性，提升焊缝质量，避免由质量极差的 点固焊缝带来的质量隐患；
(4)本发明还提供了三种维度约束的咬合结构形式，可以满足不同约束要求的直焊缝，因此具有较高的工艺完整性。
附图说明
图1为本发明一实施例的一种免拼点焊接装置的结构示意图；
图2为三角形的一维约束咬合结构示意图；
图3为矩形的一维约束咬合结构示意图；
图4为倒钩形的二维约束咬合结构示意图；
图5为燕尾形的二维约束咬合结构示意图；
图6为三维约束咬合结构施焊示意图；
图7为本发明另一实施例的一种免拼点焊接装置的结构示意图。
其中，1连接支架；2-1焊枪；2-2焊丝；3位姿调整机构；4-1切割机本体；4-2切割片；5-1板材；5-2焊缝；5-3咬合结构；6刚性衬垫；7-1激光切割头；7-2激光。
具体实施方式
下面结合具体实施例对本发明作进一步描述。以下实施例仅用于更加清楚地说明本发明的技术方案，而不能以此来限制本发明的保护范围。
如前所述，现有技术方案在实施过程中存在以下缺点：前期“拼点-打磨”工序耗时严重，且点固焊缝存在“质量差”、“成本高”以及“效率低”等问题。
为此，在一实施例中，本发明提供了一种免拼点焊接装置，如图 1所示，包括连接支架1、焊枪2-1、焊丝2-2、位姿调整机构3、切割机本体4-1、切割片4-2、焊接板材5-1、焊缝5-2、咬合结构5-3。
其中，连接支架1固定在焊接机器人或者焊接专机的工具端，焊枪2-1固定在连接支架上，切割机本体4-1通过位姿调整机构3与连接支架1固定连接。切割片4-2位于切割机本体4-1的下端，位姿调整机构3可以实现切割片4-2位置、姿态的调整。焊接板材5-1上设有咬合结构5-3，两块板材5-1组对后，可以通过咬合结构5-3实现多维自由度的约束。
咬合结构5-3可以采用一维约束形式，例如三角形、矩形，如图2、3所示，它可以使焊缝两侧的板材5-1在焊接过程中无法沿焊缝的平行方向产生位移。除三角形、矩形外，还可以采用梯形、锯齿形等其它结构。
在上述一维约束形式的基础上，可以通过在焊缝端部进行少量点焊，由此将两块板材5-1简单固定，实现二维约束力，使得板材在焊接过程中不易脱开。
咬合结构5-3还可以采用其它二维约束形式，如图4、5所示的倒钩形、燕尾形结构，使得焊缝两侧的板材5-1在焊接过程中无法沿焊缝的垂直和平行两个方向产生位移。
在上述一维约束和二维约束的基础之上，可以通过施加刚性衬垫6并将其与两板材固定连接来实现咬合结构5-3的三维约束形式，如图6所示。
在一具体实施方式中，在上述一维约束的基础上，可以通过夹具 将刚性衬垫6固定在两板材焊缝的背面，实现三维约束。
在另一实施方式中，在上述一维约束的基础上，可以将刚性衬垫6通过在其边缘与咬合结构5-3接触位置随机进行少量点固焊的形式固定在咬合结构5-3背面，从而实现三维约束。
在另一实施方式中，在如图4、5所示的二维约束的基础上，可以通过夹具将刚性衬垫6固定在两板材焊缝的背面，实现三维约束。
在另一实施方式中，在如图4、5所示的二维约束的基础上，可以将刚性衬垫6在其边缘与咬合结构5-3接触位置随机进行少量点固焊的形式固定在咬合结构5-3背面，从而实现三维约束。
其中，刚性衬垫6上可设置凹槽，以方便熔池流下去。
在另一实施方式中，还可以通过在上述一维约束的咬合结构5-3处随机进行小参数少量点焊，实现三维约束。
在另一实施方式中，还可以通过在上述如图4、5所示的二维约束的咬合结构5-3处随机进行小参数少量点焊，实现三维约束。
当焊缝为环形焊缝时，咬合结构5-3可以采用如图2-4所示的一维、二维约束形式。在此基础上，可以通过在所述一维或二维约束的咬合结构5-3处随机进行小参数少量点焊，实现三维约束，或者，可以采用刚性衬垫进行固定。当使用刚性衬垫时，刚性衬垫采用环形或圆形衬垫，通过在其外径边缘与咬合结构5-3接触位置进行少量点焊的形式将刚性衬垫固定在咬合结构5-3背面，从而实现三维约束。
需要说明的是，在咬合结构处采用小参数点焊，在后续去除咬合结构时，焊点会随咬合结构一同被去除。
咬合结构5-3在焊缝长度方向上的分布可以根据板材5-1结构的刚度以及工艺进行调整。
咬合结构5-3的宽度(即单侧板材边缘凸起高度或者凹下深度)可以根据工艺进行调整，宽度范围为0.5～6mm。
由于熔焊的热源会熔化一部分的母材，所以切割片4-2应至少能够去除咬合结构5-3宽度的80％。
在另一实施例中，本发明提供了一种直焊缝免拼点焊接方法，其利用图1所示装置进行。该方法包括：
a.根据实际约束维度需要，将板材5-1的边缘按照图2～5的方式进行切割；
b.将板材5-1按照咬合结构的形式进行组对锁死，在焊缝端部进行点焊固定，或者在咬合结构处随机进行小参数点焊进行固定，或者，使用刚性衬垫6固定；如果使用刚性衬垫6，则可以通过夹具或者将刚性衬垫通过夹具或者在其边缘与咬合结构接触位置进行少量点焊的形式固定在焊缝的背面；
c.操作焊接机器人或者焊接专机的工具端，调整焊枪2-1的位置，然后再调整切割片4-2的位置，使二者与焊缝中心对齐，同时切割片4-2的下边沿不高于焊缝的根部；
d.启动切割机本体4-1，如图1所示，切割片4-2旋转方向需要与焊接方向配合使得切屑飞向远离焊枪的方向。切割片4-2和焊枪2-1在焊接机器人或者焊接专机的带动下沿焊缝方向运动。切割片4-2进入板材后将咬合结构5-3逐一去除，焊枪2-1在到达焊缝起始处时开 始起弧，之后切割片4-2在前去除咬合结构5-3，焊枪2-1在后进行正常焊接；
e.焊枪2-1在完成焊接后熄弧，关闭切割机本体4-1。
在另一实施例中，本发明提供了一种环形焊缝免拼点焊接方法，其利用图1所示装置进行。该方法包括：
a.根据实际约束维度需要，可以先将板材5-1的边缘按照图2～4的方式进行切割后再进行卷圆，也可以卷圆后配合转台对板材5-1边缘进行切割；
b.将板材5-1按照咬合结构的形式进行组对锁死，在焊缝咬合结构5-3处随机进行少量点焊固定，或者使用刚性衬垫6固定，得到环形结构件；
如果使用刚性衬垫固定，则需使用圆形或环形衬垫，并将圆形或环形衬垫通过在其外径边缘与咬合结构5-3接触位置进行少量点焊的形式固定在咬合结构背面；
c.将环形结构件置于转台上，调整焊枪2-1的位置，然后再调整切割片4-2的位置，使二者与焊缝中心对齐，同时切割片4-2的下边沿不高于焊缝的根部；
d.启动切割机本体4-1，如图1所示，切割片4-2旋转方向需要与焊接方向配合使得切屑飞向远离焊枪2-1的方向。切割片4-2和焊枪2-1保持固定，转台带动环形结构件转动。切割片4-2进入板材5-1后将咬合结构5-3逐一去除，焊枪2-1在后进行正常焊接；
e.在所有咬合结构5-3均被去除后，切割机本体4-1抬起，焊枪 2-1在完成剩余的焊接后熄弧，关闭切割机本体4-1。
在另一实施例中，作为切割片4-2的替代方式，也可以用激光切割头7-1替代切割机本体4-1，激光切割头7-1可实现直线或者摆动切割，如图7所示，采用激光7-2切割来去除咬合结构5-3。当咬合结构较宽时，可以采用扫描激光进行切割。
在另一实施例中，本发明提供了一种直焊缝免拼点焊接方法，其利用如图7所示装置进行。所述方法包括：
a.根据实际约束维度需要，将板材5-1的边缘按照图2～5的方式进行切割；
b.将板材5-1按照咬合结构的形式进行组对锁死，在焊缝端部进行点焊固定，或者在咬合结构处随机进行小参数点焊进行固定，或者，使用刚性衬垫6固定；
c.操作焊接机器人或者焊接专机的工具端，调整焊枪2-1的位置，然后再调整用激光切割头7-1的位置，使二者与焊缝中心对齐；
d.启动激光切割头7-1，如图7所示。激光切割头7-1和焊枪2-1在焊接机器人或者焊接专机的带动下沿焊缝方向运动。激光切割头7-1进入板材后将咬合结构5-3逐一去除，焊枪2-1在到达焊缝起始处时开始起弧，之后激光切割头7-1在前去除咬合结构5-3，焊枪2-1在后进行正常焊接；
e.焊枪2-1在完成焊接后熄弧，关闭激光切割头7-1。
在另一实施例中，本发明提供了一种环形焊缝免拼点焊接方法，其利用如图7所示装置进行，该方法包括：
a.根据实际约束维度需要，可以先将板材5-1的边缘按照图2～4的方式进行切割后再进行卷圆，也可以卷圆后配合转台对板材5-1边缘进行切割；
b.将板材5-1按照咬合结构的形式进行组对锁死，在焊缝咬合结构5-3处随机进行少量点焊固定或者使用圆形或环形衬垫固定，得到环形结构件；
c.将环形结构件置于转台上，调整焊枪2-1的位置，然后再调整激光切割头7-1的位置，使二者与焊缝中心对齐；
d.启动激光切割头7-1，如图1所示。激光切割头7-1和焊枪2-1保持固定，转台带动环形结构件转动。激光切割头7-1进入板材5-1后将咬合结构5-3逐一去除，焊枪2-1在后进行正常焊接；
e.在所有咬合结构5-3均被去除后，激光切割头7-1抬起，焊枪2-1在完成剩余的焊接后熄弧，关闭激光切割头7-1。
需要特别说明的是，本申请的重点在于通过板材的“自我咬合固定”以及焊前的“去除”来实现免拼点焊接，因此本说明书中展示的几种咬合结构只是示例，其它咬合结构、咬合点去除方式或者本示例中的变形都在本发明保护范围之内。
以上已以较佳实施例公布了本发明，然其并非用以限制本发明，凡采取等同替换或等效变换的方案所获得的技术方案，均落在本发明的保护范围内。

Claims (15)

  1. 一种板材焊接用咬合结构，其特征在于，所述咬合结构(5-3)位于两板材边缘处，用于在两板材组对咬合后约束板材的相互移动。
  2. 根据权利要求1所述的一种板材焊接用咬合结构，其特征在于，所述咬合结构(5-3)包括设置在两板材边缘的相互配合的三角形、矩形、梯形、锯齿形、倒钩形结构。
  3. 根据权利要求1所述的一种板材焊接用咬合结构，其特征在于，所述咬合结构(5-3)包括设置在两板材边缘的相互配合的燕尾形结构。
  4. 根据权利要求2或3所述的一种板材焊接用咬合结构，其特征在于，所述咬合结构(5-3)还包括固定在咬合结构(5-3)背面的刚性衬垫(6)。
  5. 根据权利要求4所述的一种板材焊接用咬合结构，其特征在于，所述刚性衬垫(6)通过夹具或者在其边缘与咬合结构(5-3)接触位置进行少量点焊的形式固定在咬合结构(5-3)背面。
  6. 根据权利要求2或3所述的一种板材焊接用咬合结构，其特征在于，所述咬合结构(5-3)上施加有小参数点焊。
  7. 根据权利要求1-3任一项所述的一种板材焊接用咬合结构，其特征在于，所述咬合结构(5-3)的宽度范围为0.5～6mm。
  8. 一种免拼点焊接装置，其特征在于，包括连接支架(1)、焊枪(2-1)、切割机构，所述焊枪(2-1)固定在连接支架(1)上，所 述切割机构通过位姿调整机构(3)与连接支架(1)固定连接，所述切割机构用于去除板材焊缝处的如权利要求1-7任一项所述的咬合结构，所述焊枪(2-1)用于对去除咬合结构后的无连接区域进行施焊。
  9. 根据权利要求8所述的一种免拼点焊接装置，其特征在于，所述切割机构包括切割机本体(4-1)和切割片(4-2)，所述切割片(4-2)可旋转地连接于切割机本体(4-1)的下端。
  10. 根据权利要求8所述的一种免拼点焊接装置，其特征在于，所述切割机构为激光切割头(7-1)。
  11. 一种直焊缝免拼点焊接方法，其利用权利要求8-10任一项所述的免拼点焊接装置进行，其特征在于，所述方法包括：
    将板材边缘按照如权利要求1-3任一项所述的咬合结构的形式进行切割；
    将切割后的板材进行组对咬合，在焊缝端部进行点焊固定，或者在咬合结构处随机进行小参数点焊进行固定，或者，将刚性衬垫通过夹具或者在其边缘与咬合结构接触位置进行少量点焊的形式固定在咬合结构背面；
    调整焊枪(2-1)位置和切割机构位置，使焊枪(2-1)和切割机构与焊缝中心对齐；
    使切割机构和焊枪(2-1)沿焊缝方向运动，切割机构在前将咬合结构去除，焊枪(2-1)跟随切割机构对去除咬合结构后的无连接区域进行焊接。
  12. 根据权利要求11所述的一种直焊缝免拼点焊接方法，其特 征在于，切割机构至少将咬合结构宽度的80％去除。
  13. 根据权利要求11所述的一种直焊缝免拼点焊接方法，其特征在于，当切割机构采用切割机本体(4-1)和切割片(4-2)时，所述切割片(4-2)的下边沿不高于焊缝的根部。
  14. 根据权利要求13所述的一种直焊缝免拼点焊接方法，其特征在于，所述切割片(4-2)旋转方向为切屑飞向远离焊枪(2-1)的方向。
  15. 一种环形焊缝免拼点焊接方法，其利用权利要求8-10任一项所述的免拼点焊接装置进行，其特征在于，所述方法包括：
    将板材边缘按照如权利要求1-2任一项所述的咬合结构的形式进行切割后再进行卷圆，或者将板材先进行卷圆后对板材边缘按照咬合结构的形式进行切割；
    将切割卷圆后的板材进行组对咬合，在焊缝咬合结构处随机进行少量点焊固定，或者将圆形或环形刚性衬垫通过在其外径边缘与咬合结构(5-3)接触位置进行少量点焊的形式固定在咬合结构背面，得到环形结构件；
    将环形结构件置于转台上，调整焊枪(2-1)位置和切割机构位置，使焊枪(2-1)和切割机构与焊缝中心对齐；
    使切割机构和焊枪(2-1)保持固定，转台带动环形结构件转动，切割机构在前将咬合结构去除，焊枪(2-1)跟随切割机构对去除咬合结构后的无连接区域进行焊接。
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