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CN-122007615-A - Intelligent laser welding workstation for high-voltage cable

CN122007615ACN 122007615 ACN122007615 ACN 122007615ACN-122007615-A

Abstract

The invention discloses a high-voltage cable intelligent laser welding workstation which comprises an operation table, a mechanical arm, a welding head, a camera component, a power component, a clamping component and a control piece, wherein the control piece is arranged on the outer side of the operation table, and comprises an image acquisition module, an image processing module, a track planning module, a motion control module, a quality detection module, a parameter adjustment module and a synchronous control module. The invention realizes the visual guidance and real-time monitoring of the welding process by the camera component, precisely positions a welding center point by an image processing algorithm, generates a smooth welding path by the track planning module, dynamically adjusts welding parameters by the parameter adjusting module according to a molten pool image, and receives the signals of the production line to realize the full-flow automation of automatic clamping, welding and loosening.

Inventors

  • GU RUIMING
  • CAI WENYAN

Assignees

  • 献县中远线缆有限公司

Dates

Publication Date
20260512
Application Date
20260320

Claims (9)

  1. 1. The intelligent laser welding workstation for the high-voltage cable comprises an operation table (1) and is characterized in that a mechanical arm (2) is arranged at the top end of the operation table (1), a welding head (21) and a camera component (22) are arranged on the mechanical arm (2), power components (3) are arranged on two sides of the top end of the operation table (1), and a clamping component (4) is arranged on the power components (3); The power assembly (3) comprises a fixing frame (36) fixedly arranged at the top end of the operating platform (1), a motor (31) is arranged at the bottom end of the fixing frame (36), a rotating shaft (32) is fixedly connected to the output end of the motor (31), a plurality of rotating rods (35) are rotatably connected to the top end of the fixing frame (36), synchronous wheels (34) are fixedly connected to the outer walls of the rotating shaft (32) and the rotating rods (35), and synchronous belts (33) are sleeved between the synchronous wheels (34); The clamping assembly (4) comprises two sliding plates (45) fixedly arranged on the synchronous belt (33), the top ends of the sliding plates (45) are fixedly connected with a mounting frame (42), the top ends of the mounting frame (42) are fixedly connected with clamping jaws (41), the top ends of the fixing frames (36) are fixedly connected with guide rails (44), the bottom ends of the mounting frame (42) are fixedly connected with sliding blocks (43), and the bottom ends of the sliding blocks (43) are in sliding connection with the guide rails (44); A control piece (5) is arranged on the outer side of the operating platform (1), and the control piece (5) is electrically connected with the mechanical arm (2), the welding head (21), the camera component (22) and the motor (31); The control element (5) comprises: The camera component (22) is used for controlling the acquisition of the end image of the cable; The image processing module is used for calculating the coordinates of the welding center point; the track planning module is used for generating a motion track of the mechanical arm (2); the motion control module is used for controlling the mechanical arm (2) to accurately track the welding track; the quality detection module is used for carrying out weld quality assessment after welding is completed; The parameter adjustment module is used for dynamically adjusting welding parameters in the welding process; And the synchronous control module is used for realizing the cooperative work with the production line beat.
  2. 2. The intelligent laser welding workstation for high-voltage cables according to claim 1, wherein the calculation process of the image processing module for calculating the coordinates of the welding center point is characterized in that the image processing module performs gray level, filtering and binarization pretreatment on an image of the end part of the cable to extract the contour of the end face of the cable, fits the end face circle through Hough transformation based on the extracted contour of the end face to obtain the center coordinates (u, v), and combines a pre-calibrated camera internal reference matrix K and a transformation matrix of a base coordinate system of a mechanical arm (2) with a camera coordinate system Converting the pixel coordinates (u, v) into three-dimensional space coordinates in a robot arm base coordinate system The coordinates are the coordinates of the welding center point.
  3. 3. The intelligent laser welding workstation for the high-voltage cable is characterized in that the specific process of generating the motion track of the mechanical arm (2) by the track planning module is that key path points of the welding track are generated in a three-dimensional space based on welding center point coordinates output by the image processing module and combined with preset welding starting point offset, welding path length and welding overlap width, and the key path points are smoothed by adopting a polynomial interpolation or B-spline curve algorithm to generate a continuous motion track of an end effector (namely a welding head (21)) of the mechanical arm (2), wherein the track comprises position and posture information.
  4. 4. The intelligent high-voltage cable laser welding workstation of claim 1, wherein the motion control module controls the mechanical arm (2) to accurately track a welding track is characterized in that the motion control module receives the continuous motion track generated by the track planning module, solves the pose sequence of an end effector into the angle sequence of each joint of the mechanical arm (2) in real time through inverse kinematics of the mechanical arm (2), drives each joint motor of the mechanical arm (2) through a servo control algorithm, enables a welding head (21) to move strictly according to a preset track, and triggers the welding head (21) to emit light when reaching a welding starting point, so as to perform laser welding.
  5. 5. The intelligent high-voltage cable laser welding workstation according to claim 1, wherein the parameter adjustment module dynamically adjusts welding parameters in the welding process, and the intelligent high-voltage cable laser welding workstation is characterized in that the camera assembly (22) acquires molten pool images of a welding area in real time in the welding process, the parameter adjustment module extracts molten pool width and length characteristics based on the molten pool images, compares the extracted molten pool characteristics with a preset standard molten pool characteristic range, reduces laser power of a welding head (21) according to a preset step length or improves welding speed if the molten pool width exceeds the upper limit of the standard range, and improves the laser power or reduces the welding speed according to the preset step length if the molten pool width is lower than the lower limit of the standard range.
  6. 6. The intelligent laser welding workstation for the high-voltage cable is characterized in that the quality detection module is used for carrying out weld quality assessment after welding is completed, the camera assembly (22) is used for collecting complete images of a weld after the welding is completed, the quality detection module is used for carrying out image segmentation on the weld images, extracting a weld area, calculating width uniformity and residual height of the weld, comparing the calculated width uniformity and residual height of the weld with a preset quality standard threshold value, and judging that the weld is unqualified and generating an alarm signal if any index exceeds the threshold value range.
  7. 7. The intelligent laser welding workstation for the high-voltage cable is characterized in that the synchronous control module is used for realizing cooperative work with the beat of a production line, and the intelligent laser welding workstation is characterized in that the synchronous control module is used for receiving a cable in-place start-stop signal sent by an upstream production line in real time, sending a forward rotation command to a motor (31) to drive a clamping assembly (4) to fold and clamp the cable when the synchronous control module receives the in-place signal, sending a start command to an image acquisition module and a subsequent module to trigger an automatic welding process after the clamping assembly is in place, sending a reverse rotation command to the motor (31) by the synchronous control module after the welding process is finished, driving the clamping assembly (4) to loosen, and sending a welding completion signal to the production line to allow the cable to enter a next station.
  8. 8. The intelligent laser welding workstation for the high-voltage cable according to claim 1, wherein the synchronous clamping process of the clamping assembly (4) is characterized in that when the motor (31) rotates positively, the rotating shaft (32) is driven to rotate, the synchronous belt (33) is driven to do circular motion through the synchronous wheel (34), the sliding plate (45) fixed on the upper side edge of the synchronous belt (33) and the sliding plate (45) fixed on the lower side edge of the synchronous belt are driven to move in opposite directions, the two mounting frames (42) and the clamping jaws (41) on the mounting frames are driven to approach each other along the guide rail (44) to realize centering and clamping of the cable, and when the motor (31) rotates reversely, the two clamping jaws (41) are far away from each other to loosen the cable.
  9. 9. The intelligent laser welding workstation for high-voltage cables according to claim 1, wherein anti-skidding patterns or flexible gaskets are arranged on the inner sides of the clamping jaws (41) and are used for protecting the surfaces of the cables and enhancing clamping stability.

Description

Intelligent laser welding workstation for high-voltage cable Technical Field The invention relates to the technical field of intelligent welding, in particular to an intelligent laser welding workstation for a high-voltage cable. Background With the rapid development of the power cable manufacturing industry, especially the continuous expansion of the production scale of high-voltage and ultra-high voltage cables, higher requirements are put on the welding quality and the production efficiency of the cable conductor connecting links. In the cable production process, the metal conductor units need to be butted efficiently and reliably so as to ensure the conductivity and mechanical strength of the cable. At present, the cable conductor connection mainly adopts resistance welding, argon arc welding or manual laser welding and other modes. However, the prior art has the following disadvantages in practical applications: first, degree of automation is low, relies on manual operation. The traditional cable welding adopts manual positioning and manual welding modes, operators need to adjust the position and welding parameters of a welding gun according to experience, labor intensity is high, efficiency is low, welding quality is highly dependent on the technical level of operators, and consistency and stability of products are difficult to ensure. Secondly, the positioning accuracy is insufficient, and the high standard requirement of the high-voltage cable is difficult to meet. The butt joint of the high-voltage cable conductors has strict requirements on the concentricity, penetration and appearance of welding seams, the existing equipment lacks a precise visual guiding and positioning mechanism, the automatic identification and precise positioning of the welding seams cannot be realized, and the quality problems of offset welding, cold welding and the like are easy to generate. Thirdly, the cooperative control capability with the production line beat is lacking. Most of the existing welding equipment is operated at independent stations, manual loading and unloading are needed, welding actions are triggered manually, seamless connection cannot be achieved with working procedures such as fixed-length cutting and conveying of upstream cables, the whole efficiency of a production line is limited, and continuous and large-scale production requirements are difficult to meet. Fourth, the welding process lacks a real-time monitoring and dynamic adjustment mechanism. In the welding process, the molten pool state is influenced by factors such as material difference, surface cleanliness and the like and can not be dynamically adjusted according to the molten pool images acquired in real time, so that the welding quality fluctuation is large, and the rejection rate is high. Fifthly, detecting the quality of the welding line with hysteresis. In the prior art, a manual spot check mode after welding is finished is mostly adopted, so that the online automatic detection of each welding line cannot be realized, defects are not found timely, and the reworking cost and the material waste are increased. Therefore, developing a high-voltage cable intelligent laser welding workstation which can realize high-precision automatic positioning, real-time regulation and control of a welding process, and cooperation with production line beats and has an online quality detection function becomes a technical problem to be solved urgently by those skilled in the art. Disclosure of Invention The invention provides a high-voltage cable intelligent laser welding workstation, which realizes visual guidance and real-time monitoring of a welding process through a camera component, precisely positions a welding center point through an image processing algorithm, generates a smooth welding path through a track planning module, dynamically adjusts welding parameters according to a molten pool image, and realizes full-flow automation of automatic clamping, welding and loosening by receiving a production line signal through a synchronous control module. The invention provides a technical scheme that the intelligent laser welding workstation for a high-voltage cable comprises an operation table (1), wherein a mechanical arm (2) is arranged at the top end of the operation table (1), a welding head (21) and a camera component (22) are arranged on the mechanical arm (2), power components (3) are arranged on two sides of the top end of the operation table (1), and a clamping component (4) is arranged on the power components (3); The power assembly (3) comprises a fixing frame (36) fixedly arranged at the top end of the operating platform (1), a motor (31) is arranged at the bottom end of the fixing frame (36), a rotating shaft (32) is fixedly connected to the output end of the motor (31), a plurality of rotating rods (35) are rotatably connected to the top end of the fixing frame (36), synchronous wheels (34) are fixedly connected to the outer walls of the r