Robotic welding device employing flexible guide rail, and welding method

A welding method using a robotic welding device comprising:

• a control box configured to pre-store various welding processes and to generate a welding parameter according to actual welding position and welding groove shape;
• a wire feed mechanism configured to feed welding wire to a welding gun;
• a flexible guide rail, attached to a welding component, wherein the flexible guide rail is provided with a plurality of magnetic adhesion devices, and the plurality of magnetic adhesion devices are located on an identical side of the flexible guide rail, and wherein any one of the magnetic adhesion devices comprises a connecting plate and an upper magnetic adhesion block and lower magnetic adhesion block and the connecting plate is fixed on the flexible guide rail through an outer side of the flexible guide rail, and the connecting plate is provided with the upper magnetic adhesion block and the lower magnetic adhesion block on an inner side of the flexible guide rail, and wherein the flexible guide rail is attached to a welding member through the upper magnetic adhesion block and the lower magnetic adhesion block of each magnetic adhesion device, and wherein the upper magnetic adhesion block and the lower magnetic adhesion block are provided with a fixing knob:
• a welding robot, comprising:
• a robot body movably disposed on the flexible guide rail and movable along the flexible guide rail;
• and
• a welding gun disposed on the robot body and controlled by the robot body to weld the welding component;
• a teaching apparatus, respectively in communication with the welding robot and the control box, and configured to control a traveling path and an operation position of the welding robot, and to adjust oscillation and welding operations of the welding gun according to an instruction of the control box;
• a remote control terminal, in communication with the control box, so as to remotely monitor and configure the welding parameter generated or acquired by the control box, and in communication with a data acquisition device of the welding robot, so as to remotely monitor and configure the welding parameter during a welding process;
• and
• a welding power supply, for supplying power, the method comprising:
• fixing a welding gun clamping device of the welding robot to a supporting structure, and then assembling the supporting structure and a rail trolley together;
• connecting the welding robot to the teaching device, connecting the teaching device to the control box, connecting the control box, wire feed mechanism, and welding robot to the welding power source, and connecting the welding wire of the wire feed mechanism to the welding gun of the welding robot, such that all can be operated normally;
• fixing the flexible guide rail to a side surface of the welding member through the any one of the magnetic adhesion devices, fixing the any one of the magnetic adhesion devices onto a side face of the welding member through an adjusting knob to make an extension direction of the flexible guide rail matched with a shape of the welding component;
• mounting the rail trolley onto the flexible guide rail to cause the welding robot to slide normally on the flexible guide rail, fixing the welding gun to the welding gun clamping device, and adjusting the welding gun to reach a welding angle;
• accessing a corresponding welding groove shape and welding position in the control box according to an actual welding groove shape of the welding component, before detecting the welding groove shape, adjusting flow of a shielding gas, an extension length of the welding wire and an angle of the welding gun;
• starting to detect the welding groove shape, pressing a start button on the teaching device to start sensing and detect a welding groove angle, a plate thickness of the welding component, a root gap, a plate thickness difference and a welding length, and after completing sensing, moving the welding gun to a welding start point to prepare for welding;
• after completing the sensing, according to a bevel detection data, displaying welding parameters generated automatically by the control box, monitoring the welding parameters by a remote control terminal, and setting the welding parameters, when needed, by the control box itself or the remote control terminal, and performing the welding during an entirety of the welding process according to a layer pass and the welding parameters set by the control box;
• remotely monitoring and adjusting the welding parameters during the welding process, through data connection between a data collector of the welding robot and a remote computer;
• and
• after completing the welding, exiting a program, disassembling the flexible guide rail and the welding robot to complete welding.