I .Design task:
1. Used in multi-position girth welding for automobile steering gear.
2. The width of the weld seam is uniform, and the overlap of the girth weld can be adjusted.
3. In the whole length of the weld, there are no welding defects, such as air hole, Incomplete penetration, dent, burn through, slag inclusion, undercut, etc.
4. Welding Qualified rate by one time is higher than 99%. It's require that the welding process is continuous and stable, with uniform and beautiful shape, penetration and width meet process requirements, clamping is convenient.
5. Production rhythm: less than 30 seconds / piece
II. Welding process analysis
1. welding technology
CO2 mixed gas, 1.2 ordinary carbon steel welding wire
2. Horizontal machine body , workpiece rotation
3. Requirements for workpiece
3.1 Requirements of workpiece: the workpiece does not need spot welding.The workpieces need to be overall consistent, workpiece shape and size accuracy should meet the product drawings requirements,the basic form and size accuracy should be controlled within ± 0.5mm.
3.2 Product surface should be clean, with no oil stains, rust and other defects.
4. Basic idea:
4.1 One set robot, workpiece rotation.
4.2 The workpiece is clamped by the fixture device to ensure he welding seam position is not offset.
4.3 Japan Panasonic TM-1400 robot and Tangshan Panasonic YD-350GR3 arc welding power supply which provide the High-speed signal transmission from which can greatly improve the quality welding and production efficiency.
4.4 The Machine adopts the welding torch which is matched with Tangshan Panasonic robot, ensure the welding system can work stable and norms under large continuous work.
4.5 Workstation shield is closed type. There is a pneumatic door at the working position, with through-beam grating protection at front side.
4.6 Flexible welding fixture of the workstation is able to quickly replace the fixture and ensure repeated positioning accuracy.
4.7 The workpiece is positioned by a positioning fixture to ensure that the weld position does not offset.
III.Equipment composition
The welding machine adopts closed structure, composed of the enclosed body, welding station, robot, fixture positioning and conductive mechanism, electrical control system, welding power and pneumatic system.
1.Machine body:
The upper part is mounted with an exhaust fan, and the outlet of the exhaust fan is connected with the exhaust pipe of the factory to exhaust the welding smoke timely.
2.Equipped with rotary worktable, which is driven by the original Panasonic 500KG external shaft and mounted with the pneumatic clamping device and the conductive mechanism . The rotary worktable has diffraction grating and electrically operated door to ensure the safety of operators, and the robot will never enter this area when workers are loading and unloading the workpiece. And if any person enters this area when the robot is welding the workpiece, the robot will immediately stop
3.The body base is welded by steel plate and steel profile, which has enough rigidity and strength. All girths shall be welded according to the requirements for weld strength, and stress treatment shall be carried out after welding to remove the internal stress and prevent deformation.
4.The welding machine body and the robot control panel are welded by steel plate and steel profile which is rigidity and strength enough.
All the wiring of the equipment has protective cover, the wiring on the ground is protected with metal wire slot, and if those wire are not on the ground ,it has bracket and bridge for installation of metal wire slot as wiring protection cover, to ensure equipment wiring meets safety requirements.
5.The compressed air system is arranged on the side of the frame mechanism, composed of filter, pressure relief valve, pressure gauge and solenoid valve. In normal use, the pressure relief valve is regulated to 0.2 ~ 0.5MPa. In order to facilitate the operator to observe, it is arranged at the enclosed fence near the operator's position: observation window for compressed air pressure gauge, and welding protective gas flow meter
6.Emergency stop button box is arranged inside the machine shell,for emergency stop of the equipment.
7.The enclosed fence which is assembled by the fence sections and sprayed plates. It has enough rigidity and strength with beautiful appearance. The front side is mounted with pneumatic lifting door, and the sliding door uses linear guide rail. The door is made of steel plate with good strength.
8.The sliding door is driven by a cylinder, and a locking device is arranged in place. There is an observation window in the sliding door, and the observation window on the door to observe an adjust the welding process. There is a Through-beam grating device to ensure the safety.
9.During the automatic operation, the roll curtain of the loading and unloading station automatically rises, easy for the operator to load and unload the workpiece, the rolling curtain at the welding position will automatically put down to prevent the arc from injuring human eyes.
10.Fixture mechanism:
The welding tool is integral type, and connected with the working table by positioning pin hole, able to be replaced quickly. The welding tool is provided with a workpiece positioning datum, after inserting the oil storage cylinder in correct position, and the cylinder port is axially pressed by the air cylinder. Then the welding torch and the deflection machine reach the designated position, waiting for welding. All pneumatic components use Japanese SMC products.
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