In the production of railway passenger, subway, light rail vehicles domain, corrugated plate between floor and traction frame welding is a very important process. The process of quality is directly related to the use of railway passenger safety and life, at the same time in the actual production is also more influence to enterprise’s production efficiency of a part.
1. The problems of manual welding
Users of the final product for railway passenger, subway and light rail passenger cars, the process of task assignment is to spell on process good corrugated plate bottom welding connection between components and towing skeleton components, preparation for the general assembly. Customer is the original manual welding, but because of welding artifacts in the project scope is larger, distribution in 30 m long, 3.2 m wide area, so the manual welding in the following several aspects of the problems existing in the production.
(1) burning through corrugated plate 1 mm thickness, and welding of towing the skeleton of steel. In practice, because of each operator proficiency and working concentration of different lead to the welding time control is not good, that cause workpiece burn through.
(2) when virtual welding corrugated plate transportation easy to deformation, welding by artificial cannot be carried out on the workpiece enough pressure between the workpiece and laminating, corrugated plate and towing parts between virtual welding; Because of separated by other artifacts, workers could not confirm with the naked eye.
(3) the production efficiency is low The artifact itself is larger, the time needed for the next time the workpiece is longer, at the same time in the process of welding workers need to constantly move, directly or indirectly caused by waste more time.
(4) the intensity of labor is big Manual welding when the workstation welder work for half a squat posture, and the work scope is big, lead to welding repeated crouch – mobile – crouch process, it is easy to cause certain parts of the body strain.
2. Automation solutions
In order to solve the above problems involved, the user equipment automation requirements are put forward. To solve the problem of the project is the key to ensure the welding quality and improve the work efficiency, to introduce the following concrete plans.
Due to the requirements of the welding work scope is big, hong han technology is put forward by the gantry, arc welding robots, pressurized structure and fixture of double location, double robot automation solutions.
Double location, double robot automation solutions gantry
The scheme has the following features:
(1) double location to shorten the workpiece loading time, set up two station, equipment overall dimensions for 60 m * 6 m * 3.5 m.
(2) gantry In order to solve the problem of work scope, adopted the way of gantry. Gantry adopts servo motor pinion and rack drive way, stepless speed regulation, the gap between the gear and rack can be adjusted. Schedule for 55 m, repeat positioning accuracy of + / – 0.1 mm. The controller of the robot according to the attached shaft way, directly to control the position of the gantry.
(3) dual robot Flexible to solder joint requirements for the respective location, industrial robot is equipped with two sets of six axis, gantry robots, using the same controller.
(4) the programming is simple job requirement in the solder joints for matrix layout, programming using coordinate input methods, has the characteristics of rapid, programming, accurate. Programmed by off-line programming ways, using Ethernet communication interface to the robot controller input program.
(5) an invisible PLC controller with robots capacitor dedicated PLC to replace the ordinary commercial PLC, provide more convenient ladder diagram editing functions. To monitor PLC ladder diagram of action. PLC programming in Windows platform, ladder diagram editor with friendly interface.
(6) welding machine and wire feeding machine adopts the European sales first, nice company, Austria blessing of welding machine and wire feeding machine, effectively guarantee the welding quality.
(7) pressurized structure In order to solve the problem of corrugated plate deformation caused by the virtual welding, and the influence of the deformation of welding quality, equipped with the workpiece pressurized structure. Pressurized structure by high pressure springs, springs, pressure cylinder and pressure adjustment of the handle.
(8) position compensation To solve the off-line programming and position deviation between the actual solder joints, using the robot’s position compensation function, trajectory tracking and compensation in the horizontal and vertical direction, ensure the quality of products.
3. The equipment is mainly cell configuration
(1) gantry drive motor adopts 3.0 kW ac servo motor, motor driven by synchronous electrical way around, drive gear and rack type, stepless speed regulation, the highest speed can be up to 20 000 mm/min, repetitive positioning accuracy of + / – 0.1 mm, for 55 to 000 mm. For ease of cleaning up orbital, equipped with clean up the track surface cleaning brush.
(2) pressure units To add pressure evenly, USES three cylinders, and pressure of each cylinder is 4000 n (400 KGF), sum pressure for 12 000 n (1200 KGF). Pressure unit with functions of floating up and down, in order to solve different bending corrugated plate, width is 3.2 m.
(3) the industrial robot adopts kr6 or 1410 industrial robot, the robot load capacity of 6 kg, repetitive positioning accuracy is + / – 0.05 mm, with inverted installation.
(4) welding machine adopts Austrian loch Fronius TS5000 MV welding power source, wire wire feed mechanism to choose the same manufacturer of VR 1500 4 r/F++ wire feeding machine, each with two sets.
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