English
创建于05.11
pipe flange robot welding
I、 The operating environment of the equipment
1.1 Working conditions: Continuous working system
1.2 Production environment:
1.2.1 Power supply: THREE-PHASE, AC380V,±10%, frequency 50±1Hz
1.2.2 Operating ambient temperature: 0 ° C to 40 ° C
1.2.3 Relative humidity: At 30 ° C, humidity up to 95% (no condensation)
1.2.4 Work continuously and stably in the above working conditions
II、 Type of weldment and work content
2.1 Typical welding workpiece types are as follows:
2.2 For the above workpieces, pre-spot welding is carried out, and manual tooling is clamped to achieve robot automatic welding.
III、 Design basis and main parameters
3.1 Design basis: According to the workpiece drawings provided by the customer and the relevant welding process requirements.
#Names of welded workpieces: pipe flanges, pipe butt joints, T-shaped pipe tees, special-shaped structure pipes
#Weldable material: Automatic welding of carbon steel and stainless steel can be achieved.
# Available for clamping pipe fittings: 76-500 mm
# Fitting length available: 200-4000 mm
#Maximum center distance of rotation: 950 mm
#Rated load capacity: 500 kg
#Welding method: MAG/MIG butt
#Weld type: Fillet, lap (ring weld, saddle weld, arc, straight weld)
3.2 Main parameters of the workstation
# Robot workstation mode: Robot mobile two-station workstation
#Welding robot travel: 3000 mm
#Robot working radius: 1400 mm
#Vertical positioner rotation center height: 1200 mm
# Workpiece bracket movement mode: Manual movement
#Workpiece rotation mode: Robot external axis coordinated control
IV、 Welding robot workstation configuration list:
Serial Number | Name | Model and Specification | Quantity (sets) | Reference Note |
|
1 | Robot systems | Robot body | TM1400 | 1 | Panasonic Japan |
Robot control cabinet | 1 | Panasonic Japan |
|||
2 | Welding power supply | YD-500GL | 1 | Panasonic Tangshan |
|
3 | External shaft motor | 1.6 kW | 2 | Panasonic Japan |
|
4 | External axis controller | 2-axis controller | 1 | Panasonic Japan |
|
5 | High voltage contact sensor | 1 | Panasonic of Japan |
||
6 | Cooling water circulation unit | 1 | Panasonic Tangshan |
||
7 | Cleaning gun shears device | 1 | TBI |
||
8 | Stand positioner | 1 | Wuxi Panasonic |
||
9 | Robot walking device | 1 | Panasonic Wuxi |
||
10 | Fixed workbench | 1000×700 mm | 1 | Wuxi Panasonic |
|
11 | Weld accessory brackets and others | 1 | Wuxi Panasonic |
||
12 | External starter box | 2 | Wuxi Panasonic |
||
This scheme adopts robot welding, manual loading and unloading of workpieces, and the robot arm drives the welding torch to achieve the automatic welding work of the workpieces.
V、
The main components of the welding robot workstation
5.1 Arc welding robot
The arc welding robot selected for this workstation is the most advanced TM1400 model newly launched by Panasonic Japan. It consists of three parts: the robot body, the robot control cabinet, and the teaching box.
The technical parameters are shown in the following table:
Items | Specifications |
|
TM-1400 |
||
Action types | Independent multi-joint type robot |
|
Control axes | 6 axes |
|
Placement method | Ground mounting, hoisting |
|
Action area | Maximum reach distance | 1437mm |
Minimum reach distance | 404mm |
|
Range of motion front and back | 1033mm |
|
Range of motion | RT axis | + 170 ° |
UA axis | -90° to +155° |
|
FA axis | -195° to +240° |
|
RW axis | + 190 ° |
|
BW axis | -130° to +110° |
|
"TW axis" | + 220 ° |
|
Maximum load on hand | 6kg |
|
Drive mode; Total drive capacity | AC servo motor drive; Total drive power 3400W |
|
Repeatability accuracy | + / - 0.08 mm |
|
Weight | 170kg |
|
Installation environment | Ambient temperature: 0-45°20%RH - 90%RH(no condensation) |
|
#The robot body is equipped with AC servo motors, which are compact in structure, fast in response, reliable, smooth and flexible in movement, efficient and have a wider range of motion.
#It can freely change the most suitable welding sequence, which is easy to shorten the production cycle and improve the precision of the workpiece after welding.
# A flexible system can be formed by changing the fixture system to accommodate future changes to the workpieces to be welded.
# The teaching box uses a large liquid crystal display for a clearer picture, and the easy-to-switch Chinese and English display makes it convenient for the operator to operate.
5.2G Ⅲ Welding robot controller
The new generation of GⅢ controllers can achieve more efficient control and more accurate precision control.
#According to welding technical requirements such as weld shape, trajectory and weld corner size, various optimal welding conditions (the best welding specification and welding posture) can be set.
#The extension length of the wire is the same, so the penetration depth is consistent with the weld shape, and spatter during the welding process is greatly reduced.
#The freedom to change the most appropriate welding sequence makes it easy to shorten the production cycle and improve the precision of the workpiece after welding.
#A flexible system can be formed by changing the fixture system to accommodate future changes to the workpieces to be welded.
# The teaching box uses a large liquid crystal display for a clearer picture, and the easy-to-switch Chinese and English display makes it convenient for the operator to operate.
5.3 Welding Power Supply
Using the YD-500GL high performance welding power supply produced by Tangshan Panasonic, which can perform CO2, MAG, MIG and other welding methods, main technical parameters:
# Welding power supply model: YD-500GL
#Input power: 3-phase AC380V±10% 50/60Hz dual-purpose
#Rated input capacity: 23.3 kVA, 22.4 kW
#Output current: 60-500 A
#Output voltage: 17-39 V
#Arc closing current: 60-500 A
# Arc termination voltage: 17-39 V
# Rated load duration rate: 100%
# Dimensions: (W)380×(D)550×(H)815 mm
# Weight: 60 kg
Multiple protection functions such as secondary short-circuit protection, overheat protection, and primary overcurrent and overvoltage protection, as well as a variety of extended functions that can adapt to complex welding processes such as robot welding and automatic welding. Good welding performance for carbon steel and stainless steel materials, light spatter short-circuit transition at low current, standard Root welding function, suitable for base and large gap welding.
5.4 Vertical positioner:
The robot workstation is a complete set of specialized equipment for welding. The workpiece clamping and repositioning form adopts the vertical positioner, and the workpiece is flipped and rotated by clamping the workpiece through the light three-jaw chuck on the worktable surface.
5.4.1 Key technical parameters:
#Rotation center height: 1200 mm (rotation center distance from the ground)
#Rated load capacity: 500 kg
#Rotation speed: 0.1-2 rpm (robot coordinated control)
5.4.2 Main performance and structural features
#The vertical positioner consists of a frame, a large base, a worktable, a three-jaw chuck, a lifting bracket, etc.
#The frame, which serves as the foundation for the installation of the entire device, is made of steel sections and steel plates welded together. It has a simple structure and stable performance.
#A single-axis displacement method is adopted to enable the flipping action of the workpiece. A precision reducer is installed inside the frame box, which drives the gear and slewing bearing through the reducer. The robot standard external axis motor method is adopted to drive the flipping, which can achieve coordinated operation with the robot.
#Connected to the worktable through the slewing bearing, the rotation center of the frame box is designed with a through-type center hole, which can accommodate the through-type clamping of 300mm diameter pipe fittings, facilitate the welding of longer workpieces in the limited space, and the long-axis workpiece clamping is more stable.
#A large diameter three-jaw chuck is installed on the worktable surface to clamp and position the workpiece by clamping the pipe diameter of the workpiece, which is easy to operate.
#The external axis motor of the robot is adopted to drive the workpiece flipping and positioner, and the robot drives the welding torch to achieve coordinated operation control between the welding torch and the workpiece.
#Precision linear guide rails are installed on the base of the positioner. Workpiece brackets are installed through the linear guide rails. The brackets can be lifted and lowered by rotating the handwheel. Pressing rollers are also installed on the workpiece brackets. By manually pressing the workpiece, remote support for workpieces of different diameters can be achieved, effectively avoiding distortion and jumping of the workpiece during rotation, and better enabling automatic welding by the robot.
#The welding fixture is an important part of the robot welding workstation. In this robot workstation, only a special large-diameter three-jaw chuck is installed, which, on the one hand, can clamp longer workpieces through the center hole; On the other hand, other clamps (provided by the user) can also be clamped through the three-jaw chuck, which can expand the clamping of various different workpieces and is more user-friendly.
5.5 Robot walking device
The robot's moving base is driven by the robot's external axis motor, which enables convenient integrated control and drive with the robot system. It is mainly composed of the base, the robot moving platform, the robot mounting seat, the drag chain, etc.
#The base is made by welding steel plates and sections, and then undergoes heat treatment to relieve stress, which can effectively ensure the long-term use of the equipment, and is finally finely processed.
² After finishing the upper part of the base, precision linear guides are installed, which can effectively ensure the smooth movement of the robot and meet the requirements of high-precision movement and positioning of the robot.
#The upper part of the base is equipped with a robot moving platform, which is connected to the base through precision linear guides and can move along with the robot. Accessories such as wire hangers can also be installed on it to provide a working platform for the robot's welding.
# The movement drive of the robot moving platform: robot external shaft motor - precision gear reducer - precision gear rack pair.
#The base is also designed with comprehensive protection measures, and metal covers are designed for linear guides, wires and cables, etc., to protect and safeguard the equipment.
5.6 Fixed worktable, a worktable made of welded steel plates and sections, the worktable surface is finely machined, and a three-jaw chuck is installed on it. Through the three-jaw chuck, the workpiece is clamped and fixed, and the workpiece is welded by the welding robot arm driving the welding torch.
5.7 High voltage contact sensor:
Contact sensing is a means used to detect positional offsets of an object workpiece. When the consistency of the workpiece does not meet the welding requirements, it is used to automatically determine the welding deviation before welding. The principle is that the welding robot turns on this function before welding, and the welding wire forms a voltage difference relative to the base material. When the welding wire slowly approaches the welding base material and comes into contact with it, it will conduct electricity (or discharge), at which point the robot detects the object workpiece and can remember the position. When teaching, the contact sensor detects one workpiece position (reference position), and when reproducing, it detects another workpiece position. The two positions are subtracted to calculate the deviation amount. Based on the deviation amount, the robot calculates the compensation amount and reflects the compensation amount at the execution position of that point.
5.8 Gun cleaning and wire cutting device:
5.8.1 Key technical parameters
#Control mode: Pneumatic
#Air source: Oil-free and dry compressed air, 6 bar
#Control signal: DC24 V
#Gun clearance time: about 4-5 seconds
#Anti-splash spray volume: Adjustable
#Splash repellent capacity: 500 ml
#Wire cutting function: Can cut up to φ1.6mm steel wire
#Weight: about 14kg (excluding the gun cleaning station base)
5.8.2 Brief Introduction to performance features
The new TBi BRG-2 gun cleaning station is equipped with a sealed fuel tank. Anti-spatter agent can be sprayed directly onto the welding gun tip. The robot's working area will not be contaminated, and the amount of spatter inhibitor used will also be reduced.
To facilitate the operator's operation and maintenance and reduce the operator's daily maintenance workload, the system is equipped with gun cleaning and silicone oil spraying devices for the robot; After the robot drives the welding torch to work for a period of time, it automatically goes to the gun cleaning device to remove the welding spatter adhering to the nozzle of the welding torch, and can spray a small amount of silicone oil into the interior of the gun to prevent the spatter from adhering firmly during welding, which is beneficial for the next gun cleaning.
5.9 Cooling water circulation device:
# The cooling water tank is a Panasonic YX-09KG product with a water pump, cooling system and water tank, connected to the welding torch, which can deliver cooling water to the gun head section for cooling, and the heated water is cooled again through the cooling system for recycling.
# High cooling capacity, up to 200 kJ/min
# The quick-plug structure between the water tank, filter and piping makes it easier to clean the water tank and filter
#The large opening cover design allows the arm to reach in for easy cleaning inside the tank
#Even if the water quality deteriorates, it is less likely to cause the pump to lock
5.10 External starter box: An external starter box is provided for the welding station, making operation simple and convenient.
VI、 Main purchased parts configuration
Serial number | Name Specifications | Brand | Notes |
1 | Precision linear guide | ABBA/ HIWIN | Taiwan |
2 | Workpiece rotation reducer | Teijin/Sumitomo | Japan |
3 | Drag chain (fully enclosed) | - | Domestic |
4 | Welding robot system | Panasonic | Japan |
5 | Cleaning gun shears device | TBI | Germany |
VII、
A brief diagram of the equipment scheme