CN102785042A - Automatic welding system and method for truck frame - Google Patents
Automatic welding system and method for truck frame Download PDFInfo
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- CN102785042A CN102785042A CN2011101265129A CN201110126512A CN102785042A CN 102785042 A CN102785042 A CN 102785042A CN 2011101265129 A CN2011101265129 A CN 2011101265129A CN 201110126512 A CN201110126512 A CN 201110126512A CN 102785042 A CN102785042 A CN 102785042A
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Abstract
The invention relates to an automatic welding system and method for a truck frame. The automatic welding system comprises an artificial stock table which is used for preparing a workpiece to be welded, an automatic conveyer car which is used for transporting the workpiece among equipment, a track which is used for the automatic conveyer car to travel, a clamping device which is used for taking the workpiece down from the automatic conveyer car and transferring to a welding position, a welding robot, a buffering table which is used for repairing welding of the workpiece after the welding and a PLC (programmable logic controller) master control system. The artificial stock table and the clamping device are arranged at two sides of the track, the PLC master control system is connected with and controls the automatic conveyer car, the welding robot, the clamping device and the buffering table through an industry field bus. The automatic welding system and method for the truck frame can greatly improve production efficiency, reasonably utilize manpower resource and realize cycle-based production.
Description
Technical field
The present invention relates to a kind of bogie frame robot welding system and method, belong to vehicle body of railway vehicle manufacturing technology field.
Background technology
At present, welding robot progressively gets into domestic rolling stock and makes the field, and in the welding production process of bogie frame, is used.But at present employed robot all is that form with unit exists in framework welding production process, and every equipment all need be equipped with 1-2 operator and operate; The overhead traveling crane handling is adopted in loading and unloading; The clamping of anchor clamps, unclamp all and to adopt manual operations, non-cutting time is long, has reduced production efficiency.In addition, the program of framework welding adopts manual calling fully, when the operation simultaneously of many kinds, has the possibility of using wrong program owing to human error, has not only reduced production efficiency, has also improved percent defective, has increased manufacturing cost.For organization of production person, there is workpiece just to carry out weld job, just quitting work when not having workpiece is in wait state, and this operation and upper and lower operation do not have the notion of beat.
What time not enough the above-mentioned this mode of production that generally adopts at present is below existing:
(1) production efficiency is low: programmed method is single, outmoded, and the welded rails accuracy rate is low, and welding efficiency is low.
(2) human resources waste: for automated job equipment, be final goal generally to reach unmanned operation, but the above-mentioned this mode of production, every robot need be equipped with 1-2 name operating personnel, and the wasting of resources is obvious.
(3) non-cutting time is many: the clamping of work piece hoisting, workpiece and unclamping, all needing the people is manual working, needs a large amount of non-cutting times, and work piece hoisting uses overhead traveling crane, inevitably can have the invalid stand-by period of waiting for overhead traveling crane.
(4) produce clockless notion, Workpiece circulation speed is slow, and interim stock is many.
Summary of the invention
Main purpose of the present invention is to address the above problem, and provides a kind of production efficiency high, rationally utilizes human resources, realizes the bogie frame robot welding system that beat-type is produced.
Another main purpose of the present invention is to provide a kind of production efficiency high, rationally utilizes human resources, realizes the bogie frame automatic soldering method that beat-type is produced.
For realizing above-mentioned purpose, technical scheme of the present invention is:
A kind of bogie frame robot welding system, this system comprise the artificial material stock platform, the track that is used for the automatic travelling bogie that said workpiece is transported, said automatic travelling bogie operation usefulness between each equipment that are used for workpiece to be welded and prepare in advance, be used for said workpiece from said automatic travelling bogie take off and be transferred to the welding position clamping device, welding robot, be used to weld repair welding is carried out in the back to said workpiece buffer table and PLC master control system; Said artificial material stock platform and said clamping device are divided into the both sides of said track, are connected through industrial field bus between said PLC master control system and said automatic travelling bogie, welding robot, clamping device and the buffer table and control.
Further; Said automatic travelling bogie includes the vertical telescopic arm that can stretch in vertical direction, walking mechanism, controller and the display that can stretch the wall arm, walk in orbit to the flexible level in said track both sides in the horizontal direction; Said controller is connected with said PLC master control system, and said vertical telescopic arm, horizontal telescopic arm and walking mechanism are controlled by servomotor.
Further, said controller comprises that unusual urgency stops monitoring module, signal collection feedback communication module and SERVO CONTROL module.
Further, said clamping device comprises two the C type anchor clamps and the bases that are oppositely arranged, and two said C type anchor clamps are connected with said base through slew gear.
Further, said clamping device is provided with near sense switch.
Further, comprise the demonstration touch-screen in the said PLC master control system.
The welding method of the above-mentioned bogie frame robot welding system of a kind of foundation; A plurality of artificial stations and welding robot station branch are located at the both sides of the track that is used for transmitting workpiece; Progressively advance according to the technological process of workpiece logistics route, until the weld job of accomplishing said workpiece with " Z " font.
Further; Confirm total productive temp according to the technological process of workpiece to be welded; According to the total productive temp after confirming each operation is carried out operation again and cut apart, confirm the activity duration of each operation and the haulage time of workpiece, confirm the actuation time of each equipment thus.
Further; Said welding robot is in welding process, and the structural parameters with workpiece store to the control module of said welding robot in advance, and said welding robot is sought the welding starting point coordinate of workpiece automatically; According to the distance and the length of weld seam, weld again many weld seams are uninterrupted continuously.
Further, carry out many weld seams continuously during uninterrupted welding, adopt follow-up welding bead parameter to successively decrease gradually, simultaneously the technology that increases progressively gradually of speed of welding at said welding robot.
Content to sum up, a kind of bogie frame robot welding system of the present invention and method compared with prior art, have following advantage:
(1) each equipment in the welding system is controlled through the PLC master control system is unified; Be implemented in the time automatic loading/unloading of setting; Automatically welding through the utilization of automatic travelling bogie and clamping device, realizes beat-type production simultaneously when stopping the stand-by period; Rationally utilize human resources, increase substantially production efficiency.
(2) this welding system is realized the full-automatic operation of welding robot and workpiece transportation; According to the classification of work station, the kind of workpiece; Control program calls automatically, avoids human factor the mistake of routine call to occur, enhances productivity; Reduce production costs, welding efficiency can double automatically.
(3) automatically travelling bogie is controlled through controller automatically, and the workpiece transshipment area of centre is formed virtual fence, realizes the security logic design of unmanned operation, in conjunction with the use of other safety monitoring system, guarantees the safety of whole production line operation.
Description of drawings
Fig. 1 is a welding system General Arrangement of the present invention;
Fig. 2 is clamping device of the present invention and welding robot structural representation.
As depicted in figs. 1 and 2, artificial material stock platform 1, automatic travelling bogie 2, track 3, clamping device 4, welding robot 5, buffer table 6, PLC master control system 7, workpiece 8, C type anchor clamps 9 show touch-screen 10.
The specific embodiment
Below in conjunction with the accompanying drawing and the specific embodiment the present invention is described in further detail:
As shown in Figure 1; A kind of bogie frame robot welding system; Comprise artificial material stock platform 1, travelling bogie 2, track 3, clamping device 4, welding robot 5, buffer table 6 and PLC master control system 7 automatically, PLC is meant the programmable logic controller (PLC) of digital operation operation electronic system.
Artificial material stock platform 1 is to be used for the manual work station that workpiece 8 to be welded is prepared in advance; For example can on this station, carry out preparatory assembling or backing welding of workpiece 8 etc.; Prepare for robot 5 welding, artificial material stock platform 1 can be provided with one or more according to the operation needs of workpiece 8.
Automatically travelling bogie 2 includes the vertical telescopic arm that can stretch in vertical direction, walking mechanism, controller and the display that can stretch the wall arm, on track 3, walk to the flexible level in track 3 both sides in the horizontal direction, and display is used to show each control program of automatic travelling bogie 2 and starts automatic travelling bogie 2 operations.Wherein, vertical telescopic arm, horizontal telescopic arm and walking mechanism are controlled by servomotor, and horizontal telescopic arm is driven by servomotor through belt, through the direction of rotation of controlling servomotor horizontal telescopic arm can be stretched to both sides.Controller is connected with PLC master control system 7; Inner Siemens's module and the PLC program used of controller; The action feature of the orbital motion when being defined in material-feeding and fetching in advance, vertical direction, horizontal direction, and utilize inner communication module to realize and the communicating by letter of PLC master control system 7 is in conjunction with the time setting of the upper and lower material of PLC master control system 7; Realize automatic upper and lower material, promptly realize the full-automatic logistics program.
Comprise in the controller that unusual urgency stops monitoring module, signal collection feedback communication module and SERVO CONTROL module.Automatically travelling bogie 2 is controlled through controller automatically, and workpiece 8 transshipment areas of centre are formed virtual fence, realizes the security logic design of unmanned operation, in conjunction with the use of other safety monitoring system, guarantees the safety of whole production line operation.
Clamping device 4 is arranged at the opposite side of track 3, and clamping device 4 clamps workpiece 8 from the automatic travelling bogie 2 and takes off, and is transferred to the required welding position of welding robot 5; Satisfying under the primary conditions such as access for welding, place restriction, as shown in Figure 2, clamping device 4 adopts double C-type revolution exchange positioner; Be that clamping device 4 is made up of two C type anchor clamps 9 and base (not shown)s that are oppositely arranged; Two C type anchor clamps 9 are connected with base through slew gear, and slew gear can adopt any structure of the prior art, and C type anchor clamps 9 can be in 180 degree direction internal conversion positions; One of them C type anchor clamps 9 is used for upper and lower material; Another C type anchor clamps 9 weld, and guarantee robot 5 uninterrupted operations, to enhance productivity.The quantity of clamping device 4 is consistent with the quantity of robot 5, and the station place of each robot 5 is all corresponding to be provided with a clamping device 4.What 9 pairs of workpiece of these anchor clamps 8 adopted is the mode of bilateral clamping; The torsional deformation that can avoid workpiece 8 in the turntable rotary course, to be produced as much as possible; And all be the mode that adopts monolateral clamping in the prior art; Be an end of an anchor clamps clamping work pieces 8, workpiece can produce defectives such as torsional deformation when turntable rotated like this.
Whether clamping device 4 is provided with near sense switch, can be ultrasonic sensing switch of the prior art, infra-red sensor switch etc. near sense switch, be used to respond to workpiece 8 put in place; When automatic travelling bogie 2 is transported to clamping device 4 positions with workpiece 8, near sense switch clamping workpiece 8 whether in the induction anchor clamps 9 this moment automatically, if there is not clamping workpiece 8; Can signal be transferred to PLC master control system 7, PLC master control system 7 can transfer to signal the controller of automatic travelling bogie 2, and the horizontal telescopic arm of controller control stretches out to the direction of anchor clamps 9; At this moment; Anchor clamps 9 unclamp and put in place, can respond to the existence of workpiece 8 equally near sense switch, and anchor clamps 9 are clamping work pieces 8 again; 8 clampings of workpiece on the dolly 2 are taken off; And the Rotate 180 degree, workpiece 8 is transferred to the welding position of welding robot 5, weld by 5 pairs of workpiece 8 of welding robot.
Buffer table 6 is to be used to weld repair welding is carried out in the back to workpiece 8 manual work station; With artificial material stock platform 1 a same side that is arranged on track 3; Workpiece 8 after robot 5 welding is transported to buffer table 6 by dolly 2, on buffer table 6, carries out other operations such as repair welding, polishing.
In robot welding system, establish steel construction respectively, as crane girder; The manual work station is formed an operation unit according to layout characteristics with 4～6 operation stations, is equipped with one in 2T crane in each operation unit, is used for the transportation of operation unit to automatic logistics feed inlet and outlet.
In this welding system; For solving the connectivity problem of manual work station and full-automatic operation station; A plurality of artificial stations such as artificial material stock platform 1, buffer table 6 and welding robot 5 station branches are located at the both sides of the track 3 that is used for transmitting workpiece 8; Progressively advance according to the technological process of workpiece 8 logistics route, until the weld job of accomplishing workpiece 8 with " Z " font.Like this, just can rationally utilize human resources, enhance productivity, also help following beat-type production.
Confirm total productive temp according to the technological process of workpiece 8 to be welded; As to set productive temp be 4 hours/framework, according to the total productive temp after confirming, each operation carried out operation cut apart again; Confirm the activity duration of each operation and the haulage time of workpiece 8; Confirm the actuation time of each equipment thus, and realize beat logistics, produce by beat logistics pulling by 7 controls of PLC master control system.
PLC master control system 7 with automatically be connected through industrial field bus (profibus) between travelling bogie 2, welding robot 5, clamping device 4 and the buffer table 6 and control, PLC master control system 7 set inside have actuation time, loading and unloading security logic, put in order line security monitoring logic and realize the robot grid and the transition of communications of PLC master control system 7.
In order to use the operator easy to use, in PLC master control system 7, comprise showing touch-screen 10, operating personnel only need be according to the kind and the technological requirement of workpiece 8, and the button that touches on the touch-screen gets final product.
In this welding system, be provided with time management unit in the PLC master control system 7, comprising system counter is arranged, after artificial startup, system counter counts from zero; Utilize touch screen interface artificially to set the triggered time of dolly 2 again, when the triggered time is identical with the system counter time, trigger dolly 2 operations; After dolly 2 triggered motion, when causing flow process to continue because of reasons such as no workpiece 8, system counter time to the triggered time was the stand-by period, is accumulated in total duty cycle.Through the management of time, hold the condition of production in the entire job cycle; To the setting in each operation triggered time, be implemented in official hour specific workpiece 8 is delivered to appointed positions.
In whole system; Form an independent network through common grid line between the main frame of a plurality of robots 5; Be used to collect the status signal of robot 5; Therefore the communication pattern that the communication pattern of this network is connected with industrial field bus there are differences, and needs to use modular converter, and that guarantees to intercom mutually is unobstructed.
Signal comprises two kinds:
Status signal: when each PLC go the rounds scanning, limit signal, the emergency stop device signal of robot 5 work stations, travelling bogie returned PLC master control system 7, PLC master control system 7 is through the logical combination to these signals, the realization sequential control.
The triggering signal that PLC master control system 7 is sent: triggering signal comprises the signal of workpiece 8 transportation actuating signals and robot 5.Robot 5 signals mainly are work station locking, anchor clamps 9 automatic clampings or unlock signal and call corresponding welding procedure signal automatically; Workpiece 8 transportation signals mainly are to connect to raise clothes control system, make the logic motion of CD-ROM drive motor according to design in advance.
In this welding system, be provided with security control unit in the PLC master control system 7, the security logic design comprises security logic design, the logical design of control security of system, whole unmanned operation district Safety Design three parts of workpiece travelling bogie 2.Guarantee loading and unloading position of foetus state meet the requirements (position of foetus can not be sky when the position of foetus was for empty, blanking during material loading) carry out the loading and unloading action again; Guarantee that robot 5 is in a safe condition when loading and unloading, function is locking loading and unloading work station, confirms that the state of work station meets the demands; Guardrail and electronic lock are equipped with in both sides, moving region at travelling bogie 2, when each electronic lock all locks, think unmanned in this zone, and when electronic lock was opened, the workpiece conveying arrangement was with out of service.
This welding system is realized the full-automatic operation of welding robot and workpiece transportation, and according to the classification of work station, the kind of workpiece, control program calls automatically; Avoid human factor the mistake of routine call to occur; Enhance productivity, reduce production costs, welding efficiency can double automatically.This welding system and method have realized full-automation, through the design of automatic material flow, accomplish a stream, and realize the beat-type production of whole production line and effectively reduced the handling stand-by period; After realizing the work pattern of a stream in the logistics, workpiece 8 rate flows increase, and are example with EMUs bogie frame of new generation, and the whole manufacturing cycle shortens 7 days.
Be that example specifies this welding method with the crossbeam welding process flow below:
Prior art middle cross beam welding process flow is:
The assembling of crossbeam--artificial welding beam--polishing of welding back weld seam---flaw detection.
Adopt the technological process after welding system of the present invention and the method to be:
(1) assembling of crossbeam, this operation is accomplished at artificial material stock platform 1 place.
(2) artificial backing welding is at first carried out in uneven place, workpiece 8 commissures, this operation is also accomplished at artificial material stock platform 1 place.
(3) operating personnel operate PLC master control system 7, start relative program, and travelling bogie 2 is transported to workpiece 8 at clamping device 4 places of welding robot 5 correspondences automatically; In the clamping device 4 confirm on the anchor clamps 9 no workpiece 8 near sense switch the time; Unclamp anchor clamps 9, the workpiece on the dolly 28 is clamped take off, behind the Rotate 180 degree; Workpiece 8 is transferred to the welding position of welding robot 5, and robot 8 welds by the welding procedure that sets in the PLC master control system 7.
(4) after welding was accomplished, clamping device 4 is the Rotate 180 degree again, and workpiece 8 is transferred to the position that dolly 2 can be got material, and dolly 2 takes off workpiece 8 from anchor clamps 9, and dolly 2 is transported to corresponding buffer table 6 places with workpiece 8 again.Again to robot 5 welding less than the position carry out artificial local repair welding.
(5) weld the afterwards polishing and the flaw detection of weld seam at last.
Though flow process is more complicated after adopting welding system of the present invention and method; But along with the dispersion of operation workload, the workload of each operation station is balance more, and crossbeam is formed realization mechanism hand and welded automatically; The manual work amount significantly reduces, and also can improve welding quality and production efficiency.
As stated, in conjunction with the given scheme content of accompanying drawing, can derive the similar techniques scheme.In every case be the content that does not break away from technical scheme of the present invention, to any simple modification, equivalent variations and modification that above embodiment did, all still belong in the scope of technical scheme of the present invention according to technical spirit of the present invention.
Claims (10)
1. bogie frame robot welding system is characterized in that: this system comprises the artificial material stock platform, the track that is used for the automatic travelling bogie that said workpiece is transported, said automatic travelling bogie operation usefulness between each equipment that are used for workpiece to be welded and prepare in advance, be used for said workpiece from said automatic travelling bogie take off and be transferred to the welding position clamping device, welding robot, be used to weld repair welding is carried out in the back to said workpiece buffer table and PLC master control system; Said artificial material stock platform and said clamping device are divided into the both sides of said track, are connected through industrial field bus between said PLC master control system and said automatic travelling bogie, welding robot, clamping device and the buffer table and control.
2. bogie frame robot welding system according to claim 1; It is characterized in that: said automatic travelling bogie includes the vertical telescopic arm that can stretch in vertical direction, walking mechanism, controller and the display that can stretch the wall arm, walk in orbit to the flexible level in said track both sides in the horizontal direction; Said controller is connected with said PLC master control system, and said vertical telescopic arm, horizontal telescopic arm and walking mechanism are controlled by servomotor.
3. bogie frame robot welding system according to claim 2 is characterized in that: said controller comprises that unusual urgency stops monitoring module, signal collection feedback communication module and SERVO CONTROL module.
4. bogie frame robot welding system according to claim 1 is characterized in that: said clamping device comprises two the C type anchor clamps and the bases that are oppositely arranged, and two said C type anchor clamps are connected with said base through slew gear.
5. bogie frame robot welding system according to claim 4 is characterized in that: said clamping device is provided with near sense switch.
6. bogie frame robot welding system according to claim 1 is characterized in that: comprise the demonstration touch-screen in the said PLC master control system.
7. welding method according to the described bogie frame robot welding system of claim 1; It is characterized in that: the both sides that a plurality of artificial stations and welding robot station branch are located at the track that is used for transmitting workpiece; Progressively advance according to the technological process of workpiece logistics route, until the weld job of accomplishing said workpiece with " Z " font.
8. welding method according to claim 7; It is characterized in that: confirm total productive temp according to the technological process of workpiece to be welded; According to the total productive temp after confirming each operation being carried out operation again cuts apart; Confirm the activity duration of each operation and the haulage time of workpiece, confirm the actuation time of each equipment thus.
9. welding method according to claim 7; It is characterized in that: said welding robot is in welding process; Structural parameters with workpiece store to the control module of said welding robot in advance; Said welding robot is sought the welding starting point coordinate of workpiece automatically, according to the distance and the length of weld seam, welds many weld seams are uninterrupted continuously again.
10. welding method according to claim 9 is characterized in that: carry out many weld seams continuously during uninterrupted welding at said welding robot, adopt follow-up welding bead parameter to successively decrease gradually, simultaneously the technology that increases progressively gradually of speed of welding.
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| CN201110126512.9A CN102785042B (en) | 2011-05-16 | 2011-05-16 | Automatic welding system for truck frame |
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| CN201110126512.9A CN102785042B (en) | 2011-05-16 | 2011-05-16 | Automatic welding system for truck frame |
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Cited By (13)
| Publication number | Priority date | Publication date | Assignee | Title |
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| CN104330414A (en) * | 2014-11-19 | 2015-02-04 | 柳州市骏信金属制品有限责任公司 | Automatic-induction detector |
| CN104401678A (en) * | 2014-09-22 | 2015-03-11 | 南车青岛四方机车车辆股份有限公司 | Full-automatic intelligent workpiece conveying method |
| CN104785939A (en) * | 2015-04-20 | 2015-07-22 | 骏马石油装备制造有限公司 | Automatic welding working station for prying base of steam-injection boiler unit and machining technology thereof |
| CN104801869A (en) * | 2015-03-20 | 2015-07-29 | 蓝姆汽车焊接设备(上海)有限公司 | Automatic welding production line of car wheel casing and production method thereof |
| CN106112330A (en) * | 2016-08-29 | 2016-11-16 | 中车青岛四方机车车辆股份有限公司 | Lateral beam of bogie automatic assembly system |
| CN106181152A (en) * | 2016-08-29 | 2016-12-07 | 中车青岛四方机车车辆股份有限公司 | Bogie frame automatic setup system |
| CN106736116A (en) * | 2016-12-29 | 2017-05-31 | 南京臻铭信机电科技有限公司 | Robot automatic welding production line based on central computer Automatic Control |
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| CN110666380A (en) * | 2019-09-29 | 2020-01-10 | 中车青岛四方机车车辆股份有限公司 | Assembly welding device, assembly welding system and assembly welding method for bogie frame |
| CN112743272A (en) * | 2020-12-31 | 2021-05-04 | 真木农业设备（安徽）有限公司 | Automatic welding system |
| CN113681115A (en) * | 2021-09-28 | 2021-11-23 | 中车长春轨道客车股份有限公司 | Process for assembling and welding brake pad supporting and hanging seat and framework of bogie of motor train unit with circumferential weld seam |
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| CN117102755A (en) * | 2023-10-20 | 2023-11-24 | 江苏中车数字科技有限公司 | Automatic welding station feeding and discharging scheduling system and method suitable for frame production |
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| CN110666380B (en) * | 2019-09-29 | 2021-06-08 | 中车青岛四方机车车辆股份有限公司 | Assembly welding device, assembly welding system and assembly welding method for bogie frame |
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| CN113681115A (en) * | 2021-09-28 | 2021-11-23 | 中车长春轨道客车股份有限公司 | Process for assembling and welding brake pad supporting and hanging seat and framework of bogie of motor train unit with circumferential weld seam |
| CN113681115B (en) * | 2021-09-28 | 2022-08-02 | 中车长春轨道客车股份有限公司 | Process for assembling and welding brake pad supporting and hanging seat and framework of bogie of motor train unit with circumferential weld seam |
| CN114850722A (en) * | 2022-06-21 | 2022-08-05 | 镇江宏联电工有限公司 | Welding set for pressure switch based on manipulator clamping location |
| CN117102755A (en) * | 2023-10-20 | 2023-11-24 | 江苏中车数字科技有限公司 | Automatic welding station feeding and discharging scheduling system and method suitable for frame production |
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