CN110270743B - Robot automatic welding system for PTA process and use method thereof - Google Patents

Robot automatic welding system for PTA process and use method thereof Download PDF

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Publication number
CN110270743B
CN110270743B CN201910658892.7A CN201910658892A CN110270743B CN 110270743 B CN110270743 B CN 110270743B CN 201910658892 A CN201910658892 A CN 201910658892A CN 110270743 B CN110270743 B CN 110270743B
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China
Prior art keywords
welding
robot
cabinet
powder feeder
switch
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CN110270743A (en
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孙骞
杨修荣
石少坚
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Funis Nanjing Pipeline Technology Co ltd
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Funis Nanjing Pipeline Technology Co ltd
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    • BPERFORMING OPERATIONS; TRANSPORTING
    • B23MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23KSOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K9/00Arc welding or cutting
    • B23K9/16Arc welding or cutting making use of shielding gas
    • B23K9/167Arc welding or cutting making use of shielding gas and of a non-consumable electrode
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B23MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23KSOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K9/00Arc welding or cutting
    • B23K9/32Accessories
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B23MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23KSOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K9/00Arc welding or cutting
    • B23K9/32Accessories
    • B23K9/325Devices for supplying or evacuating shielding gas
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B25HAND TOOLS; PORTABLE POWER-DRIVEN TOOLS; MANIPULATORS
    • B25JMANIPULATORS; CHAMBERS PROVIDED WITH MANIPULATION DEVICES
    • B25J11/00Manipulators not otherwise provided for

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Physics & Mathematics (AREA)
  • Plasma & Fusion (AREA)
  • Robotics (AREA)
  • Arc Welding In General (AREA)
  • Arc Welding Control (AREA)

Abstract

The invention discloses a robot automatic welding system for a PTA process, which comprises a control system, a welding system and a traveling system, wherein the control system comprises a cabinet and a control box; the welding system comprises a gas cylinder, a plasma generator, an alternating current-direct current TIG welding machine, a refrigerating water tank, a welding gun, a powder feeder frame and a transfer box; the walking system comprises a robot control cabinet, a demonstrator, a robot, an external shaft and a tool chuck. Methods of using the welding system are also disclosed. The invention can effectively reduce the dependence of welding on people, reduces the operation difficulty, is convenient to use, and has high welding efficiency and good quality.

Description

Robot automatic welding system for PTA process and use method thereof
Technical Field
The invention relates to the field of welding, in particular to a robot automatic welding system for a PTA process and a using method thereof.
Background
At present, the exploitation drill bit in industries such as petroleum exploitation, mining machinery, coal exploitation and the like needs to have a hard wear-resistant layer, the hardness needs to reach HRC50-60, and the wear-resistant layer material is difficult to be drawn into a welding wire due to higher hardness, and is mainly made of powder materials. The flame spray welding is mainly used for the transition process of the high-hardness material which needs impact resistance in the current market, and the transition process is manually operated, so that the following problems are easily caused in the construction process:
1. the welding efficiency is low, and the whole workpiece is reddened during the spray welding due to the operation of personnel during the flame spray welding, so that the time for waiting for the interlayer temperature is needed for preventing the flowing after the spray welding is finished at one position.
2. The welding quality is unstable, influence factors are many due to the relation of personnel operation during spray welding, the qualification rate of the artificial flame spray welding petroleum drilling bit is only about 75 percent according to incomplete statistics, the reworking rate is higher, and delamination is the main factor.
3. The operation environment is bad, the oxygen acetylene flame is adopted during spray welding, the environmental temperature is more than 40 ℃ during summer operation, and professional health cannot be guaranteed.
4. The safety coefficient is low, and flame spray welding flame is oxyacetylene flame, which is easy to generate tempering.
5. The difficulty of process operation is high, the dependence of purely manual operation on operators is high, and the operation experience is rich due to the relationship of fire and weather.
Disclosure of Invention
The invention aims to: aiming at the defects and shortcomings of the prior art, the invention provides the robot automatic welding system for the PTA process, which can effectively reduce the dependence of welding on people, reduce the operation difficulty, is convenient to use, and has high welding efficiency and good quality, and the use method thereof.
The technical scheme is as follows: the invention relates to a robot automatic welding system for a PTA process, which is characterized in that: the welding system comprises a control system, a welding system and a traveling system, wherein the control system comprises a cabinet and a control box;
the welding system comprises a gas cylinder, a plasma generator, an alternating current-direct current TIG welding machine, a refrigerating water tank, a welding gun, a powder feeder frame and a transfer box; the gas cylinder is respectively connected with the plasma generator, the alternating current-direct current TIG welder and the refrigerating water tank through the relay wire; the plasma generator is connected with the alternating current-direct current TIG welding machine through a welding gun cable, and the welding gun cable, the transfer box and the welding gun are sequentially connected; the welding gun is connected with the powder feeder through a powder feeding pipe, the powder feeder is connected with the powder feeder frame through a clamp holder II, and the powder feeder is connected with the welding gun through a powder feeder relay line;
the walking system comprises a robot control cabinet, a demonstrator, a robot, an external shaft and a tool chuck; the robot control cabinet is connected with the cabinet through a communication line I and connected with the control box through a communication line II, the top of the robot control cabinet is connected with the demonstrator, and the demonstrator controls the positions of the robot and the external shaft; the robot is connected with the control box through a communication line III and is connected with an external shaft through a communication line IV; the top of the outer shaft is provided with a tool chuck for fixing a workpiece.
The side part of the cabinet is connected with an external power supply through a 380V electric plug, the cabinet is provided with a computer screen, a door handle, a main switch and an emergency stop switch II, and the cabinet is provided with an indication lamp I which is lighted in use, an indication lamp II which is lighted in suspension and an indication lamp III which is lighted in error.
The cabinet feeds signals back to the computer screen through the PLC system module.
Wherein, the control box is provided with an electric switch I, an electric switch II and an emergency stop switch I.
The robot is provided with a clamp I, and a positioning pin hole for fixing the welding gun is formed in the clamp I.
Wherein the robot is a six-axis robot and the external axis is a two-axis positioner.
Wherein, the installation position of the external shaft is in the travel range of the robot.
The tool chuck is a four-jaw chuck and is concentric with the rotating shaft.
Wherein, the installation position of the powder feeder is higher than the installation position of the welding gun by more than 500mm, and the top of the powder feeder is provided with a cover.
The application method of the robot automatic welding system for the PTA process is characterized in that: comprising the following steps:
(1) The 380V electric plug is connected with an external power supply, a main switch on the cabinet is opened, and the welding system is powered;
(2) Mounting a workpiece to be welded on a tool chuck of an external shaft of the robot, rotating the tool chuck to screw the workpiece to be concentric with the tool chuck, and if the workpiece is non-circular, directly placing the workpiece on the tool chuck;
(3) 9TCP of the robot is written by using a demonstrator, the precision is ensured to be within 1mm, and the robot is written to cooperate with an external shaft to ensure that the cooperation precision is ensured to be within 2 mm;
(4) Controlling a robot and an external shaft through a demonstrator, debugging a robot program of a workpiece to be welded, editing a welding program, and completing adjustment and determination of welding parameters on an AC/DC TIG welder and a plasma generator panel;
(5) Opening a cover on the powder feeder, and pouring powder into the powder feeder;
(6) Installing a pressure reducing gauge on the surface of the gas cylinder, and adjusting the pressure of the pressure gauge to be 0.4-06 mpa;
(7) Opening a switch of the gas bottle to enable gas of one bottle body to be independently led to the plasma generator, and controlling the gas flow by the plasma generator and directly transmitting the gas flow to the welding gun;
(8) Opening a switch of the gas bottle to enable the other bottle body to be connected with an alternating current-direct current TIG welding machine for gas diversion, wherein one path is powder feeding gas which is directly connected with a powder feeding device after controlling the gas flow through the alternating current-direct current TIG welding machine, and the other path is welding gun protecting gas which is connected with a welding gun protecting gas after controlling the gas flow through the alternating current-direct current TIG welding machine;
(9) Opening a switch of the refrigeration water tank, wherein a flow alarm is arranged at the water inlet, so that one path of water body is connected to a welding gun through the flow alarm, and the other path is connected to a tool chuck of an external shaft;
(10) Setting a welding program on a computer screen of the cabinet, and controlling the whole welding;
(11) The operation modes of the demonstrator and the robot control cabinet are adjusted to be in an automatic state, and an electric switch I of a control box is used for supplying power and starting welding;
(12) When a problem is encountered in the welding process, stopping is performed through a scram switch I on the control box or a scram switch II on the cabinet;
(13) After welding is finished, detecting a welding seam, and finishing welding operation after the welding seam is qualified.
The beneficial effects are that: compared with the prior art, the invention has the following remarkable advantages: under the condition of product specification agreement, the invention can completely realize full-automatic welding, has stable welding quality, improves the welding efficiency by more than 50 percent, reduces the operation difficulty of personnel, and ensures that an operator can realize automatic welding by pressing one button; in addition, the working environment is good, the energy is saved, the safety is realized, the materials are saved, the use is reliable, and the device has the characteristics of reliable use, recycling and the like.
Drawings
FIG. 1 is a schematic diagram of the structure of the present invention;
in the drawing, a cabinet is 1, a robot control cabinet is 2, a demonstrator is 3, a control box is 4, a gas cylinder is 5, a plasma generator is 6, an alternating current-direct current TIG welding machine is 7, a refrigerating water tank is 8, a robot is 9, a welding gun is 10, an external shaft is 11, a tool chuck is 12, a powder feeder is 13, a powder feeder frame is 14, a communication line I is 15, a communication line II is 16, a communication line III is 17, a welding gun cable is 18, a powder feeder relay line is 19, a communication line IV is 20, a relay line is 21, an electric switch I is 22, a power switch II is 23, a scram switch I is 24, a main switch is 25, a computer screen is 26, a door handle is 27, a transfer box is 29, a holder I is 30, a powder feeder pipe is 31, a cover is 32, a positioning pin hole is 33, an indicator lamp I is 34, an indicator lamp II is 35, an indicator lamp III is 36, a scram switch II is 37, and a 380V electric plug is provided.
Detailed Description
The technical scheme of the invention is further described below with reference to the accompanying drawings and the specific embodiments.
The invention relates to a robot automatic welding system for a PTA process, which is characterized in that: the welding device comprises a control system, a welding system and a traveling system, wherein the control system comprises a cabinet 1 and a control box 4; the welding system comprises a gas cylinder 5, a plasma generator 6, an alternating current-direct current TIG welding machine 7, a refrigerating water tank 8, a welding gun 10, a powder feeder 13, a powder feeder frame 14 and a transfer box 28; the gas cylinder 5 is respectively connected with the plasma generator 6, the alternating current-direct current TIG welding machine 7 and the refrigeration water tank 8 through the relay line 21; the plasma generator 6 is connected with the alternating current-direct current TIG welding machine 7 through a welding gun cable 18, and the welding gun cable 18 and a transfer box 28 are sequentially connected with the welding gun 10; the welding gun 10 is connected with the powder feeder 13 through a powder feeder pipe 30, the powder feeder 13 is connected with the powder feeder frame 14 through a clamp holder II32, and the powder feeder 13 is connected with the welding gun 10 through a powder feeder relay wire 19; the walking system comprises a robot control cabinet 2, a demonstrator 3, a robot 9, an external shaft 11 and a tool chuck 12; the robot control cabinet 2 is connected with the cabinet 1 through a communication line I15 and is connected with the control box 4 through a communication line II16, the top of the robot control cabinet 2 is connected with the demonstrator 3, and the demonstrator 3 controls the positions of the robot 9 and the external shaft 11; the robot 9 is connected with the control box 4 through a communication line III17 and is connected with the external shaft 11 through a communication line IV 20; the top of the outer shaft 11 is provided with a tool chuck 12 for fixing a workpiece. The side part of the cabinet 1 is connected with an external power supply through a 380V electric plug 38, the cabinet 1 is provided with a computer screen 26, a door handle 27, a main switch 25 and an emergency stop switch II37, and the cabinet 1 is provided with an indication lamp I34 which is lighted in use, an indication lamp II35 which is lighted in suspension and an indication lamp III36 which is lighted in error; the cabinet 1 feeds back signals to the computer screen 26 through the PLC system module; the control box 4 is provided with an electric switch I22, an electric switch II23 and a scram switch I24; the robot 9 is provided with a holder I29 and a positioning pin hole 33 for fixing the welding gun 10 is arranged on the holder I29; the robot 9 is a six-axis robot and the external axis 11 is a two-axis positioner; the mounting position of the outer shaft 11 is within the stroke range of the robot 9; the tool chuck 12 is a four-jaw chuck, and the tool chuck 12 is concentric with the rotating shaft; the mounting position of the powder feeder 13 is 500mm higher than the mounting position of the welding gun 10, and a cover 31 is arranged on the top of the powder feeder 13.
A method of using a robotic automated welding system for a PTA process, comprising the steps of:
(1) The 380V electric plug 38 is connected to an external power supply, the main switch 25 on the cabinet 1 is opened, and the whole welding system is powered;
(2) Mounting a workpiece to be welded on a tool chuck 12 of an external shaft 11 of the robot 9, rotating the tool chuck 12 to screw the workpiece concentric with the tool chuck 12, and if the workpiece is non-circular, directly placing the workpiece on the tool chuck 12;
(3) The demonstrator 3 is used for writing a TCP of the robot 9, the precision is guaranteed to be within 1mm, the robot 9 and the external shaft 11 are written to cooperate with the TCP, and the cooperation precision is guaranteed to be within 2 mm;
(4) Controlling a robot 9 and an external shaft 11 through a demonstrator 3, debugging a robot program of a workpiece to be welded, editing a welding program, and completing adjustment and determination of welding parameters on panels of an alternating current-direct current TIG welding machine 7 and a plasma generator 6;
(5) Opening the cover 31 on the powder feeder 13 to pour the powder into the powder feeder 13;
(6) Installing a pressure reducing gauge on the surface of the gas cylinder 5, and adjusting the pressure of the pressure gauge to be 0.4-06 mpa;
(7) Opening a switch of the gas bottle 5 to enable gas of one bottle body to be independently led to the plasma generator 6, and controlling the gas flow by the plasma generator 6 and directly transmitting the gas flow to the welding gun 10;
(8) Opening a switch of the gas bottle 5 to enable the other bottle body to be connected with the alternating current-direct current TIG welding machine 7 for gas diversion, wherein one path is powder feeding gas which is directly connected with the powder feeding device 13 after controlling the gas flow through the alternating current-direct current TIG welding machine 7, and the other path is connected with the protective gas of the welding gun 10, and is connected to the protective gas of the welding gun 10 after controlling the gas flow through the alternating current-direct current TIG welding machine 7;
(9) Opening a switch of the refrigeration water tank 8, arranging a flow alarm at the water inlet, enabling one path of water body to be connected into the welding gun 10 through the flow alarm, and the other path to be connected into the tool chuck 12 of the external shaft 11;
(10) Setting a welding program on a computer screen 26 of the cabinet 1 to control the whole welding;
(11) The operation mode of the demonstrator 3 and the robot control cabinet 2 is adjusted to be an automatic state, and an electric switch I22 of the control box 4 is used for supplying power and starting welding;
(12) Problems are encountered in the welding process, and stopping is carried out through a scram switch I24 on the control box 4 or a scram switch II37 on the cabinet 1;
(13) After welding is finished, detecting a welding seam, and finishing welding operation after the welding seam is qualified.

Claims (6)

1. A automatic welding system of robot for PTA technology, its characterized in that: the welding device comprises a control system, a welding system and a traveling system, wherein the control system comprises a cabinet (1) and a control box (4);
the welding system comprises a gas cylinder (5), a plasma generator (6), an alternating current-direct current TIG welding machine (7), a refrigerating water tank (8), a welding gun (10), a powder feeder (13), a powder feeder frame (14) and a transfer box (28); the gas cylinder (5) is respectively connected with the plasma generator (6), the alternating current-direct current TIG welding machine (7) and the refrigeration water tank (8) through a relay line (21); the plasma generator (6) is connected with the alternating current-direct current TIG welding machine (7) through a welding gun cable (18), and the welding gun cable (18) and the transfer box (28) are sequentially connected with the welding gun (10); the welding gun (10) is connected with the powder feeder (13) through a powder feeder pipe (30), the powder feeder (13) is connected with the powder feeder frame (14) through a clamp holder II (32), and the powder feeder (13) is connected with the welding gun (10) through a powder feeder relay line (19);
the walking system comprises a robot control cabinet (2), a demonstrator (3), a robot (9), an external shaft (11) and a tool chuck (12); the robot control cabinet (2) is connected with the cabinet (1) through a communication line I (15) and is connected with the control box (4) through a communication line II (16), the top of the robot control cabinet (2) is connected with the demonstrator (3), and the demonstrator (3) controls the positions of the robot (9) and the external shaft (11); the robot (9) is connected with the control box (4) through a communication line III (17) and is connected with the external shaft (11) through a communication line IV (20); the top of the outer shaft (11) is provided with a tool chuck (12) for fixing a workpiece;
the side part of the cabinet (1) is connected with an external power supply through a 380V electric plug (38), the cabinet (1) is provided with a computer screen (26), a door handle (27), a main switch (25) and an emergency stop switch II (37), and the cabinet (1) is provided with an indication lamp I (34) which is lighted in use, an indication lamp II (35) which is lighted in suspension and an indication lamp III (36) which is lighted in error; the cabinet (1) feeds signals back to a computer screen (26) through a PLC system module; the control box (4) is provided with an electric switch I (22), an electric switch II (23) and an emergency stop switch I (24); the installation position of the powder feeder (13) is 500mm higher than the installation position of the welding gun (10), and the top of the powder feeder (13) is provided with a cover (31).
2. The robotic automated welding system for the PTA process of claim 1, wherein: the robot (9) is provided with a clamp holder I (29) and a positioning pin hole (33) for fixing the welding gun (10) is arranged on the clamp holder I (29).
3. The robotic automated welding system for the PTA process of claim 1, wherein: the robot (9) is a six-axis robot and the external shaft (11) is a two-axis positioner.
4. The robotic automated welding system for the PTA process of claim 1, wherein: the installation position of the external shaft (11) is within the travel range of the robot (9).
5. The robotic automated welding system for the PTA process of claim 1, wherein: the tool chuck (12) is a four-jaw chuck, and the tool chuck (12) is concentric with the rotating shaft.
6. The method of using a robotic automated welding system for a PTA process according to claim 1, wherein: comprising the following steps:
(1) The 380V electric plug (38) is connected to an external power supply, a main switch (25) on the cabinet (1) is opened, and the whole welding system is powered;
(2) Mounting a workpiece to be welded on a tool chuck (12) of an external shaft (11) of the robot (9), rotating the tool chuck (12) to screw the workpiece concentric with the tool chuck (12), and if the workpiece is non-circular, directly placing the workpiece on the tool chuck (12);
(3) The teaching device (3) is used for writing a TCP of the robot (9), the precision is guaranteed to be within 1mm, the robot (9) and the external shaft (11) are written to cooperate with the TCP, and the cooperation precision is guaranteed to be within 2 mm;
(4) Controlling a robot (9) and an external shaft (11) through a demonstrator (3), debugging a robot program of a workpiece to be welded, editing the welding program, and completing adjustment and determination of welding parameters on panels of an alternating current-direct current TIG welding machine (7) and a plasma generator (6);
(5) Opening a cover (31) on the powder feeder (13) and pouring powder into the powder feeder (13);
(6) Installing a pressure reducing gauge on the surface of a gas cylinder (5), and adjusting the pressure of the pressure gauge to be 0.4-06 mpa;
(7) Opening a switch of the gas bottle (5) to enable gas of one bottle body to be independently led to the plasma generator (6), and controlling the gas flow by the plasma generator (6) and directly transmitting the gas flow to the welding gun (10);
(8) Opening a switch of the gas bottle (5) to enable the other bottle body to be connected with an alternating current-direct current TIG welding machine (7) for gas splitting, wherein one path is powder feeding gas which is directly connected with a powder feeding device (13) after controlling the gas flow through the alternating current-direct current TIG welding machine (7), and the other path is connected with a welding gun (10) protective gas, and is connected to the welding gun (10) protective gas after controlling the gas flow through the alternating current-direct current TIG welding machine (7);
(9) Opening a switch of a refrigeration water tank (8), arranging a flow alarm at a water inlet, enabling one path of water body to be connected with a welding gun (10) through the flow alarm, and enabling the other path to be connected with a tool chuck (12) of an external shaft (11);
(10) A welding program is arranged on a computer screen (26) of the cabinet (1) to control the whole welding;
(11) The operation mode of the demonstrator (3) and the robot control cabinet (2) is adjusted to be an automatic state, and an electric switch I (22) of the control box (4) is used for supplying power and starting welding;
(12) Problems are encountered in the welding process, and stopping is carried out through a scram switch I (24) on the control box (4) or a scram switch II (37) on the cabinet (1);
(13) After welding is finished, detecting a welding seam, and finishing welding operation after the welding seam is qualified.
CN201910658892.7A 2019-07-22 2019-07-22 Robot automatic welding system for PTA process and use method thereof Active CN110270743B (en)

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* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN111558717B (en) * 2020-05-19 2023-04-28 中国人民解放军火箭军工程大学 Spare part micro-arc pulse plasma rapid additive manufacturing device and method
CN114083096B (en) * 2021-05-23 2022-11-08 福尼斯(南京)表面工程技术有限公司 Method for surfacing high-temperature-resistant wear-resistant hard alloy on surface of cutting edge of blow-in drill bit of steel mill
CN113814543B (en) * 2021-05-23 2022-10-14 福尼斯(南京)表面工程技术有限公司 PTA welding method of double-way powder feeding electric arc mixed powder alloying

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DE102013018331A1 (en) * 2013-10-31 2015-04-30 Linde Aktiengesellschaft Method for joining or separating workpieces that are not electrically conductive
CN205989108U (en) * 2016-09-12 2017-03-01 阳江东华激光智能科技有限公司 A kind of handle of a knife robot welding system
CN210231874U (en) * 2019-07-22 2020-04-03 福尼斯(南京)表面工程技术有限公司 A automatic welding system of robot for PTA technology

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* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN102489841A (en) * 2011-11-24 2012-06-13 重庆理工大学 Alloy powder filling tungsten argon arc welding method for aluminum alloys
DE102013018331A1 (en) * 2013-10-31 2015-04-30 Linde Aktiengesellschaft Method for joining or separating workpieces that are not electrically conductive
CN205989108U (en) * 2016-09-12 2017-03-01 阳江东华激光智能科技有限公司 A kind of handle of a knife robot welding system
CN210231874U (en) * 2019-07-22 2020-04-03 福尼斯(南京)表面工程技术有限公司 A automatic welding system of robot for PTA technology

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