CN111283309A - Method and system for welding pump wheel shaft sleeve of hydraulic torque converter - Google Patents
Method and system for welding pump wheel shaft sleeve of hydraulic torque converter Download PDFInfo
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- CN111283309A CN111283309A CN202010092141.6A CN202010092141A CN111283309A CN 111283309 A CN111283309 A CN 111283309A CN 202010092141 A CN202010092141 A CN 202010092141A CN 111283309 A CN111283309 A CN 111283309A
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K9/00—Arc welding or cutting
- B23K9/16—Arc welding or cutting making use of shielding gas
- B23K9/173—Arc welding or cutting making use of shielding gas and of a consumable electrode
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K37/00—Auxiliary devices or processes, not specially adapted to a procedure covered by only one of the preceding main groups
- B23K37/04—Auxiliary devices or processes, not specially adapted to a procedure covered by only one of the preceding main groups for holding or positioning work
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K9/00—Arc welding or cutting
- B23K9/32—Accessories
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Abstract
The invention provides a method and a system for welding a pump wheel shaft sleeve of a hydraulic torque converter, which comprises the following steps: step M1: a double-gun MAG welding is adopted to match with a servo rotating motor, and an upper clamping and pressing device and a lower clamping and pressing device are adopted to establish a hydraulic torque converter pump wheel shaft sleeve welding unit; step M2: clamping and positioning the pump wheel casing shaft sleeve with more than preset precision; step M3: continuously welding in segments by using MAG welding double guns; step M4: and data real-time acquisition and MES networked control are carried out, and the welding result information of the pump axle sleeve of the hydraulic torque converter is obtained. The qualification rate of the product of the invention basically reaches more than 99.8 percent. The whole system has the advantages of high welding efficiency, small welding deformation, stable and reliable welding quality, digital welding of the whole process, networked MES system control and calling of scanning formula data, elimination of the influence of human factors and convenience for product quality control and tracing. The invention has great popularization and application values from the aspects of process and economic benefit.
Description
Technical Field
The invention relates to a welding system and a welding method in the technical field of welding, in particular to a method and a system for welding a pump wheel shaft sleeve of a hydraulic torque converter.
Background
The current methods for welding the pump wheel shaft sleeve include laser welding, electron beam welding, MAG welding and other welding methods. The electron beam ring welding is carried out in a vacuum environment, the welding quality is high, and the appearance is attractive. However, vacuum pumping is required every time, so that the total welding time is not short and the investment cost is high, while the laser welding does not need vacuum pumping, but has the problems of rigorous assembly and operation conditions, high investment cost and the like. The conventional MAG welding mode has low investment cost, and along with the development of welding power supply technology, the MAG welding can also adopt higher welding speed, lower heat input and better welding quality, is simple and convenient to operate, and is an ideal welding method if the problems of weld forming and efficiency can be solved.
In patent document CN204524577, the sleeve structure is a flat welding structure, the thermal deformation is large, and the dimensional accuracy is difficult to ensure. Meanwhile, the shaft sleeve welding and clamping device is not provided with a central positioning device, a shaft sleeve pressing device, a jacking device for a pump wheel shell and a shaft sleeve and a circulating water cooling water device at the shaft sleeve welding position. The air cooling device beside the workpiece is far away from the welding position, so that when the welding heat is not completely transferred to the edge of the workpiece at the end of welding, the welding efficiency is greatly influenced if the workpiece needs to be taken away after being cooled, and the expected cooling effect cannot be generated if the workpiece is taken away immediately after the welding is finished.
Disclosure of Invention
Aiming at the defects in the prior art, the invention aims to provide a method and a system for welding a pump wheel shaft sleeve of a hydraulic torque converter.
The invention provides a method for welding a pump wheel shaft sleeve of a hydraulic torque converter, which comprises the following steps: step M1: a double-gun MAG welding is adopted to match with a servo rotating motor, and an upper clamping and pressing device and a lower clamping and pressing device are adopted to establish a hydraulic torque converter pump wheel shaft sleeve welding unit; step M2: clamping and positioning the pump wheel casing shaft sleeve with more than preset precision; step M3: continuously welding in segments by using MAG welding double guns; step M4: and data real-time acquisition and MES networked control are carried out, and the welding result information of the pump axle sleeve of the hydraulic torque converter is obtained.
Preferably, the step M2 includes: step M2.1: the pump wheel and the shaft sleeve are arranged on a supporting table surface, the shaft sleeve is positioned through the center of the shaft sleeve, then the rotary air claw rotates by 90 degrees to press the pump wheel shell, the middle cylinder ascends to a position to tightly push the end surface of the welding position of the pump wheel shell and the shaft sleeve, and the three-thimble outer jacking device ascends to tightly push the pump wheel shell; step M2.2: and locking the lifting cylinder in the middle of the hydraulic locking device, and finally pressing the pressing shaft sleeve by the pressing device.
Preferably, the step M3 includes: step M3.1: in the process of performing 200-degree girth welding by two guns, various welding is adopted in an arc starting section, a middle welding section and an arc closing section respectively; arc starting current (100-;
the arc striking adopts slightly high current and longer arc length, so that reliable arc striking is facilitated, and meanwhile, the filling amount is smaller, so that smooth and flexible transition of a welding line during arc striking is ensured. The fixed-point arc-closing is adopted, the arc pit is conveniently and well filled by lower arc-closing current, smaller voltage and longer arc-closing time, shrinkage cavity and arc pit crack generation are prevented, and the attractive weld forming and smooth transition are ensured. And the middle section is welded at a faster welding speed and a larger welding specification (the specification is welding current 205-.
The pulse welding method can accurately control the heat input quantity, ensure the penetration and accurately control the heat input quantity, and reduce the welding deformation.
Fixed-point arcing is adopted to ensure reliable arcing, the arc length is long, the current is small, the leakage and transition pile height of arcing spot welding can be avoided, and meanwhile, after the arcing is successful, the turntable rotates, so that the transition of the welding line in the overlap joint area of the arcing and the arc stopping is smooth and soft, and the overhigh metal of the welding line is avoided. The longer arc length has the effect of making the arc softer during arc striking and reducing splashing.
The arc is closed at fixed points by adopting small current and small voltage, so that the arc pit can be filled fully and uniformly without overhigh filling, and the solidification speed of a molten pool can be slowed down by longer arc closing time, thereby avoiding the crack defect of the arc pit.
The root of the directional groove of welding wire extension line, and skew 0.5mm to pump wheel shell direction a little to guarantee that the groove root fully melts through and reduce the welding seam metal of axle sleeve side simultaneously and pile high, make things convenient for subsequent manufacturing procedure of axle sleeve, for example high frequency induction etc..
Preferably, step M3 further includes: step M3.2: when welding, adopt the circulating water cooling device to take away the unnecessary heat near the welding position of pump wheel shell and axle sleeve fast, reduce the diffusion of unnecessary heat on the work piece to reduce the thermal contraction deformation that welding heat input brought effectively, control axle sleeve welded size precision.
Preferably, step M4 includes: step M4.1: before welding, a scanning gun scans two-dimensional codes of the pump wheel and the shaft sleeve to form a product type identification code; step M4.2: the PLC main controller is issued by the MES, and during welding, the main control system directly calls the formula data of the product according to the scanning code of the product; step M4.3: and starting welding, wherein in the welding process, the data acquisition unit acquires key process parameters such as current, voltage, welding speed and the like of the left and right welding power supplies, evaluates the product quality and sets out-of-tolerance alarm, when the set threshold value is exceeded, the system alarms and even stops welding, and meanwhile, the data acquisition system also reports corresponding welding parameters, equipment states and the like to the MES network control unit in real time. The whole process realizes whole-flow digitization and networked control, real-time collection and evaluation of welding key data and product quality tracing, and direct formula data calling based on scanning codes realizes scanning welding.
According to the invention, the welding system for the pump wheel shaft sleeve of the hydraulic torque converter comprises: module M1: establishing a hydraulic torque converter pump hub welding unit; module M2: clamping and positioning the pump wheel casing shaft sleeve with more than preset precision; module M3: continuously welding in segments by using MAG welding double guns; module M4: and data real-time acquisition and MES networked control are carried out, and the welding result information of the pump axle sleeve of the hydraulic torque converter is obtained.
Preferably, said module M2 comprises: module M2.1: the pump wheel and the shaft sleeve are arranged on a supporting table surface, the shaft sleeve is positioned through the center of the shaft sleeve, then the rotary air claw rotates by 90 degrees to press the pump wheel shell, the middle cylinder ascends to a position to tightly push the end surface of the welding position of the pump wheel shell and the shaft sleeve, and the three-thimble outer jacking device ascends to tightly push the pump wheel shell; module M2.2: and locking the lifting cylinder in the middle of the hydraulic locking device, and finally pressing the pressing shaft sleeve by the pressing device.
Preferably, said module M3 comprises: module M3.1: in the process of performing 200-degree girth welding by two guns, various welding is adopted in an arc starting section, a middle welding section and an arc closing section respectively; arc starting current (100-;
the arc striking adopts slightly high current and longer arc length, so that reliable arc striking is facilitated, and meanwhile, the filling amount is smaller, so that smooth and flexible transition of a welding line during arc striking is ensured. The fixed-point arc-closing is adopted, the arc pit is conveniently and well filled by lower arc-closing current, smaller voltage and longer arc-closing time, shrinkage cavity and arc pit crack generation are prevented, and the attractive weld forming and smooth transition are ensured. And the middle section is welded at a faster welding speed and a larger welding specification (the specification is welding current 205-.
The pulse welding method can accurately control the heat input quantity, ensure the penetration and accurately control the heat input quantity, and reduce the welding deformation.
Fixed-point arcing is adopted to ensure reliable arcing, the arc length is long, the current is small, the leakage and transition pile height of arcing spot welding can be avoided, and meanwhile, after the arcing is successful, the turntable rotates, so that the transition of the welding line in the overlap joint area of the arcing and the arc stopping is smooth and soft, and the overhigh metal of the welding line is avoided. The longer arc length has the effect of making the arc softer during arc striking and reducing splashing.
The arc is closed at fixed points by adopting small current and small voltage, so that the arc pit can be filled fully and uniformly without overhigh filling, and the solidification speed of a molten pool can be slowed down by longer arc closing time, thereby avoiding the crack defect of the arc pit.
The root of the directional groove of welding wire extension line, and skew 0.5mm to pump wheel shell direction a little to guarantee that the groove root fully melts through and reduce the welding seam metal of axle sleeve side simultaneously and pile high, make things convenient for subsequent manufacturing procedure of axle sleeve, for example high frequency induction etc..
Preferably, the module M3 further includes: module M3.2: when welding, adopt the circulating water cooling device to take away the unnecessary heat near the welding position of pump wheel shell and axle sleeve fast, reduce the diffusion of unnecessary heat on the work piece to reduce the thermal contraction deformation that welding heat input brought effectively, control axle sleeve welded size precision.
Preferably, the module M4 includes: module M4.1: before welding, a scanning gun scans two-dimensional codes of the pump wheel and the shaft sleeve to form a product type identification code; module M4.2: the PLC main controller is issued by the MES, and during welding, the main control system directly calls the formula data of the product according to the scanning code of the product; module M4.3: and starting welding, wherein in the welding process, the data acquisition unit acquires key process parameters such as current, voltage, welding speed and the like of the left and right welding power supplies, evaluates the product quality and sets out-of-tolerance alarm, when the set threshold value is exceeded, the system alarms and even stops welding, and meanwhile, the data acquisition system also reports corresponding welding parameters, equipment states and the like to the MES network control unit in real time. The whole process realizes whole-flow digitization and networked control, real-time collection and evaluation of welding key data and product quality tracing, and direct formula data calling based on scanning codes realizes scanning welding.
Compared with the prior art, the invention has the following beneficial effects:
1. the invention adopts fillet welding at the neck part of the shaft sleeve to replace the traditional flat welding of the shaft sleeve, and the welding position is directly at the restraining and positioning positions of the central positioning device of the shaft sleeve, the pressing device at the upper end of the shaft sleeve and the jacking device at the lower end of the shaft sleeve, thereby reducing the welding thermal shrinkage deformation to the maximum extent, and improving the important indexes of the product, such as the coaxiality, the planeness and the like;
2. according to the invention, the copper support surface at the lower end of the pump wheel shell shaft sleeve in angle welding and the circulating water cooling device can reduce heat input transferred to the pump wheel shell by shaft sleeve welding, thereby effectively reducing large thermal shrinkage deformation possibly brought by large standard welding and ensuring the dimensional precision of the pump wheel shell shaft sleeve;
3. according to the invention, double-gun 90-degree spot welding is cancelled, and direct segmented continuous welding is carried out, the welding time of one shaft sleeve is 16 seconds, the clamping, positioning and the total working beat are at most 45 seconds, so that the production efficiency is greatly improved;
4. according to the invention, on the premise of meeting the welding efficiency by adopting the sectional continuous welding plus fixed-point small-specification arc starting and arc closing welding strategies, the welding leakage of the arc starting section is prevented, and the smooth and flexible transition of the lap joint part is ensured, the arc crater is full and has no crack, the height of the welding seam is low, and the appearance is formed uniformly.
5. According to the invention, data are collected in real time, MES (manufacturing execution system) control and code scanning formula are called, so that the whole process of shaft sleeve welding is digitalized and networked, the data collection is convenient for product quality tracing, the code scanning formula directly calls a function, the problem of artificial data input errors is avoided, the reliability and convenience of the system are improved, and the influence of artificial factors is reduced.
6. The qualification rate of the product of the invention basically reaches more than 99.8 percent. The whole system has the advantages of high welding efficiency, small welding deformation, stable and reliable welding quality, digital welding of the whole process, networked MES system control and calling of scanning formula data, elimination of the influence of human factors and convenience for product quality control and tracing. The invention has great popularization and application values from the aspects of process and economic benefit.
Drawings
Other features, objects and advantages of the invention will become more apparent upon reading of the detailed description of non-limiting embodiments with reference to the following drawings:
FIG. 1 is a schematic view of a weld of a pump hub of a twin-gun torque converter according to an embodiment of the present invention;
FIG. 2 shows the position relationship between the pump hub and the weld seam in the embodiment of the present invention.
Fig. 3 is a schematic diagram of an information network structure for welding the pump hub in the embodiment of the present invention.
In the figure:
Left MAG welding gun 21 welding wire 15
Right MAG welding gun 22 MES network management and control system 16
Upper shaft sleeve pressing mechanism 4 code scanning gun 18
Jacking cylinder 8 video monitoring 24
Circulating water cooling device 27 of central jacking cylinder 10
Pneumatic motor 12 sweep station 28
Detailed Description
The present invention will be described in detail with reference to specific examples. The following examples will assist those skilled in the art in further understanding the invention, but are not intended to limit the invention in any way. It should be noted that it would be obvious to those skilled in the art that various changes and modifications can be made without departing from the spirit of the invention. All falling within the scope of the present invention.
As shown in fig. 1 to 3, a method for welding a pump hub sleeve of a hydraulic torque converter according to the present invention includes: step M1: establishing a hydraulic torque converter pump hub welding unit; step M2: clamping and positioning the pump wheel casing shaft sleeve with more than preset precision; step M3: continuously welding in segments by using MAG welding double guns; step M4: and data real-time acquisition and MES networked control are carried out, and the welding result information of the pump axle sleeve of the hydraulic torque converter is obtained.
The invention relates to a welding system and a welding method for a pump wheel shaft sleeve of a hydraulic torque converter, belonging to the technical field of welding. The method specifically comprises the following steps: firstly, establishing a hydraulic torque converter pump axle sleeve welding system by adopting a double-gun MAG welding matched servo rotating motor and an upper clamping and pressing device and a lower clamping and pressing device; secondly, high-precision clamping and positioning are carried out on the pump wheel shaft sleeve; step three, based on MAG welding double-gun 200-degree girth welding sectional welding strategy control; and step four, data real-time acquisition and MES networked control. The whole system has the advantages of high welding efficiency, high clamping and positioning accuracy, small welding deformation, stable and reliable welding quality, full-flow digital welding, MES system networked control and direct calling of scanning formula data, elimination of the influence of human factors and convenience for product quality control and tracing. The invention has great popularization and application values from the aspects of process and economic benefit.
Preferably, the step M2 includes: step M2.1: the pump wheel and the shaft sleeve are arranged on a supporting table surface, the shaft sleeve is positioned through the center of the shaft sleeve, then the rotary air claw rotates by 90 degrees to press the pump wheel shell, the middle cylinder ascends to a position to tightly push the end surface of the welding position of the pump wheel shell and the shaft sleeve, and the three-thimble outer jacking device ascends to tightly push the pump wheel shell; step M2.2: and locking the lifting cylinder in the middle of the hydraulic locking device, and finally pressing the pressing shaft sleeve by the pressing device.
Preferably, the step M3 includes: step M3.1: in the process of performing 200-degree girth welding by two guns, various welding is adopted in an arc starting section, a middle welding section and an arc closing section respectively; arc starting current (100-;
the arc striking adopts slightly high current and longer arc length, so that reliable arc striking is facilitated, and meanwhile, the filling amount is smaller, so that smooth and flexible transition of a welding line during arc striking is ensured. The fixed-point arc-closing is adopted, the arc pit is conveniently and well filled by lower arc-closing current, smaller voltage and longer arc-closing time, shrinkage cavity and arc pit crack generation are prevented, and the attractive weld forming and smooth transition are ensured. And the middle section is welded at a faster welding speed and a larger welding specification (the specification is welding current 205-.
The pulse welding method can accurately control the heat input quantity, ensure the penetration and accurately control the heat input quantity, and reduce the welding deformation.
Fixed-point arcing is adopted to ensure reliable arcing, the arc length is long, the current is small, the leakage and transition pile height of arcing spot welding can be avoided, and meanwhile, after the arcing is successful, the turntable rotates, so that the transition of the welding line in the overlap joint area of the arcing and the arc stopping is smooth and soft, and the overhigh metal of the welding line is avoided. The longer arc length has the effect of making the arc softer during arc striking and reducing splashing.
The arc is closed at fixed points by adopting small current and small voltage, so that the arc pit can be filled fully and uniformly without overhigh filling, and the solidification speed of a molten pool can be slowed down by longer arc closing time, thereby avoiding the crack defect of the arc pit.
The root of the directional groove of welding wire extension line, and skew 0.5mm to pump wheel shell direction a little to guarantee that the groove root fully melts through and reduce the welding seam metal of axle sleeve side simultaneously and pile high, make things convenient for subsequent manufacturing procedure of axle sleeve, for example high frequency induction etc..
Preferably, step M3 further includes: step M3.2: when welding, adopt the circulating water cooling device to take away the unnecessary heat near the welding position of pump wheel shell and axle sleeve fast, reduce the diffusion of unnecessary heat on the work piece to reduce the thermal contraction deformation that welding heat input brought effectively, control axle sleeve welded size precision.
Preferably, step M4 includes: step M4.1: before welding, a scanning gun scans two-dimensional codes of the pump wheel and the shaft sleeve to form a product type identification code; step M4.2: the PLC main controller is issued by the MES, and during welding, the main control system directly calls the formula data of the product according to the scanning code of the product; step M4.3: and starting welding, wherein in the welding process, the data acquisition unit acquires key process parameters such as current, voltage, welding speed and the like of the left and right welding power supplies, evaluates the product quality and sets out-of-tolerance alarm, when the set threshold value is exceeded, the system alarms and even stops welding, and meanwhile, the data acquisition system also reports corresponding welding parameters, equipment states and the like to the MES network control unit in real time. The whole process realizes whole-flow digitization and networked control, real-time collection and evaluation of welding key data and product quality tracing, and direct formula data calling based on scanning codes realizes scanning welding.
Specifically, in one embodiment, a torque converter pump axle sleeve welding method includes:
establishing a hydraulic torque converter pump wheel shaft sleeve welding system by adopting double-gun MAG welding and matching with a servo motor;
the embodiment is implemented on a torque converter pump hub sleeve welding system 23. As shown in fig. 1, in the present embodiment, the CPU315-2PN/DP of siemens S7-300 series is used as a core of a control system, the TP900 touch screen is used as a control unit, and the V90 servo driver and the SM321/SM 322I/O module and the like realize control over the servo rotating device 11, the two welding power supplies 21, the air cylinder and the like. The two welding guns 21 and 22 are symmetrically distributed according to 180 degrees, the welding guns 21 and 22 form an angle of 35 degrees with the axis of the shaft sleeve 3, the angle welding position is that the plane of the upper pressing mechanism 4 is strictly parallel to the supporting table surface of the shaft sleeve 3 and must be concentrically arranged with the shaft sleeve center positioning device 5, the pump impeller 1 and the shaft sleeve 3 are placed on the supporting table surface and are positioned by the shaft sleeve center positioning device 5, and the upper pressing mechanism 4, the shaft sleeve positioning center 5 and the rotating center of the turntable 26 must be concentrically arranged. Three thimbles 7 driven by the cylinder are the same in height, are uniformly distributed at intervals of 120 degrees and have the same distance to the center 5 of the shaft sleeve, three rotary gas claws 6 are strictly arranged on a plane and are uniformly distributed at intervals of 120 degrees, the three rotary gas claws are synchronously driven by a starting motor 12 through a synchronous toothed belt 13, a servo motor 11 fixedly connected with a turntable 26 mainly plays a rotary role during welding, and the angle and the speed of assembly welding are accurately controlled through a position control mode.
Step two, realizing the high-precision clamping and positioning of the pump wheel shell shaft sleeve:
before welding, firstly, a hydraulic torque converter pump wheel 1 and a shaft sleeve 3 are placed on a supporting table surface of a rotary table 26 through a robot or a manual work, and are positioned through a shaft sleeve center positioning device 5, then a rotary air claw 6 rotates in place, a center jacking air cylinder 10 rises, jacking air cylinders 8 of three ejector pins 7 rise to jack the pump wheel shell 1 tightly, then a hydraulic locking device 9 locks the center jacking air cylinder 10, a compression air cylinder 4 on the upper portion descends to compress the shaft sleeve 3, and the pump wheel shell 1 and the shaft sleeve 3 are respectively pushed up and down through the actions of the air cylinders and the oil cylinders, so that high-precision and accurate positioning and clamping of welding of the pump wheel shell 1 and the shaft sleeve 3 are realized.
Step three, based on MAG welding double-gun 200-degree girth welding subsection welding strategy control:
after the upper compacting device 4 is in place, the two MAG guns 21 and 22 descend to the place to start arc striking, and after the arc striking is successful, the lower servo motor 11 starts to rotate to perform 200-degree double-gun 180-degree symmetrical welding, so that the pump impeller shaft sleeve welding of the hydraulic torque converter is completed.
When the shaft sleeve 3 is welded, the included angle between a welding gun and the axis of the shaft sleeve is 40 degrees, the welding gun points to the center of the bottom of the fillet welding groove of the shaft sleeve and horizontally deviates 0.5mm towards the direction of the pump wheel shell, and a method of directly performing 200-degree double-gun continuous girth welding without spot welding is adopted. The segmentation strategy is as follows: different welding strategies are adopted in the arc starting section, the middle welding section and the arc ending section respectively. Arc starting current (100A), arc starting time (0.8s), trimming voltage (15), welding current (225A), trimming voltage (-16), arc stopping current (60A), arc stopping time (1.8s), trimming voltage (-10), welding speed of 720deg/min, welding angle (200deg), direct current pulse of a welding method and unified welding; ensuring symmetrical and uniform heat input and beautiful appearance formation.
Further, the circulating cooling water device 27 cools the position near the welding position of the pump impeller and the shaft sleeve in real time, so that the heat input of the pump impeller and the shaft sleeve is obviously reduced, the welding thermal deformation is reduced, the influence of the welding deformation on the terminal size is overcome, and the welding size precision and the welding quality of products are better ensured.
Step four, data real-time acquisition and MES networked control:
during welding, the code scanning gun 18 scans two-dimensional codes of the pump wheel and the shaft sleeve to form a product type identification code, then the product type identification code is transmitted to the PLC main controller 19 through the MES system 16, formula data of corresponding product models are directly called, and then welding is started. In the welding process, the data acquisition system 17 collects key process parameters such as welding current, welding voltage, welding speed and the like, evaluates the product quality and sets out an out-of-tolerance alarm, and when the product quality exceeds a set threshold value, the system alarms and stops welding. Meanwhile, the data acquisition system can report corresponding welding parameters, equipment states and the like to the MES network control system in real time. The whole process realizes whole-flow digitization and networked control, real-time collection and evaluation of welding key data and product quality tracing, and direct formula data calling based on scanning codes realizes scanning welding.
The embodiment realizes the high-efficiency and high-precision welding of the pump wheel shaft sleeve, the weld joint is full and attractive in forming, the transition of the lap joint area is smooth and soft, and the efficiency and the quality are remarkably improved compared with the prior art. The welding time of the whole product is 16.6 seconds, the total working time is 45 seconds, after welding, various indexes (such as radial runout of a shaft sleeve surface and radial runout of a positioning shaft) are tested, and the qualification rate of the product reaches more than 99.98%. Meanwhile, the full-flow digitization, the networked control, the direct calling of the formula data, the scanning and welding, the real-time acquisition of the welding data and the tracing of the product quality of the embodiment extremely improve the intelligent degree of the production process and the controllability and the stability of the product quality.
According to the invention, the welding system for the pump wheel shaft sleeve of the hydraulic torque converter comprises: module M1: establishing a hydraulic torque converter pump hub welding unit; module M2: clamping and positioning the pump wheel casing shaft sleeve with more than preset precision; module M3: continuously welding in segments by using MAG welding double guns; module M4: and data real-time acquisition and MES networked control are carried out, and the welding result information of the pump axle sleeve of the hydraulic torque converter is obtained.
Preferably, said module M2 comprises: module M2.1: the pump wheel and the shaft sleeve are arranged on a supporting table surface, the shaft sleeve is positioned through the center of the shaft sleeve, then the rotary air claw rotates by 90 degrees to press the pump wheel shell, the middle cylinder ascends to a position to tightly push the end surface of the welding position of the pump wheel shell and the shaft sleeve, and the three-thimble outer jacking device ascends to tightly push the pump wheel shell; module M2.2: and locking the lifting cylinder in the middle of the hydraulic locking device, and finally pressing the pressing shaft sleeve by the pressing device.
Preferably, said module M3 comprises: module M3.1: in the process of performing 200-degree girth welding by two guns, various welding is adopted in an arc starting section, a middle welding section and an arc closing section respectively; arc starting current (100-;
the arc striking adopts slightly high current and longer arc length, so that reliable arc striking is facilitated, and meanwhile, the filling amount is smaller, so that smooth and flexible transition of a welding line during arc striking is ensured. The fixed-point arc-closing is adopted, the arc pit is conveniently and well filled by lower arc-closing current, smaller voltage and longer arc-closing time, shrinkage cavity and arc pit crack generation are prevented, and the attractive weld forming and smooth transition are ensured. And the middle section is welded at a faster welding speed and a larger welding specification (the specification is welding current 205-.
The pulse welding method can accurately control the heat input quantity, ensure the penetration and accurately control the heat input quantity, and reduce the welding deformation.
Fixed-point arcing is adopted to ensure reliable arcing, the arc length is long, the current is small, the leakage and transition pile height of arcing spot welding can be avoided, and meanwhile, after the arcing is successful, the turntable rotates, so that the transition of the welding line in the overlap joint area of the arcing and the arc stopping is smooth and soft, and the overhigh metal of the welding line is avoided. The longer arc length has the effect of making the arc softer during arc striking and reducing splashing.
The arc is closed at fixed points by adopting small current and small voltage, so that the arc pit can be filled fully and uniformly without overhigh filling, and the solidification speed of a molten pool can be slowed down by longer arc closing time, thereby avoiding the crack defect of the arc pit.
The root of the directional groove of welding wire extension line, and skew 0.5mm to pump wheel shell direction a little to guarantee that the groove root fully melts through and reduce the welding seam metal of axle sleeve side simultaneously and pile high, make things convenient for subsequent manufacturing procedure of axle sleeve, for example high frequency induction etc..
Preferably, the module M3 further includes: module M3.2: when welding, adopt the circulating water cooling device to take away the unnecessary heat near the welding position of pump wheel shell and axle sleeve fast, reduce the diffusion of unnecessary heat on the work piece to reduce the thermal contraction deformation that welding heat input brought effectively, control axle sleeve welded size precision.
Preferably, the module M4 includes: module M4.1: before welding, a scanning gun scans two-dimensional codes of the pump wheel and the shaft sleeve to form a product type identification code; module M4.2: the PLC main controller is issued by the MES, and during welding, the main control system directly calls the formula data of the product according to the scanning code of the product; module M4.3: and starting welding, wherein in the welding process, the data acquisition unit acquires key process parameters such as current, voltage, welding speed and the like of the left and right welding power supplies, evaluates the product quality and sets out-of-tolerance alarm, when the set threshold value is exceeded, the system alarms and even stops welding, and meanwhile, the data acquisition system also reports corresponding welding parameters, equipment states and the like to the MES network control unit in real time. The whole process realizes whole-flow digitization and networked control, real-time collection and evaluation of welding key data and product quality tracing, and direct formula data calling based on scanning codes realizes scanning welding.
Specifically, in one embodiment, a pump hub sleeve welding system includes: the device comprises a pump wheel shell 1, a left MAG welding gun 21, a right MAG welding gun 22, a shaft sleeve 3, a shaft sleeve lower pressing mechanism 4, a shaft sleeve center positioning device 5, a rotary air claw 6, an ejector pin 7, a jacking cylinder 8, a hydraulic locking device 9, a center jacking cylinder 10, a center jacking device, an outer jacking device, a hydraulic locking device, a circulating water cooling device 27, a servo rotating device 11, a rotary disc 26, a control system, a data acquisition system, an MES system, a code scanning gun, a welding power supply and video monitoring.
The left MAG welding gun and the right MAG welding gun are symmetrically arranged along the circumferential direction of the pump wheel shell by 180 degrees, the angle between the welding guns and the axis of the shaft sleeve is 30-45 degrees, and the extension line of the welding wire points to the central position of fillet welding of the pump wheel shell and the shaft sleeve and deviates by 0.5mm in the horizontal direction.
The circulating water cooling device specifically comprises: a circulating water cooling device is arranged below a supporting table top connected with a shaft sleeve central positioning device, and the supporting table top is usually made of copper with excellent heat conductivity. During welding, under the conduction of circulating cooling water and heat conducting copper, heat near the welding position of the shaft sleeve can be directly and rapidly transferred out, the heat input of a workpiece is greatly reduced, and the thermal shrinkage deformation of welding is effectively prevented.
The outer jacking device is three thimbles which are uniformly distributed at intervals of 120 degrees and strictly positioned on the same plane, a jacking cylinder at the lower part drives the thimbles to lift, and the distance of each thimble along the radial direction is accurately adjustable, so that the jacking position on the pump wheel shell is conveniently determined according to different product types.
The rotary pressing device specifically comprises: comprises a rotary air claw, a tooth-shaped synchronous belt and a starting motor. When the pneumatic gripper works, the starting motor drives the synchronous belt, and the synchronous belt drives the three rotary pneumatic grippers. Three gas claws are uniformly distributed at intervals of 120 degrees and strictly positioned on the same plane, the height of the rotary gas claw is accurate and adjustable, the compression height can be conveniently determined according to different product types, and the pneumatic motor is arranged on the table top of the rotary table.
The locking device specifically comprises: when the central jacking cylinder and the outer jacking cylinder are tightly jacked in place, the jacking cylinder is locked by hydraulic drive, and the cylinder on the lower part is prevented from moving when the shaft sleeve is pressed downwards by the cylinder on the upper part.
Furthermore, all the devices except the upper shaft sleeve pressing device are positioned on the rotary turntable and are concentrically arranged, the rotary turntable is controlled by the lower rotary servo device during welding, and the angle and the speed of the shaft sleeve are accurately controlled through a position control mode of the servo motor.
The upper pressing device specifically comprises: the shaft sleeve is driven by a lifting cylinder at the upper part to press downwards. The hold-down device must be strictly coaxial with the bushing centering device on the support table.
Furthermore, the rotary air claw compresses the top surface of the pump wheel, the central air cylinder tightly pushes the shaft sleeve and the connecting surface of the pump wheel, the outer thimble tightly pushes the effective surface in the inner part of the pump wheel shell, the central positioning device accurately positions the shaft sleeve, the pressing air cylinder on the upper part compresses the shaft sleeve, and finally the lifting air cylinder is locked through the hydraulic locking device, so that the high-precision clamping and positioning of the pump wheel and the shaft sleeve are realized through inner pushing, outer pushing, external pressing, internal pressing, locking and central positioning.
In the description of the present application, it is to be understood that the terms "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", and the like indicate orientations or positional relationships based on those shown in the drawings, and are only for convenience in describing the present application and simplifying the description, but do not indicate or imply that the referred device or element must have a specific orientation, be constructed in a specific orientation, and be operated, and thus, should not be construed as limiting the present application.
The foregoing description of specific embodiments of the present invention has been presented. It is to be understood that the present invention is not limited to the specific embodiments described above, and that various changes or modifications may be made by one skilled in the art within the scope of the appended claims without departing from the spirit of the invention. The embodiments and features of the embodiments of the present application may be combined with each other arbitrarily without conflict.
Claims (10)
1. A method for welding a pump wheel shaft sleeve of a hydraulic torque converter is characterized by comprising the following steps:
step M1: a double-gun MAG welding is adopted to match with a servo rotating motor, and an upper clamping and pressing device and a lower clamping and pressing device are adopted to establish a hydraulic torque converter pump wheel shaft sleeve welding unit;
step M2: clamping and positioning the pump wheel casing shaft sleeve with more than preset precision;
step M3: continuously welding in segments by using MAG welding double guns;
step M4: and data real-time acquisition and MES networked control are carried out, and the welding result information of the pump axle sleeve of the hydraulic torque converter is obtained.
2. The torque converter pump hub sleeve welding method of claim 1, wherein the step M2 comprises:
step M2.1: the pump wheel and the shaft sleeve are arranged on a supporting table surface, the shaft sleeve is positioned through the center of the shaft sleeve, then the rotary air claw rotates by 90 degrees to press the pump wheel shell, the middle cylinder ascends to a position to tightly push the end surface of the welding position of the pump wheel shell and the shaft sleeve, and the three-thimble outer jacking device ascends to tightly push the pump wheel shell;
step M2.2: and locking the lifting cylinder in the middle of the hydraulic locking device, and finally pressing the pressing shaft sleeve by the pressing device.
3. The torque converter pump hub sleeve welding method of claim 1, wherein the step M3 comprises:
step M3.1: in the process of welding two guns by 200-degree girth welding, a plurality of welding strategies are respectively adopted in an arc starting section, a middle welding section and an arc ending section, and welding parameters in the plurality of welding strategies are as follows:
the arc starting current is 100-150A, the arc starting time is 0.6-0.8s, the trimming voltage is 10-15V, the welding current is 205-230A, the trimming voltage is-10-16, the arc closing current is 60-100A, the arc closing time is 1.5-2.0s, the trimming voltage is-10-16V, the welding speed is 700-720deg/min, the welding angle is 200deg, and the direct current pulse welding and the unified welding are adopted.
4. The torque converter pump hub sleeve welding method of claim 3, wherein step M3 further comprises:
step M3.2: and during welding, a circulating water cooling device is adopted to take away heat near the welding position of the pump wheel shell and the shaft sleeve.
5. The torque converter pump hub sleeve welding method of claim 1, wherein step M4 comprises:
step M4.1: before welding, a scanning gun scans two-dimensional codes of the pump wheel and the shaft sleeve to form a product type identification code;
step M4.2: the PLC main controller is issued by the MES, and during welding, the main control unit directly calls the formula data of the product according to the scanning code of the product;
step M4.3: and starting welding, wherein in the welding process, the data acquisition unit acquires key process parameters such as current, voltage, welding speed and the like of the left and right welding power supplies, evaluates the product quality and sets out an out-of-tolerance alarm, and when the set threshold value is exceeded, the data acquisition unit alarms and even stops welding, and simultaneously, the data acquisition unit can report corresponding welding parameters, equipment states and the like to the MES network control unit in real time.
6. A torque converter pump axle sleeve welding system, comprising:
module M1: a double-gun MAG welding is adopted to match with a servo rotating motor, and an upper clamping and pressing device and a lower clamping and pressing device are adopted to establish a hydraulic torque converter pump wheel shaft sleeve welding unit;
module M2: clamping and positioning the pump wheel casing shaft sleeve with more than preset precision;
module M3: continuously welding in segments by using MAG welding double guns;
module M4: and data real-time acquisition and MES networked control are carried out, and the welding result information of the pump axle sleeve of the hydraulic torque converter is obtained.
7. The torque converter pump hub sleeve welding system of claim 6, wherein said module M2 comprises:
module M2.1: the pump wheel and the shaft sleeve are arranged on a supporting table surface, the shaft sleeve is positioned through the center of the shaft sleeve, then the rotary air claw rotates by 90 degrees to press the pump wheel shell, the middle cylinder ascends to a position to tightly push the end surface of the welding position of the pump wheel shell and the shaft sleeve, and the three-thimble outer jacking device ascends to tightly push the pump wheel shell;
module M2.2: and locking the lifting cylinder in the middle of the hydraulic locking device, and finally pressing the pressing shaft sleeve by the pressing device.
8. The torque converter pump hub sleeve welding system of claim 6, wherein said module M3 comprises:
module M3.1: in the process of welding two guns by 200-degree girth welding, a plurality of welding strategies are adopted in an arc starting section, a middle welding section and an arc ending section respectively, and welding parameters in the plurality of welding strategies are as follows:
the arc starting current is 100-150A, the arc starting time is 0.6-0.8s, the trimming voltage is 10-15V, the welding current is 205-230A, the trimming voltage is-10-16, the arc closing current is 60-100A, the arc closing time is 1.5-2.0s, the trimming voltage is-10-16V, the welding speed is 700-720deg/min, the welding angle is 200deg, and the direct current pulse welding and the unified welding are adopted.
9. The torque converter pump hub sleeve welding system of claim 8, wherein module M3 further comprises:
module M3.2: and during welding, a circulating water cooling device is adopted to take away heat near the welding position of the pump wheel shell and the shaft sleeve.
10. The torque converter pump hub sleeve welding system of claim 6, wherein module M4 comprises:
module M4.1: before welding, a scanning gun scans two-dimensional codes of the pump wheel and the shaft sleeve to form a product type identification code;
module M4.2: the PLC main controller is issued by the MES, and during welding, the main control unit directly calls the formula data of the product according to the scanning code of the product;
module M4.3: and starting welding, wherein in the welding process, the data acquisition unit acquires key process parameters such as current, voltage, welding speed and the like of the left and right welding power supplies, evaluates the product quality and sets out an out-of-tolerance alarm, and when the set threshold value is exceeded, the data acquisition unit alarms and even stops welding, and simultaneously, the data acquisition unit can report corresponding welding parameters, equipment states and the like to the MES network control unit in real time.
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| CN202010092141.6A CN111283309B (en) | 2020-02-14 | 2020-02-14 | Method and system for welding pump wheel shaft sleeve of hydraulic torque converter |
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| CN202010092141.6A CN111283309B (en) | 2020-02-14 | 2020-02-14 | Method and system for welding pump wheel shaft sleeve of hydraulic torque converter |
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