CN112475533A - Railway wagon self-adaptive welding method - Google Patents
Railway wagon self-adaptive welding method Download PDFInfo
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- CN112475533A CN112475533A CN202011197560.2A CN202011197560A CN112475533A CN 112475533 A CN112475533 A CN 112475533A CN 202011197560 A CN202011197560 A CN 202011197560A CN 112475533 A CN112475533 A CN 112475533A
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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
- B23K9/02—Seam welding; Backing means; Inserts
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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
- B23K9/095—Monitoring or automatic control of welding parameters
Abstract
The invention discloses a railway wagon self-adaptive welding method, which comprises the following steps: detecting the actual weld gap of the workpiece to be welded; determining welding parameters according to the detection result; specifically, theoretical weld gaps are classified according to the size of the gaps, and corresponding welding parameters are set for the theoretical weld gaps of different levels; determining the grade of the actual welding seam gap and acquiring corresponding welding parameters; and welding the welding seam of the workpiece to be welded according to the welding parameters. According to the self-adaptive welding method for the railway wagon, the welding assembly gap is monitored in real time in the welding process, and appropriate welding parameters are matched according to the detection result, so that a welding seam with good appearance and internal quality is obtained, meanwhile, the production cost caused by reworking of workpieces is reduced, the labor intensity of workers is improved, and the working efficiency is improved.
Description
Technical Field
The application belongs to the technical field of welding, and particularly relates to a railway wagon self-adaptive welding method.
Background
With the continuous development of railway freight cars, the automation degree is higher and higher, and the assembly requirements on welding seams are stricter and stricter, particularly the assembly clearance is generally required to be less than 2 mm. But the design of the railway freight car has more medium plate bending compression parts, such as sleeper beams, arc plates and other structures, and the assembly clearance has irregular ultra-difference due to the compression error, and the local part even reaches 4 mm. This causes great trouble to the automatic welding process, leads to welding quality to appear great defect, and the welding seam shaping is poor, and poker welding seam outward appearance is relatively poor.
The existing railway wagon has poor consistency of assembly gaps and large local gaps, and the following two welding methods are mainly adopted: firstly, a clearance out-of-tolerance part is detected by a feeler gauge, backing welding is firstly carried out on the clearance out-of-tolerance part by adopting a manual gas shielded welding method, then a grinding machine is adopted for grinding and cleaning, and then automatic welding is adopted; and secondly, reworking the part, and modifying the shape by adopting a mechanical method and a thermal cutting method again to correct the welding clearance within the range of less than 2 mm.
The prior art mainly has the following defects:
1) need the manual work to carry out the backing welding, then adopt the grinder to polish, the work efficiency is low, increases the cost.
2) Reworking of parts affects production and is time consuming and labor intensive.
3) Because the manual welding has uncertainty, the welding quality can not be ensured, and the backing welding has high requirements on welders.
Disclosure of Invention
In order to solve the technical problems, the invention provides a railway wagon self-adaptive welding method, which solves the problem of poor welding quality caused by uneven welding gaps due to various reasons in the production process and improves the production efficiency.
The technical scheme adopted for realizing the aim of the invention is that the railway wagon self-adaptive welding method comprises the following steps:
detecting the actual weld gap of the workpiece to be welded;
determining welding parameters according to the detection result; specifically, theoretical weld gaps are classified according to the size of the gaps, and corresponding welding parameters are set for the theoretical weld gaps of different levels; determining the grade of the actual welding seam gap and acquiring corresponding welding parameters;
and welding the welding seam of the workpiece to be welded according to the welding parameters.
Further, the step of classifying the theoretical weld gap according to the gap size specifically includes:
the gap range of the theoretical weld gap meeting the welding requirement is divided into more than two levels, and each level corresponds to one theoretical weld gap range.
Further, dividing the gap range of the theoretical weld gap meeting the welding requirements into more than two levels specifically comprises:
the gap range of the theoretical weld gap meeting the welding requirements is divided into three levels, which are respectively: in the first level, the theoretical weld seam gap s1 is less than or equal to 1 mm; in the second level, the theoretical weld seam clearance s2 is 1mm < s2 and is not more than 2 mm; in the third grade, the theoretical weld seam clearance s3 is 2mm < s3 ≤ 3.5 mm.
Further, the setting of corresponding welding parameters for the theoretical weld gaps of different levels specifically includes:
and respectively setting corresponding welding parameters for the theoretical weld gaps of the three levels, wherein the welding parameters comprise welding current, welding arc voltage and welding speed.
Further, the setting of corresponding welding parameters for the theoretical weld gaps of the three levels respectively specifically includes:
setting corresponding welding parameters for the theoretical weld gaps of the three levels respectively; and at least one of the welding parameters is decreased from the first level to the third level in turn.
Further, the setting of corresponding welding parameters for the theoretical weld gaps of the three levels respectively specifically includes:
setting the welding parameters corresponding to the first-level theoretical weld gap as follows: the welding current is 240-270A, the welding arc voltage is 27-30V, and the welding speed is 500-700 mm/min;
setting the welding parameters corresponding to the second-level theoretical weld gap as follows: the welding current is 240-270A, the welding arc voltage is 27-30V, and the welding speed is 450-700 mm/min;
setting the welding parameters corresponding to the third level theoretical weld gap as follows: the welding current is 220-240A, the welding arc voltage is 27-30V, and the welding speed is 400-450 mm/min.
Further, the welding parameters corresponding to the third-level weld gap further include: welding swing, the swing amplitude is 2-4mm, and the swing frequency is 10-30 times/min.
Further, the actual weld gap of the workpiece to be welded is detected, and the method specifically comprises the following steps:
and detecting the actual welding seam gap of the workpiece to be welded by using the laser sensing device.
Further, the welding seam of the workpiece to be welded according to the welding parameters specifically includes:
and welding the welding seam of the workpiece to be welded through a robot welding system according to the welding parameters.
Further, the determining the welding parameters according to the detection result specifically includes:
weld gap grading information and welding parameter information corresponding to theoretical weld gaps of different grades are stored in the robot welding system in advance;
the laser sensing device feeds back the actual welding seam gap obtained through detection to the robot welding system, and the robot welding system automatically matches the grade of the actual welding seam gap according to the detection result and obtains corresponding welding parameters.
According to the technical scheme, the self-adaptive welding method for the railway wagon, provided by the invention, comprises the steps of firstly detecting the actual welding seam gap of a workpiece to be welded; then, welding parameters are determined according to the detection result; and finally, welding the welding line of the workpiece to be welded according to the welding parameters. When the welding parameters are determined, firstly, theoretical weld gaps are classified according to the size of the gaps, corresponding welding parameters are set for the theoretical weld gaps of different levels, then the level of the actual weld gaps obtained through detection is determined, and the corresponding welding parameters are obtained. Through the steps, different welding parameters are implemented for the welding assembly gaps with different gap sizes, the welding parameters are matched with the gap sizes, and the welding assembly gaps with different gap sizes can obtain the optimal welding effect and the optimal welding seam quality.
Compared with the prior art, the self-adaptive welding method for the railway wagon provided by the invention has the advantages that the welding assembly clearance is monitored in real time in the welding process, and the proper welding parameters are matched according to the detection result, so that the welding seam with better appearance and internal quality is obtained, meanwhile, the production cost brought by the rework of the workpiece is reduced, the labor intensity of workers is improved, and the working efficiency is improved.
Drawings
FIG. 1 is a block flow diagram of an adaptive welding method for rail wagons according to an embodiment of the invention.
Detailed Description
In order to make the present application more clearly understood by those skilled in the art to which the present application pertains, the following detailed description of the present application is made with reference to the accompanying drawings by way of specific embodiments.
In order to solve the technical problems of low work efficiency, high welding cost and incapability of ensuring welding quality in the prior art, the invention provides a railway wagon self-adaptive welding method, which is basically designed as follows:
a railway wagon self-adaptive welding method comprises the following steps: detecting the actual weld gap of the workpiece to be welded; determining welding parameters according to the detection result; specifically, theoretical weld gaps are classified according to the size of the gaps, and corresponding welding parameters are set for the theoretical weld gaps of different levels; determining the grade of the actual welding seam gap and acquiring corresponding welding parameters; and welding the welding seam of the workpiece to be welded according to the welding parameters.
According to the self-adaptive welding method for the railway wagon, the welding assembly gap is monitored in real time in the welding process, and appropriate welding parameters are matched according to the detection result, so that a welding seam with good appearance and internal quality is obtained, meanwhile, the production cost caused by reworking of workpieces is reduced, the labor intensity of workers is improved, and the working efficiency is improved.
For a clearer understanding of the present application, the following detailed description of the present invention is given in conjunction with an exemplary embodiment:
referring to fig. 1, in an embodiment of the present invention, a method for adaptively welding a railway wagon includes the following steps:
and S1, detecting the actual weld gap of the workpiece to be welded.
Specifically, the actual weld gap detection can adopt two detection modes, namely manual detection and automatic detection of a mechanical device. The manual detection can adopt visual inspection, or an operator adopts a feeler gauge to detect the position with the out-of-tolerance clearance; the automatic detection of the mechanical device can adopt any gap detection device and corresponding detection method, such as a laser vision sensing weld gap detection device, an ultrasonic weld gap detection device and the like. In view of detection accuracy, automatic detection by mechanical means or manual feeler detection is preferable.
In this embodiment, the actual weld gap of the workpiece to be welded is detected by using the laser sensing device. Specifically, a laser vision sensor shoots laser stripe images of assembly welding seams of workpieces to be welded, the position and the height of the laser vision sensor are adjusted, the assembly welding seams of the workpieces to be welded are located in the center of a detection area of the laser vision sensor, and actual welding seam gaps are calculated by analyzing characteristics of the laser stripe images of the welding seam gaps.
S2, determining welding parameters according to the detection result, comprising two steps:
and S21, classifying the theoretical weld joint gaps according to the sizes of the gaps, and setting corresponding welding parameters for the theoretical weld joint gaps of different levels.
S211, classifying the theoretical weld joint gap according to the gap size:
because the welding operation can only effectively weld the assembly gap within a certain gap range, the adaptive welding method of the railway freight car is only applicable to the weld gap meeting the welding requirement, when the weld gap is too large and the welding operation is difficult to implement, the parts need to be reworked, the mechanical method and the thermal cutting method need to be adopted again for repairing, so that the weld gap meets the welding requirement, and then the technical scheme of the invention is implemented. Therefore, the theoretical weld gap is classified according to the gap size, and particularly, the theoretical weld gap meeting the welding requirement is classified.
Specifically, the gap range of the theoretical weld gap meeting the welding requirements is divided into more than two levels, and each level corresponds to one weld gap range. For example, the gap range of the theoretical weld gap can be divided into more than two levels according to the sequence of the weld gap from small to large, and the higher the level is, the larger the corresponding theoretical weld gap is; conversely, the gap range of the theoretical weld gap may be divided into more than two levels according to the order of the weld gap from large to small, and the higher the level is, the smaller the corresponding theoretical weld gap is.
In this embodiment, the gap range of the theoretical weld gap is divided into three levels according to the sequence of the weld gap from small to large, which are respectively: in the first level, the theoretical weld seam gap s1 is less than or equal to 1 mm; in the second level, the theoretical weld seam clearance s2 is 1mm < s2 and is not more than 2 mm; in the third grade, the theoretical weld seam clearance s3 is 2mm < s3 ≤ 3.5 mm. For the welding seam clearance larger than 4mm, the welding quality is poor, the parts are preferably reworked, and the mechanical method and the thermal cutting method are adopted again for repairing the parts, so that the welding seam clearance meets the welding requirement.
S212, after the theoretical weld gaps are classified, corresponding welding parameters are set for the theoretical weld gaps of different levels according to the size of the weld gaps of each level. The welding parameters may include welding current, welding arc voltage, welding speed, parameters related to the welding weaving (e.g., weaving amplitude, weaving frequency), and the like.
Because the classification of the weld gaps is divided according to the sequence of the weld gaps from small to large or from large to small, at least one parameter in the corresponding welding parameters set for the weld gaps of the three levels is sequentially decreased progressively or sequentially increased progressively from the first level to the third level. The welding parameters are matched with the size of the gap, so that the welding assembly gaps with different sizes can obtain the optimal welding effect and the optimal welding quality.
Specifically, corresponding welding parameters are respectively set for the welding seam gaps of three levels, and the specific contents are as follows:
setting welding parameters corresponding to a first-level theoretical weld gap (the weld gap s1 is less than or equal to 1mm) as follows: the welding current is 240-270A, the welding arc voltage is 27-30V, and the welding speed is 500-700 mm/min;
setting the welding parameters corresponding to the second-level theoretical weld gap (the weld gap s2 is 1mm < s2 ≤ 2mm) as follows: the welding current is 240-270A, the welding arc voltage is 27-30V, and the welding speed is 450-700 mm/min;
setting the welding parameters corresponding to the third-class theoretical weld gap (the weld gap s3 is 2mm < s3 ≤ 3.5mm) as follows: the welding current is 220-240A, the welding arc voltage is 27-30V, and the welding speed is 400-450 mm/min.
The larger the welding gap is, the corresponding welding current is reduced, and the welding speed is reduced, so that the residence time of the welding wire metal in the molten pool is increased to fill the welding seam, and the optimal welding effect and welding seam quality are obtained.
As the third-level theoretical weld gap is 2-4mm and is large, in order to ensure the welding quality, for the third-level theoretical weld gap, welding parameters also comprise welding swing, the swing amplitude is 2-4mm, the swing frequency is 10-30 times/min, and preferably 20 times/min.
And S22, determining the grade of the actual weld gap and acquiring corresponding welding parameters.
In this embodiment, the wagon self-adaptive welding method adopts the robot welding system to perform automatic welding, and the classification information of the weld gaps and the welding parameter information corresponding to theoretical weld gaps of different levels are stored in the robot welding system in advance. The laser sensing device feeds back the detected weld gap to the robot welding system, and the robot welding system automatically matches the level of the detected actual weld gap according to the detection result and acquires corresponding welding parameters.
And S3, welding the welding seam of the workpiece to be welded according to the welding parameters.
In the embodiment, the self-adaptive welding method for the rail wagon adopts the robot welding system to perform automatic welding, and the robot welding system performs welding on the welding seam of the workpiece to be welded according to the welding parameters.
Application example:
the adaptive welding method for a railway wagon according to the embodiment 1 is further described by taking the welding of the sleeper beam of the railway wagon of C70 as an example, but the adaptive welding method for a railway wagon according to the present invention is not limited to this type of railway wagon.
The concrete steps for completing the welding of the sleeper beam of the C70 railway wagon are as follows:
1. and (4) hoisting the sleeper beam web and the lower cover plate bending piece to an assembly tire position, and opening the clamping device for clamping.
2. And opening the warehouse card welding robot and parallelly walking to a safety point.
3. And starting the detection function of the laser sensor with the more relevant model.
4. And detecting the gap of the straight-line-section welding line to be in the range of 1-2mm, and transmitting the information to the welding robot.
5. The control system of the welding robot selects HF-2 program welding parameters (corresponding to the second level), welding current is 270A, welding voltage is 30V, welding speed is 700mm/min, and the swing parameters are set to not swing.
6. After the welding of 400mm in the beginning stage of the straight line segment is finished, the clearance of the welding line is detected to be 3.5mm by the passing sensor, the welding robot finishes the self-adaptive selection of a welding program, HF-3 program welding parameters (corresponding to a third level) are adopted, the welding current is 220A, the welding voltage is 27V, the welding speed is 420mm/min, the swing parameter is set to be 2mm, and the frequency is 20 times/min.
7. And matching corresponding welding parameters according to the detected gap to perform arc transition stage and broken line segment welding, and completing the welding of the whole welding line.
And after welding, the welding quality of the whole welding line is detected, the deviation value of the welding angle size of the whole welding line is within 1mm, the deviation value of the welding residual height is within 2mm, the surface of the welding line is smooth, and the welding defects such as undercut and the like are avoided.
Through the embodiment, the invention has the following beneficial effects or advantages:
1) according to the self-adaptive welding method for the railway wagon, the welding assembly gap is monitored in real time in the welding process, and appropriate welding parameters are matched according to the detection result, so that a welding seam with good appearance and internal quality is obtained, meanwhile, the production cost caused by reworking of workpieces is reduced, the labor intensity of workers is improved, and the working efficiency is improved.
2) The self-adaptive welding method for the railway wagon provided by the invention adopts the robot welding system to carry out automatic welding, has high production efficiency, excellent quality of automatic welding seams and uniform and attractive appearance forming of the welding seams, avoids the processes of manual backing welding and polishing, does not need rework caused by local defects, and reduces the production cost of transferring, machining and the like caused by rework of parts.
3) According to the self-adaptive welding method for the railway wagon, the laser sensing device is used for detecting the welding gap in real time, manual detection of the gap is replaced, the labor cost is saved, manual errors are avoided, and the labor intensity is reduced.
While the preferred embodiments of the present application have been described, additional variations and modifications in those embodiments may occur to those skilled in the art once they learn of the basic inventive concepts. Therefore, it is intended that the appended claims be interpreted as including preferred embodiments and all alterations and modifications as fall within the scope of the application.
It will be apparent to those skilled in the art that various changes and modifications may be made in the present application without departing from the spirit and scope of the application. Thus, if such modifications and variations of the present application fall within the scope of the claims of the present application and their equivalents, the present application is intended to include such modifications and variations as well.
Claims (10)
1. A railway wagon self-adaptive welding method is characterized by comprising the following steps:
detecting the actual weld gap of the workpiece to be welded;
determining welding parameters according to the detection result; specifically, theoretical weld gaps are classified according to the size of the gaps, and corresponding welding parameters are set for the theoretical weld gaps of different levels; determining the grade of the actual welding seam gap and acquiring corresponding welding parameters;
and welding the welding seam of the workpiece to be welded according to the welding parameters.
2. The railway wagon adaptive welding method as claimed in claim 1, wherein: the method comprises the following steps of classifying theoretical weld gaps according to the gap sizes, and specifically comprises the following steps:
the gap range of the theoretical weld gap meeting the welding requirement is divided into more than two levels, and each level corresponds to one theoretical weld gap range.
3. The railway wagon adaptive welding method as claimed in claim 2, wherein: the gap range of the theoretical weld gap meeting the welding requirement is divided into more than two levels, and the method specifically comprises the following steps:
the gap range of the theoretical weld gap meeting the welding requirements is divided into three levels, which are respectively: in the first level, the theoretical weld seam gap s1 is less than or equal to 1 mm; in the second level, the theoretical weld seam clearance s2 is 1mm < s2 and is not more than 2 mm; in the third grade, the theoretical weld seam clearance s3 is 2mm < s3 ≤ 3.5 mm.
4. A railway wagon adaptive welding method as claimed in claim 3, wherein: the setting of corresponding welding parameters for the theoretical weld gaps of different levels specifically comprises:
and respectively setting corresponding welding parameters for the theoretical weld gaps of the three levels, wherein the welding parameters comprise welding current, welding arc voltage and welding speed.
5. The railway wagon adaptive welding method as claimed in claim 4, wherein: the setting of corresponding welding parameters for the theoretical weld gaps of the three levels respectively specifically comprises:
setting corresponding welding parameters for the theoretical weld gaps of the three levels respectively; and at least one of the welding parameters is decreased from the first level to the third level in turn.
6. The railway wagon adaptive welding method as claimed in claim 4, wherein: the setting of corresponding welding parameters for the theoretical weld gaps of the three levels respectively specifically comprises:
setting the welding parameters corresponding to the first-level theoretical weld gap as follows: the welding current is 240-270A, the welding arc voltage is 27-30V, and the welding speed is 500-700 mm/min;
setting the welding parameters corresponding to the second-level theoretical weld gap as follows: the welding current is 240-270A, the welding arc voltage is 27-30V, and the welding speed is 450-700 mm/min;
setting the welding parameters corresponding to the third level theoretical weld gap as follows: the welding current is 220-240A, the welding arc voltage is 27-30V, and the welding speed is 400-450 mm/min.
7. The railway wagon adaptive welding method as claimed in claim 6, wherein: the welding parameters corresponding to the third-level weld gap further comprise: welding swing, the swing amplitude is 2-4mm, and the swing frequency is 10-30 times/min.
8. The railway wagon adaptive welding method as claimed in any one of claims 1 to 7, wherein: treat the actual welding seam clearance of welding workpiece and detect, specifically include:
and detecting the actual welding seam gap of the workpiece to be welded by using the laser sensing device.
9. The railway wagon adaptive welding method as claimed in claim 8, wherein: the welding of the welding seam of the workpiece to be welded according to the welding parameters specifically comprises:
and welding the welding seam of the workpiece to be welded through a robot welding system according to the welding parameters.
10. The railway wagon adaptive welding method as claimed in claim 9, wherein: the determining of the welding parameters according to the detection result specifically further comprises:
weld gap grading information and welding parameter information corresponding to theoretical weld gaps of different grades are stored in the robot welding system in advance;
the laser sensing device feeds back the actual welding seam gap obtained through detection to the robot welding system, and the robot welding system automatically matches the grade of the actual welding seam gap according to the detection result and obtains corresponding welding parameters.
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Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
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| CN113649723A (en) * | 2021-09-06 | 2021-11-16 | 青岛海尔工业智能研究院有限公司 | Welding method of welding system and welding system |
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Application publication date: 20210312 |