CN113084407B - Intelligent welding production line for trolley frame and partition plate - Google Patents
Intelligent welding production line for trolley frame and partition plate Download PDFInfo
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- CN113084407B CN113084407B CN202110407264.9A CN202110407264A CN113084407B CN 113084407 B CN113084407 B CN 113084407B CN 202110407264 A CN202110407264 A CN 202110407264A CN 113084407 B CN113084407 B CN 113084407B
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- 238000003466 welding Methods 0.000 title claims abstract description 198
- 238000004519 manufacturing process Methods 0.000 title claims abstract description 78
- 238000005192 partition Methods 0.000 title claims abstract description 57
- 230000007246 mechanism Effects 0.000 claims abstract description 18
- 238000003825 pressing Methods 0.000 claims description 16
- 238000005266 casting Methods 0.000 claims description 12
- 238000004891 communication Methods 0.000 claims description 12
- 238000000034 method Methods 0.000 claims description 11
- 238000012544 monitoring process Methods 0.000 claims description 11
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims description 10
- 239000003638 chemical reducing agent Substances 0.000 claims description 9
- 230000009471 action Effects 0.000 claims description 7
- 230000008569 process Effects 0.000 claims description 7
- 239000000110 cooling liquid Substances 0.000 claims description 3
- 238000012806 monitoring device Methods 0.000 claims description 3
- 238000013021 overheating Methods 0.000 claims description 3
- 238000012546 transfer Methods 0.000 claims 1
- 239000000428 dust Substances 0.000 description 2
- 230000000694 effects Effects 0.000 description 2
- 238000009434 installation Methods 0.000 description 2
- 239000000463 material Substances 0.000 description 2
- 238000005498 polishing Methods 0.000 description 2
- 230000002159 abnormal effect Effects 0.000 description 1
- 238000011161 development Methods 0.000 description 1
- 238000010586 diagram Methods 0.000 description 1
- 238000007599 discharging Methods 0.000 description 1
- 239000012636 effector Substances 0.000 description 1
- 230000014509 gene expression Effects 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 238000006467 substitution reaction Methods 0.000 description 1
Classifications
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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
-
- 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
- B23K37/003—Cooling means
-
- 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
- B23K37/02—Carriages for supporting the welding or cutting element
- B23K37/0252—Steering means
-
- 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
- B23K37/0426—Fixtures for other work
- B23K37/0435—Clamps
- B23K37/0443—Jigs
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P90/00—Enabling technologies with a potential contribution to greenhouse gas [GHG] emissions mitigation
- Y02P90/02—Total factory control, e.g. smart factories, flexible manufacturing systems [FMS] or integrated manufacturing systems [IMS]
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- Optics & Photonics (AREA)
- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Manipulator (AREA)
Abstract
The invention provides an intelligent welding production line for a bogie frame and a partition plate, which comprises the following steps: the device comprises a welding manipulator system, a sliding table mechanism, a positioner system, a multifunctional platform, a central control system, a safety protection system and an auxiliary system; the invention controls and coordinates the cooperation of each operation module through the central control system, and the structure of each module is highly matched with the welding function requirement of the bogie frame, thereby meeting the requirement of automatic welding of parts such as main beam partition plates, bogie frames and the like of various types of cranes. The welding robot can automatically finish welding only by inputting the model of the corresponding bogie frame or the related size data of the corresponding baffle plate, and the bogie frame and the baffle plate can be produced in a collinear manner in a production line and can be additionally welded with other parts such as a saddle; the utilization rate of the production line is very high.
Description
Technical Field
The invention relates to the technical field of hoisting equipment, in particular to an intelligent welding production line for a bogie frame and a partition plate.
Background
The existing production modes of the main beam partition plate and the trolley frame of the hoisting machinery are mostly manual welding, and the crane is required to be utilized for overturning for many times in the welding process, so that the production efficiency is low, the labor intensity is high, and the intelligent welding production line is adopted for automatically producing the main beam partition plate and the trolley frame, so that the labor intensity can be effectively reduced, and the production efficiency is improved. However, most of the hoisting machinery is produced in a single piece in a customized manner, so that each crane product is produced, and the sizes of various parts of each crane product are different, thereby creating challenges for automatic mass production. However, how to solve the above-mentioned difficulties, the application of the intelligent welding production line in the field of hoisting machinery is the effort of various manufacturers in the field.
Disclosure of Invention
In order to solve the problems, the invention provides an intelligent welding production line for a bogie frame and a partition plate, which aims to realize automatic welding of parts such as main beam partition plates, bogie frames and the like of various types of cranes.
The invention adopts the following technical means:
an intelligent welding production line for a bogie frame and a partition plate, comprising: welding manipulator system, slip table mechanism, positioner system, multi-functional platform, main control system, safety protection system and auxiliary system:
welding manipulator system: comprises a welding power supply, a welding gun, a robot mechanical system, a robot control system, a wire feeding system and a water chiller.
The welding power supply, the wire feeding system and the water chiller act by receiving corresponding control signals of the PLC in the main control system; the welding power supply is responsible for providing welding currents in different modes such as pulse, direct current and the like for the welding gun to weld; the robot mechanical system is responsible for receiving the instruction from the robot controller and implementing the corresponding welding action; the welding of each position of the welding workpiece can be realized; the robot control system is mainly used for storing corresponding robot control programs and welding programs, various position information and other data of the robot, receiving communication of the PLC and controlling the robot to realize welding according to the corresponding welding programs; the wire feeding system is responsible for providing welding wires for the welding gun according to signal control; the cold water machine is responsible for circulation of cooling liquid to cool the welding gun and prevent the welding gun from being damaged due to overheating; the whole set of welding manipulator system can realize the stable welding function of the welding gun on the workpiece to be welded, and can automatically switch various welding modes, such as pulse, direct current and the like, according to the control of a welding program, so as to achieve the optimal welding effect.
The positioner system comprises: comprises a bogie frame clamp, a positioner clamp frame and a servo motor. The positioner rotates according to the signal sent by the PLC, the robot controller or the servo controller and is matched with the robot to weld the workpiece to be welded. Wherein: the whole set of casting crane frame clamp consists of a middle welding frame, a pressing plate, a product limiting block, a shared product positioning pin, a product frame, a quick-change adjusting cushion block, a pressing plate limiting block, a top disc and the like, and is responsible for completing clamping of workpieces to be welded. The fixture frame of the positioner is responsible for fixing the bogie frame fixture, and after automatic welding begins, the positioner can rotate through a servo motor to drive the fixture frame and drive the casting crane fixture so as to match with the welding robot to finish automatic welding of the casting crane bogie frame; the servo motor is responsible for receiving a signal instruction of the robot control system or the servo control system, and drives the clamp frame to rotate according to the instruction.
Sliding table mechanism: comprises a slipway main structure, a speed reducer, a servo motor, a ground rail structure, a slide rail slider, a gear rack and the like. The main structure of the sliding table can play a bearing role on the welding manipulator system, and the speed reducer and the servo motor are responsible for providing power for the sliding table; the ground rail structure is responsible for providing a flat reference plane for placing a sliding rail and a sliding block, and provides support for the movement of the sliding table; the sliding rail sliding block is responsible for bearing the whole sliding table and the cantilever part of the sliding table, namely the weight of the welding manipulator system and the gear rack are used for receiving power generated by the servo motor, so that each part of the sliding table mechanism can move along the direction of the sliding rail. The whole set of sliding table system can realize that the sliding table is matched with the robot to carry out moving operation according to signals received from the PLC and the robot controller, so that the robot is transferred among all welding stations, and the effective welding range of the robot is increased.
Multifunctional platform: comprises a multifunctional platform body, a quick clamping device, a quick positioning pin and the like. The multifunctional platform is generally used for welding a large partition plate, and the specific clamping mode is as follows: and placing the large partition plate on a multifunctional platform, quickly positioning the large partition plate against a right angle formed by quick positioning pins, inserting a quick clamp of the partition plate into a reserved hole on a partition plate station, and screwing a clamp handle to clamp the partition plate by the clamp. The separator can be fixed on the separator welding station by repeating the process for several times at each edge of the separator, so that the automatic welding of the separator is convenient for the welding robot.
And (3) a main control system: the intelligent control system comprises a PLC, an electric control cabinet, a servo controller, a touch screen, a main control desk, an industrial personal computer, a router and a display. The components are communicated by adopting a ProfiNet bus communication protocol, the PLC is used for sending and receiving various control signals to other systems, and the servo controller is used for receiving the control signals of the PLC or the control signals of the touch screen and the central control button independently. The master control PLC performs unified coordination, management and control on the whole production line; the touch screen is responsible for sending various operations and input parameters of an operator to the PLC, and is a main way for the operator to control the production line. Meanwhile, information provided by the PLC is received, and parameters such as welding current, voltage, welding speed, production takt and the like are displayed; the industrial personal computer is connected with the PLC communication network and the company intranet, can download standardized drawings from the company intranet according to the actual model of the workpiece to be welded, is connected with the display screen, and displays real-time production data of the production line on the large screen. Meanwhile, a robot teaching box in the robot control system is mainly used for programming and maintaining teaching of the robot, and a main control console button is used for assisting a touch screen, so that an operator can operate conveniently; the whole set of main control system can realize that operators can effectively control the whole production line, and realize the automatic production function of the whole production line.
Safety protection system: comprises a safety fence, a safety door, a robot bracket, an emergency stop button, a light curtain and the like; the safety fence is characterized in that each component can be communicated with the PLC, and the safety fence is mainly used for preventing personnel from entering and shielding arc light generated by welding. And the division can be flexibly performed according to the actual production condition. The safety door is used for personnel to enter and exit, and simultaneously controls the operation of the whole system, and after the safety door is opened, the whole production line cannot be started; the robot bracket can detect the collision state of the robot in real time, and automatically stops the robot when the collision of the robot is detected, so as to protect a robot system from collision damage; the emergency stop buttons are arranged at all parts of the production line, and the equipment can be stopped immediately by pressing the emergency stop buttons; each station is provided with a light curtain system, and the light curtain is shielded in any state, so that the control system can give an alarm; the whole set of safety protection system can realize the protection function of personnel safety.
Auxiliary system 7: the automatic monitoring system comprises a power interface, a compressed air interface, a monitoring system, a sensor and the like, wherein the power interface and the compressed air interface are used for being connected with an external pneumatic or electric tool so as to facilitate auxiliary work of welding such as polishing and dust removal of an operator, the monitoring system can monitor the real-time state of a production line, and the sensor comprises monitoring equipment such as a pressure gauge, a flowmeter and the like; each monitoring device collects data in real time, and periodically transmits the collected data to the PLC and the industrial personal computer, so that the real-time current, voltage, welding speed and other welding parameters of the workstation and consumption conditions of welding wires, gas and other consumable materials can be monitored and counted. The whole auxiliary system can provide auxiliary functions for operators.
1. The whole set of system has the function of equipment management, can display the working state of working equipment in real time on a central console, display necessary operation parameters in real time, and set a comprehensive information display system to display the data.
2. The whole set of system needs to have flexible equipment scheduling operation function. The operator calls the stored teaching program or parameterized program, and different called combined equipment completes various work tasks according to the instructions issued by the operator. For example: the double manipulators are cooperated to weld four butt joints of the large partition board simultaneously, the welding of the cross frames can be finished one by independent action of a single manipulator, the welding of the partition board can be finished independently by one manipulator, the welding of the trolley frame can be finished by the other manipulator and the positioner, and the equipment operation can be flexibly organized according to the production capacity and the process arrangement.
3. Further, the welding system of the production line has stronger weld locating, weld tracking, bridging welding and other capacities, can automatically find the weld position, can automatically correct the welding position, and reduces the influence of the blanking precision difference or the assembly precision difference on the welding quality and the welding efficiency to the minimum.
4. Further, the baffle welding clamping platform adopts a multifunctional operation platform, can be divided into 2-20 welding stations according to the size of the baffle, adopts a quick locating pin to divide stations freely, can be propped against the right angle position formed by the locating pins to position quickly, and adopts a quick welding clamping tool to clamp manually.
5. Furthermore, the positioner is provided with a trolley frame clamping and positioning tool, and a manual clamping and positioning mode is adopted, so that the tool is required to cover a small area, the clamping is firm, the positioning is accurate, and the feeding and discharging operations are convenient.
6. Further, the whole system has enough openness and expandability, and different working tools can be added or changed according to the technical development and production requirements.
7. Further, the whole system is provided with multiple safety measures, so that the safety of operators and equipment is ensured. For example: during normal production, operators can start working after evacuating the working area of the equipment, and the equipment automatically stops when an abnormal event occurs.
Through the realization of the technical scheme, the invention meets the requirement of automatic welding of parts such as main beam partition plates, bogie frames and the like of various types of cranes. The welding robot can automatically finish welding only by inputting the model of the corresponding bogie frame or the related size data of the corresponding baffle plate, and the bogie frame and the baffle plate can be produced in a collinear manner in a production line and can be additionally welded with other parts such as a saddle and the like. The utilization rate of the production line is very high.
Compared with the prior art, the invention has the following advantages:
compared with the existing manual welding, the invention has the advantages that the production efficiency of the partition plate is improved by about 1.6 times, the production efficiency of the bogie frame is improved by about 2.8 times, and the plate working procedure after the welding of the partition plate and the baking and repairing working procedure after the welding of the bogie frame can be canceled.
Drawings
In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings that are required in the embodiments or the description of the prior art will be briefly described, and it is obvious that the drawings in the following description are some embodiments of the present invention, and other drawings may be obtained according to the drawings without inventive effort to a person skilled in the art.
FIG. 1 is an apparatus layout of the present invention;
FIG. 2 is a table frame tooling fixture of the present invention;
FIG. 3 is an overview of the device connection of the present invention;
FIG. 4 is an overview of a workstation network layout of the present invention;
FIG. 5 is a station diagram of the positioner of the present invention;
FIG. 6 is a touch screen display structure of the present invention;
FIG. 7 is a logical operation portion of the welding program of the present invention;
in the figure:
1. a welding manipulator system;
2. a positioner system;
2-1, a bogie frame clamp; 2-2, positioner clamp frame; 2-3, a servo motor;
201. welding the frame; 202. a pressing plate; 203-210, a product limiting block; 211-213, a common product locating pin; 214. a product frame; 215. quick-changing adjusting cushion blocks; 216. a pressing plate limiting block; 217. a gasket; 218-225, hexagon socket head cap screws and washers; 226. a positioning pin; 227. a gasket; 228. a slipknot bolt; 229. an internal thread cylindrical pin; 230. a top plate; 231. an internal thread cylindrical pin;
3. a slipway mechanism;
4. a multifunctional platform;
5. a main control system;
6. a safety protection system;
7. an auxiliary system;
Detailed Description
It should be noted that, without conflict, the embodiments of the present invention and features of the embodiments may be combined with each other. The invention will be described in detail below with reference to the drawings in connection with embodiments.
For the purpose of making the objects, technical solutions and advantages of the embodiments of the present invention more apparent, the technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings in the embodiments of the present invention, and it is apparent that the described embodiments are only some embodiments of the present invention, not all embodiments. The following description of at least one exemplary embodiment is merely exemplary in nature and is in no way intended to limit the invention, its application, or uses. All other embodiments, which can be made by those skilled in the art based on the embodiments of the invention without making any inventive effort, are intended to be within the scope of the invention.
It is noted that the terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of exemplary embodiments according to the present invention. As used herein, the singular is also intended to include the plural unless the context clearly indicates otherwise, and furthermore, it is to be understood that the terms "comprises" and/or "comprising" when used in this specification are taken to specify the presence of stated features, steps, operations, devices, components, and/or combinations thereof.
The relative arrangement of the components and steps, numerical expressions and numerical values set forth in these embodiments do not limit the scope of the present invention unless it is specifically stated otherwise. Meanwhile, it should be clear that the dimensions of the respective parts shown in the drawings are not drawn in actual scale for convenience of description. Techniques, methods, and apparatus known to those of ordinary skill in the relevant art may not be discussed in detail, but are intended to be part of the specification where appropriate. In all examples shown and discussed herein, any specific values should be construed as merely illustrative, and not a limitation. Thus, other examples of the exemplary embodiments may have different values. It should be noted that: like reference numerals and letters denote like items in the following figures, and thus once an item is defined in one figure, no further discussion thereof is necessary in subsequent figures.
In the description of the present invention, it should be understood that the azimuth or positional relationships indicated by the azimuth terms such as "front, rear, upper, lower, left, right", "lateral, vertical, horizontal", and "top, bottom", etc., are generally based on the azimuth or positional relationships shown in the drawings, merely to facilitate description of the present invention and simplify the description, and these azimuth terms do not indicate and imply that the apparatus or elements referred to must have a specific azimuth or be constructed and operated in a specific azimuth, and thus should not be construed as limiting the scope of protection of the present invention: the orientation word "inner and outer" refers to inner and outer relative to the contour of the respective component itself.
Spatially relative terms, such as "above … …," "above … …," "upper surface at … …," "above," and the like, may be used herein for ease of description to describe one device or feature's spatial location relative to another device or feature as illustrated in the figures. It will be understood that the spatially relative terms are intended to encompass different orientations in use or operation in addition to the orientation depicted in the figures. For example, if the device in the figures is turned over, elements described as "above" or "over" other devices or structures would then be oriented "below" or "beneath" the other devices or structures. Thus, the exemplary term "above … …" may include both orientations of "above … …" and "below … …". The device may also be positioned in other different ways (rotated 90 degrees or at other orientations) and the spatially relative descriptors used herein interpreted accordingly.
In addition, the terms "first", "second", etc. are used to define the components, and are only for convenience of distinguishing the corresponding components, and the terms have no special meaning unless otherwise stated, and therefore should not be construed as limiting the scope of the present invention.
As shown in fig. 1 to 3, the present invention provides an intelligent welding production line for a bogie frame and a partition plate, comprising: welding manipulator system 1, slip table mechanism 3, positioner system 2, multi-functional platform 4, main control system 5, safety protection system 6 and auxiliary system 7:
welding robot system 1: the welding machine comprises a welding power supply, a welding gun, a robot mechanical system, a robot control system, a wire feeding system and a water chiller;
the welding power supply, the wire feeding system and the water chiller act by receiving corresponding control signals of the PLC in the main control system; the welding power supply is responsible for providing welding currents in different modes such as pulse, direct current and the like for the welding gun to weld; the robot mechanical system is responsible for receiving the instruction from the robot controller and implementing the corresponding welding action; the welding of each position of the welding workpiece can be realized; the robot control system is mainly used for storing corresponding robot control programs and welding programs, various position information and other data of the robot, receiving communication of the PLC and controlling the robot to realize welding according to the corresponding welding programs; the wire feeding system is responsible for providing welding wires for the welding gun according to signal control; the cold water machine is responsible for circulation of cooling liquid to cool the welding gun and prevent the welding gun from being damaged due to overheating; the whole set of welding manipulator system can realize the stable welding function of the welding gun on the workpiece to be welded, and can automatically switch various welding modes, such as pulse, direct current and the like, according to the control of a welding program, so as to achieve the optimal welding effect.
Positioner system 2: comprises a bogie frame clamp 2-1, a positioner clamp frame 2-2 and a servo motor 2-3. The positioner rotates according to the signal sent by the PLC, the robot controller or the servo controller and is matched with the robot to weld the workpiece to be welded. Wherein: the whole set of casting crane frame clamp consists of a welding frame 201, a pressing plate 202, product limiting blocks 203-210, common product locating pins 211-213, a product frame 214, a quick-change adjusting cushion block 215, a pressing plate limiting block 216, a top disk 230 and the like in the figure 2, and is responsible for completing the clamping of workpieces to be welded. The fixture frame 2-2 of the positioner is responsible for fixing the bogie frame fixture, and after automatic welding begins, the fixture frame is driven by rotation of the servo motor 2-3 to drive the casting crane fixture so as to complete automatic welding of the casting crane frame by matching with the welding robot; the servo motor 2-3 is responsible for receiving a signal instruction of the robot control system or the servo control system, and drives the clamp frame to rotate according to the instruction.
Slipway mechanism 3: comprises a slipway main structure, a speed reducer, a servo motor, a ground rail structure 3-4, a slide rail sliding block and a gear rack; the main structure of the sliding table can play a bearing role on the welding manipulator system 1, and the speed reducer and the servo motor are responsible for providing power for the sliding table; the ground rail structure is responsible for providing a flat reference plane for placing a sliding rail and a sliding block, and provides support for the movement of the sliding table; the sliding rail sliding block is responsible for bearing the whole sliding table and the cantilever part of the sliding table, namely the weight of the welding manipulator system 1 and the gear rack are used for receiving power generated by the servo motor, so that each part of the sliding table mechanism can move along the direction of the sliding rail. The whole set of sliding table system can realize that the sliding table is matched with the robot to carry out moving operation according to signals received from the PLC and the robot controller, so that the robot is transferred among all welding stations, and the effective welding range of the robot is increased.
Multifunctional platform 4: comprises a multifunctional platform body, a quick clamping device and a quick positioning pin. The multifunctional platform is generally used for welding a large partition plate, and the specific clamping mode is as follows: and placing the large partition plate on a multifunctional platform, quickly positioning the large partition plate against a right angle formed by quick positioning pins, inserting a quick clamp of the partition plate into a reserved hole on a partition plate station, and screwing a clamp handle to clamp the partition plate by the clamp. The separator can be fixed on the separator welding station by repeating the process for several times at each edge of the separator, so that the automatic welding of the separator is convenient for the welding robot.
The main control system 5: the intelligent control system comprises a PLC, an electric control cabinet, a servo controller, a touch screen, a main control desk, an industrial personal computer, a router and a display. The components are communicated by adopting a ProfiNet bus communication protocol, the PLC5-1 is used for sending and receiving various control signals to other systems, and the servo controller is used for receiving the control signals of the PLC or the control signals of the touch screen and the central control button independently. The master control PLC performs unified coordination, management and control on the whole production line; the touch screen is responsible for sending various operations and input parameters of an operator to the PLC, and is a main way for the operator to control the production line. Meanwhile, information provided by the PLC is received, and parameters such as welding current, voltage, welding speed, production takt and the like are displayed; the industrial personal computer is connected with the PLC communication network and the company intranet, can download standardized drawings from the company intranet according to the actual model of the workpiece to be welded, is connected with the display screen, and displays real-time production data of the production line on the large screen. Meanwhile, a robot teaching box in the robot control system is mainly used for programming and maintaining teaching of the robot, and a main control console button is used for assisting a touch screen, so that an operator can operate conveniently; the whole set of main control system can realize that operators can effectively control the whole production line, and realize the automatic production function of the whole production line.
Safety protection system 6: comprises a safety fence, a safety door, a robot bracket, an emergency stop button, a light curtain and the like; the safety fence is characterized in that each component can communicate with the PLC5-1, is mainly used for preventing personnel from entering, and shields arc light generated by welding. And the division can be flexibly performed according to the actual production condition. The safety door is used for personnel to enter and exit, and simultaneously controls the operation of the whole system, and after the safety door is opened, the whole production line cannot be started; the robot bracket can detect the collision state of the robot in real time, and automatically stops the robot when the collision of the robot is detected, so as to protect a robot system from collision damage; the emergency stop buttons are arranged at all parts of the production line, and the equipment can be stopped immediately by pressing the emergency stop buttons; each station is provided with a light curtain system, and the light curtain is shielded in any state, so that the control system can give an alarm; the whole set of safety protection system can realize the protection function of personnel safety.
Auxiliary system 7: the automatic monitoring system comprises a power interface, a compressed air interface, a monitoring system, a sensor and the like, wherein the power interface and the compressed air interface are used for being connected with an external pneumatic or electric tool so as to facilitate auxiliary work of welding such as polishing and dust removal of an operator, the monitoring system can monitor the real-time state of a production line, and the sensor comprises monitoring equipment such as a pressure gauge, a flowmeter and the like; each monitoring device collects data in real time, and periodically transmits the collected data to the PLC and the industrial personal computer, so that the real-time current, voltage, welding speed and other welding parameters of the workstation and consumption conditions of welding wires, gas and other consumable materials can be monitored and counted. The whole auxiliary system can provide auxiliary functions for operators.
Examples:
some embodiments of the present invention will be described in detail below with reference to the accompanying drawings.
As shown in the attached figure 1, the intelligent welding production line for the trolley frame and the partition plate comprises two welding robots, wherein the two welding robots are respectively fixed on two sets of sliding tables through sliding rail sliding blocks, two sets of main structures of the sliding tables are arranged on a ground rail structure through the sliding rail sliding blocks, the two robots can move in the X and Z axis directions of the sliding tables under the driving of a servo motor, a speed reducer, a gear rack and other structures, and meanwhile, the main structures of the sliding tables can also move in the Y axis direction; the welding gun is arranged on the installation surface of the end effector of the robot and is connected with a wire feeding system arranged on the installation surface of the shell equipment of the robot through a cable; the wire feeding system is connected with a robot control system, a welding power supply and a water chiller which are arranged on the slipway through cables, so that the wire feeding system can move along with the slipway and the robot under the control of a PLC (programmable logic controller); the PLC in the electric control cabinet is connected with the touch screen and the main control desk through a network and receives control signals to control the actions of the robot and the sliding table; the positioner system 2 and the multifunctional platform 4 are sequentially arranged and are parallel to the track of the sliding table mechanism, the positioner clamp frame 2-2 is driven by the servo motor 2-3, and the PLC sends an instruction to the servo motor 2-3 through the network control servo controller so as to enable the servo motor to be matched with the action of the robot and the sliding table for welding; the safety fence is arranged around the whole production line, and the safety door, the emergency stop button, the light curtain, the power interface, the compressed air interface, the monitoring system and the like are all arranged on the safety fence to provide safety and auxiliary functions for the production line. The router provides network communication for the whole set of production lines, and the network layout is shown in fig. 4.
The production process flow of the invention is as follows:
a bogie frame:
the blank of the trolley frame to be welded is clamped on a trolley frame clamp 2-1 shown in figure 2: selecting corresponding limiting blocks 203-210, common product positioning pins 211-213, product frames 214 and other parts according to the model of the casting crane frame to be clamped, fixing the common product positioning pins 211-213 with the corresponding sizes of the workpieces to be welded at the bottom of the welding frame 201 by using hexagon socket head cap screws, and fixing the corresponding limiting blocks 203-210 at the left side of the welding frame by using the hexagon socket head cap screws and gaskets 218-225; the casting crane frame is hoisted into the welding frame 201 by taking the limiting blocks 203-210 as the reference, and is abutted against the limiting blocks 203-210, and meanwhile, the shape of the casting crane frame is tightly attached to the common product positioning pins 211-213. According to actual needs, the corresponding product frame 214 is fixed on the pressing plate 202, the pressing plate 202 is placed on the top of the clamp, the pressing plate 202 is clamped on the welding frame 201 by using the slipknot bolts 228 and screwed, and after clamping, the top plate 230 is screwed so as to clamp a workpiece. The combination of the jig and the workpiece is hoisted to the positioner and is fixed to the positioner frame 2-2 by bolts.
Fixing the bogie frame fixture 2-1 on the positioner frame 2-2 shown in fig. 5; the operator operates on a touch screen in the main control system 5 shown in the drawings; selecting a corresponding bogie frame model from the parameter settings shown in figure 4, and pressing an automatic operation button; the sliding table mechanism 3 is driven by the servo motor 2-3 to move to the bogie frame positioner system 2 through the ground rail structure, the welding robot 1 arranged at the sliding block moves in the X/Y/Z axis direction through the sliding rail under the cooperation of the gear and the rack, so that the welding gun is aligned to the position to be welded of the workpiece, and the positioner clamp frame 2-2 drives the tool clamp clamped with the workpiece to rotate under the action of the servo motor 2-3 and is matched with the robot to finish welding. In the welding process, the sliding table mechanism 3 and the positioner system 2 also act under the control of a welding program, and the welding work of the trolley frame is completed by matching with a robot.
Partition board:
after the blank of the partition board to be welded is positioned quickly by utilizing a quick positioning pin, the blank is clamped on a multifunctional platform shown in the figure 1 by using a quick clamping fixture; the operator operates on a touch screen in the main control system 5 shown in the drawings; the corresponding dimension parameters of the partition boards such as the width B, B, the B6, the B7, the B8, the B13, the B14, the length H, H, the H9 and the like are input into a template formula shown in the figure 4, and after a send key is pressed, the parameters are sent to a PLC by a touch screen and temporarily stored; selecting a corresponding partition plate model from the parameter settings shown in figure 4, and pressing an automatic operation button; the PLC will send dimension data of the diaphragm, such as width B, B, B6, B7, B8, B13, B14, length H, H, H9, etc., to the data register of the robot control system. Under the cooperation of the gear and the rack, the welding robot moves in the X/Y/Z axis direction through the slide rail so as to lead the welding gun to be aligned with the position to be welded of the workpiece; before welding starts, the welding robot automatically searches the position according to the principle that a welding gun is in contact with a workpiece, and the size data of the partition plate are called from a data register of a robot control system according to a corresponding welding program. The called data and the data obtained by locating obtain the accurate coordinates of each point of the partition board to be welded through logical operation (as shown in figure 7), and the program automatically plans the welding seam according to the coordinates so as to automatically weld the partition board by the robot. The welding robot can finish automatic welding of the partition plate.
Finally, it should be noted that: the above embodiments are only for illustrating the technical solution of the present invention, and not for limiting the same; although the invention has been described in detail with reference to the foregoing embodiments, it will be understood by those of ordinary skill in the art that: the technical scheme described in the foregoing embodiments can be modified or some or all of the technical features thereof can be replaced by equivalents; such modifications and substitutions do not depart from the spirit of the invention.
Claims (10)
1. An intelligent welding production line for a trolley frame and a partition plate, which is characterized by comprising the following steps:
the welding manipulator system (1), the sliding table mechanism (3), the positioner system (2), the multifunctional platform (4) and the main control system (5);
the welding robot system (1) includes: the welding machine comprises a welding power supply, a welding gun, a robot mechanical system, a robot control system, a wire feeding system and a water chiller;
the welding power supply, the wire feeding system and the water chiller operate by receiving corresponding control signals of the PLC in the main control system (5);
the welding power supply is responsible for providing pulse and direct current welding currents in different modes for a welding gun to weld;
the robot mechanical system is responsible for receiving the instruction from the robot controller, implementing the corresponding welding action, and realizing the welding of each position of the welding workpiece;
the robot control system is mainly used for storing corresponding robot control programs and welding programs, various position information and other data of the robot, and meanwhile, is connected with the communication of the PLC in the controlled system (5) to control the robot to realize welding according to the corresponding welding programs;
the wire feeding system is responsible for providing welding wires for the welding gun according to signal control; the cold water machine is responsible for circulation of cooling liquid to cool the welding gun and prevent the welding gun from being damaged due to overheating;
the positioner system (2) rotates according to the signal sent by the PLC, the robot controller or the servo controller and is matched with the robot to weld the workpiece to be welded;
the positioner system (2) includes: a bogie frame clamp (2-1) for clamping a workpiece to be welded, a positioner clamp frame (2-2) for fixing the bogie frame clamp, and a servo motor (2-3) for driving the positioner clamp frame (2-2) to rotate;
the main body structure of the sliding table mechanism (3) plays a bearing role on the welding manipulator system (1), and the power part of the sliding table mechanism is matched with signals received by the PLC and the robot controller to carry out moving operation so as to enable the robot to transfer among welding stations and increase the effective welding range of the robot;
the multifunctional platform (4) is used for separating welding stations and is convenient for a robot to automatically weld the welding stations;
and the main control system (5) is used for uniformly coordinating, managing and controlling the whole production line by the internal PLC.
2. The intelligent welding production line for the trolley frames and the partition plates according to claim 1, wherein,
further comprises: a safety protection system (6);
the safety protection system (6) comprises: safety fence, safety door, robot bracket, emergency stop button and light curtain; the electric control part of each component is communicated with the PLC;
the safety fence is arranged at a station position of the production line or a position needing protection, and is mainly used for preventing personnel from entering and shielding arc light generated by welding;
the safety door is used for personnel to enter and exit in the working area of the production line, and the control is configured so that the whole production line cannot be started after the safety door is opened;
the robot bracket detects the collision state of the robot in real time, and automatically stops the robot when the collision of the robot is detected, so as to protect a robot system from collision damage;
the emergency stop buttons are arranged at all parts of the production line, and the equipment can be stopped immediately by pressing the emergency stop buttons;
a light curtain system is installed at each station separated by a multifunctional platform, and the control is configured to block the light curtain in any state, so as to trigger the control system to alarm.
3. An intelligent welding production line for a bogie frame and a partition plate according to claim 1 or 2, wherein,
further comprises: an auxiliary system (7);
the auxiliary system (7) comprises: the system comprises a power interface, a compressed air interface, a monitoring system and a sensor;
the power interface and the compressed air interface are used for connecting an external pneumatic or electric tool;
the monitoring system monitors the real-time state of the production line;
the sensor comprises: monitoring devices such as pressure gauges and flow meters collect data in real time and periodically send the collected data to a main control system (5).
4. An intelligent welding production line for a bogie frame and a partition plate according to claim 1 or 2, wherein,
the main control system (5) comprises: the system comprises a PLC, an electric control cabinet, a servo controller, a touch screen, a main control desk, an industrial personal computer, a router and a display;
the components are communicated by adopting a ProfiNet bus communication protocol, the PLC is used for sending and receiving various control signals to other systems, and the servo controller is used for receiving the control signals of the PLC or the control signals of the touch screen and the central control button independently;
the PLC is used for uniformly coordinating, managing and controlling the whole production line; the touch screen is responsible for sending various operations of an operator and various input parameters to the PLC, and is a main way for the operator to control the production line; meanwhile, information provided by the PLC is received, and parameters such as welding current, voltage, welding speed, production takt and the like are displayed; the industrial personal computer is connected with the PLC communication network and the company intranet at the same time, can download standardized drawings from the company intranet according to the actual model of the workpiece to be welded, is connected with the display screen, and displays real-time production data of the production line on the large screen; meanwhile, a robot teaching box in the robot control system is mainly used for teaching programming and maintaining the robot; the main control desk button is used for assisting the touch screen, so that an operator can operate conveniently.
5. An intelligent welding production line for a bogie frame and a partition plate according to claim 3, wherein,
the main control system (5) comprises: the system comprises a PLC, an electric control cabinet, a servo controller, a touch screen, a main control desk, an industrial personal computer, a router and a display;
the components are communicated by adopting a ProfiNet bus communication protocol, the PLC is used for sending and receiving various control signals to other systems, and the servo controller is used for receiving the control signals of the PLC or the control signals of the touch screen and the central control button independently;
the PLC is used for uniformly coordinating, managing and controlling the whole production line; the touch screen is responsible for sending various operations of an operator and various input parameters to the PLC, and is a main way for the operator to control the production line; meanwhile, information provided by the PLC is received, and parameters such as welding current, voltage, welding speed, production takt and the like are displayed; the industrial personal computer is connected with the PLC communication network and the company intranet at the same time, can download standardized drawings from the company intranet according to the actual model of the workpiece to be welded, is connected with the display screen, and displays real-time production data of the production line on the large screen; meanwhile, a robot teaching box in the robot control system is mainly used for teaching programming and maintaining the robot; the main control desk button is used for assisting the touch screen, so that an operator can operate conveniently.
6. An intelligent welding production line for a bogie frame and a partition plate according to claim 1 or 2, wherein,
the multi-function platform (4) comprises: a multifunctional platform body, a quick clamping device and a quick positioning pin; the multifunctional platform is generally used for welding a large partition plate, and the specific clamping mode is as follows: placing the large partition board on a multifunctional platform, propping against a right angle position formed by quick positioning pins to quickly position, inserting a quick clamp of the partition board into a hole reserved on a partition board station, and screwing a clamp handle to clamp the partition board by the clamp; the separator can be fixed on the welding stations of the separator by repeating the process for several times at each edge of the separator, and then a plurality of welding stations are separated.
7. An intelligent welding production line for a bogie frame and a partition plate according to claim 3, wherein,
the multi-function platform (4) comprises: a multifunctional platform body, a quick clamping device and a quick positioning pin; the multifunctional platform is generally used for welding a large partition plate, and the specific clamping mode is as follows: placing the large partition board on a multifunctional platform, propping against a right angle position formed by quick positioning pins to quickly position, inserting a quick clamp of the partition board into a hole reserved on a partition board station, and screwing a clamp handle to clamp the partition board by the clamp; the separator can be fixed on the welding stations of the separator by repeating the process for several times at each edge of the separator, and then a plurality of welding stations are separated.
8. An intelligent welding production line for a bogie frame and a partition plate according to claim 1 or 2, wherein,
slip table mechanism (3), include: the device comprises a slipway main structure, a speed reducer, a servo motor, a ground rail structure, a slide rail sliding block and a gear rack;
the main structure of the sliding table has a bearing function on the welding manipulator system (1), and the speed reducer and the servo motor are responsible for providing power for the sliding table; the ground rail structure is responsible for providing a flat reference plane for placing a sliding rail and a sliding block, and provides support for the movement of the sliding table; the sliding rail sliding block is responsible for bearing the whole sliding table and the cantilever part of the sliding table, namely the weight of the welding manipulator system (1); the rack and pinion is used for receiving power generated by the servo motor, so that each part of the sliding table mechanism can move along the direction of the sliding rail.
9. An intelligent welding production line for a bogie frame and a partition plate according to claim 3, wherein,
slip table mechanism (3), include: the device comprises a slipway main structure, a speed reducer, a servo motor, a ground rail structure, a slide rail sliding block and a gear rack;
the main structure of the sliding table has a bearing function on the welding manipulator system (1), and the speed reducer and the servo motor are responsible for providing power for the sliding table; the ground rail structure is responsible for providing a flat reference plane for placing a sliding rail and a sliding block, and provides support for the movement of the sliding table; the sliding rail sliding block is responsible for bearing the whole sliding table and the cantilever part of the sliding table, namely the weight of the welding manipulator system (1); the rack and pinion is used for receiving power generated by the servo motor, so that each part of the sliding table mechanism can move along the direction of the sliding rail.
10. An intelligent welding production line for a bogie frame and a partition plate according to claim 1 or 2, wherein,
the positioner system (2), wherein the casting crane frame clamp (2-1) comprises: the welding device comprises a welding frame (201), a pressing plate (202), a product limiting block, a common product positioning pin, a product frame (214), a quick-change adjusting cushion block (215), a pressing plate limiting block (216) and a top disc (230); the whole clamp is responsible for completing clamping of the workpiece to be welded;
the fixture frame (2-2) of the positioner is responsible for fixing the bogie frame fixture, and after automatic welding is started, the fixture frame is driven by rotation of the servo motor (2-3) to drive the casting crane fixture so as to match with the welding robot to finish automatic welding of the casting crane bogie frame; the servo motor (2-3) is responsible for receiving a signal instruction of the robot control system or the servo control system and driving the clamp frame to rotate according to the instruction.
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| CN118682380A (en) * | 2024-08-27 | 2024-09-24 | 昆山市华霆精密机械有限公司 | Welding tool for industrial robot machining |
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