CN114871611B - Automatic preparation system and method for welding pulley - Google Patents

Automatic preparation system and method for welding pulley Download PDF

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Publication number
CN114871611B
CN114871611B CN202210499944.2A CN202210499944A CN114871611B CN 114871611 B CN114871611 B CN 114871611B CN 202210499944 A CN202210499944 A CN 202210499944A CN 114871611 B CN114871611 B CN 114871611B
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welding
pulley
turnover
workstation
area
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CN114871611A (en
Inventor
王传存
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Shanghai Zhenhua Port Machinery Heavy Industries Co
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Shanghai Zhenhua Port Machinery Heavy Industries Co
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Priority to PCT/CN2022/097784 priority patent/WO2023216351A1/en
Publication of CN114871611A publication Critical patent/CN114871611A/en
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    • BPERFORMING OPERATIONS; TRANSPORTING
    • B23MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23KSOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K31/00Processes relevant to this subclass, specially adapted for particular articles or purposes, but not covered by only one of the preceding main groups
    • B23K31/02Processes relevant to this subclass, specially adapted for particular articles or purposes, but not covered by only one of the preceding main groups relating to soldering or welding
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B23MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23KSOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K37/00Auxiliary devices or processes, not specially adapted to a procedure covered by only one of the preceding main groups
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B23MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23KSOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K37/00Auxiliary devices or processes, not specially adapted to a procedure covered by only one of the preceding main groups
    • B23K37/04Auxiliary devices or processes, not specially adapted to a procedure covered by only one of the preceding main groups for holding or positioning work
    • B23K37/047Auxiliary devices or processes, not specially adapted to a procedure covered by only one of the preceding main groups for holding or positioning work moving work to adjust its position between soldering, welding or cutting steps
    • YGENERAL 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
    • Y02TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02PCLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P90/00Enabling technologies with a potential contribution to greenhouse gas [GHG] emissions mitigation
    • Y02P90/02Total factory control, e.g. smart factories, flexible manufacturing systems [FMS] or integrated manufacturing systems [IMS]

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Physics & Mathematics (AREA)
  • Optics & Photonics (AREA)
  • Butt Welding And Welding Of Specific Article (AREA)

Abstract

The invention discloses an automatic preparation system of a welding pulley, which comprises the following components: the welding workstation is provided with a plurality of sets for realizing double-sided inner and outer circle welding seams of the welding pulley; the turnover mechanism is arranged at one side of the welding workstation and used for turning over the pulley on the welding workstation; the welding fume treatment mechanism is used for treating fume generated by the welding workstation; the central control PLC is used for controlling the operation of the welding workstation, the welding fume treatment mechanism and the turnover mechanism; the touch screen is used for inputting operation instructions. The invention also discloses an automatic preparation method of the welding pulley, which is realized by adopting an automatic preparation system of the welding pulley. The invention can improve the working efficiency and stabilize the welding quality of products.

Description

Automatic preparation system and method for welding pulley
Technical Field
The invention relates to a pulley preparation technology, in particular to an automatic preparation system and method for a welded pulley.
Background
The pulley manufactured by the conventional casting process has large energy consumption and serious pollution, and the rope grooves at key positions are difficult to avoid the defects of metal shrinkage; the utilization rate of the forged pulley material is low, the blank manufacturing and machining costs are high, and the overall manufacturing cost is high; the forming method of the welded pulley mainly comprises the steps of splicing and welding the outer ring of the ring section, the web plate, the supporting tube and the inner ring of the ring section, wherein the web plate, the supporting tube and the inner ring of the ring section can be made of low-strength steel, the outer ring of the ring section has high carbon steel grades, different steel grades are adopted, the weight can be reduced, the production cost is reduced, but the high carbon steel of the rope groove has higher surface hardness through quenching, and the wear resistance and the practicability of the welded pulley are further improved.
Disclosure of Invention
Aiming at the defects in the prior art, the invention aims to provide an automatic preparation system and method for a welding pulley, which can improve the working efficiency and stabilize the welding quality of products.
In order to achieve the above purpose, the invention adopts the following technical scheme:
in one aspect, an automated manufacturing system for a welding pulley includes:
the welding workstation is provided with a plurality of sleeves and is used for realizing the welding of welding seams of the inner ring and the outer ring of the two sides of the welding pulley;
the turnover mechanism is arranged at one side of the welding workstation and used for turning over the pulley on the welding workstation by 180 degrees;
the welding fume treatment mechanism is used for treating fume generated by the welding workstation;
the central control PLC is used for controlling the operation and monitoring of the welding workstation, the welding fume treatment mechanism and the turnover mechanism;
and the touch screen is used for inputting operation instructions and monitoring the state of the welding workstation.
Preferably, the welding workstation is provided with four sets, and one set of turnover mechanism is shared, and the four sets of welding workstations can be combined arbitrarily as required to finish the welding of one pulley.
Preferably, the welding workstations are arranged in parallel and share one set of turnover mechanism.
Preferably, the welding work stations comprise a welding work table, a sliding rail arranged on the welding work table, an electric three-jaw arranged on the welding work table and moving along the sliding rail, and a welding robot arranged on one side of the welding work table.
Preferably, the turnover mechanism comprises a turnover truss and turnover claws arranged on the turnover truss;
the turnover claw is provided with a turnover motor, a lifting motor and a clamping motor.
Preferably, the welding workstation is provided with an upper part area, a lower part area, a welding area and a turnover area;
the upper part and the lower part are respectively arranged at the two ends of the slide rail, the welding area is respectively arranged at the two ends of the slide rail, and the turnover area is respectively arranged at the two ends of the slide rail.
Preferably, the welding fume treatment mechanism comprises a dust collecting cover arranged above the welding workstation and a dust collecting device communicated with the dust collecting cover;
valves are arranged on the dust collecting hoods, and the opening of the valves is controlled according to the size of smoke dust.
An automatic preparation method of a welding pulley adopts the automatic preparation system of the welding pulley to execute the following steps:
s1, hoisting the pulley in the upper and lower part areas by an operator, placing the pulley on a welding workbench, inputting a command on the touch screen, and clamping the pulley by an electric three-jaw on the welding workbench;
s2, the welding workbench moves the pulley to the welding area;
s3, the welding robot performs welding operation on the inner ring and the outer ring of the surface A of the pulley;
s4, the welding workbench moves the pulley to the turnover mechanism;
s5, the electric three-jaw loosens the pulley, the turnover claw clamps, lifts and turns over the pulley for 180 degrees again, and then descends;
s6, clamping the pulley by the welding workbench and moving the pulley to the welding area;
s7, the welding robot performs welding operation on the inner ring and the outer ring of the surface B of the pulley;
s8, the welding workbench moves the pulley to the upper and lower part areas;
s9, unloading the pulley after welding is completed, and finishing the preparation of the pulley.
According to the automatic preparation system and method for the welding pulley, the labor intensity of technical workers is reduced, the quality of the welding pulley is improved by automatic welding, the construction environment is improved, full automation of double-sided welding of the pulley is realized, and the production efficiency is further improved.
Drawings
FIG. 1 is a schematic view of an in-situ deployment of an automated preparation system of the present invention;
FIG. 2 is a bottom view of FIG. 1;
FIG. 3 is a schematic flow chart of the automated preparation method of the present invention;
FIG. 4 is a schematic view of upper and lower pulleys in the automated manufacturing process of the present invention;
FIG. 5 is a schematic view of a welding pulley in an automated manufacturing process of the present invention;
FIG. 6 is a schematic view of a reversing pulley in an automated manufacturing process of the present invention;
fig. 7 is a schematic view of a weld on a pulley.
Detailed Description
In order to better understand the above technical solution of the present invention, the technical solution of the present invention is further described below with reference to the accompanying drawings and examples.
Referring to fig. 1 and 2, the present invention provides an automated manufacturing system for a welding pulley, comprising:
four sets of welding workstations 101, 102, 103 and 104 are arranged in parallel and are used for realizing double-sided inner and outer circle welding seams of the welding pulley 100;
the turnover mechanism 200 is arranged on one side of the welding work stations 101, 102, 103 and 104 and is used for turning over the pulleys 100 on the welding work stations 101, 102, 103 and 104 by 180 degrees;
a welding fume treatment mechanism 300 for treating fume generated during the operation of the welding workstations 101, 102, 103, 104;
the central control PLC is used for controlling the operation actions of the welding workstations 101, 102, 103, 104, the turnover mechanism 200 and the welding fume treatment mechanism 300;
and the touch screen is used for inputting various operation instructions by technicians.
The welding stations 101, 102, 103, 104 each include a welding table 1, a slide rail 2, an electric three jaw 3, and a welding robot 4. The slide rail 2 is mounted on the welding work stations 101, 102, 103 and 104, the electric three-jaw 3 is used for clamping an inner hole of the pulley 100, the electric three-jaw 3 is moved on the slide rail 2 through the moving motor, and the welding robot 4 is mounted beside the welding work stations 101, 102, 103 and 104 and is used for welding inner and outer circle welding seams on two sides (A side and B side) of the pulley 100.
The welding workstations 101, 102, 103 and 104, four welding power supplies, a central control PLC and a touch screen form an industrial network, a welding program is pre-stored in a robot demonstrator, after the welding program number is input through the touch screen, the welding robot 4 automatically invokes the welding program, and then the welding robot 4 can automatically weld.
The welding fume treatment mechanism 300 includes a dust collection device 5 and a dust collection cover 6. The number of dust hoods 6 corresponds to the number of welding stations 101, 102, 103, 104, and are disposed above the welding position where the welding robot 4 performs welding, and are communicated with the dust collection device 5 through the gas collecting pipe 7. A valve 8 is arranged on each dust hood 6 to control the opening and closing of the dust hood 6.
The turnover mechanism 200 includes a turnover truss 9 and turnover claws 10 mounted on the turnover truss 9.
The turning claw 10 is provided with a turning motor 11, a lifting motor 12 and a clamping motor 13.
The upper and lower part areas 14, the welding area 15 and the turnover area 16 are uniformly distributed on the welding tables 101, 102, 103 and 104. The upper and lower member areas 14 correspond to one end of the slide rail 2, the welding area 15 corresponds to a welding working position of the welding robot 4, and the turning area 16 corresponds to the other end of the slide rail 2 and also corresponds to the turning mechanism 200. The flipping regions 16 of the welding stations 101, 102, 103, 104 share a set of flipping mechanisms 200.
The invention also provides an automatic preparation method of the welding pulley, which is combined with the figures 3 to 7, and the automatic preparation system of the welding pulley adopts the invention to execute the following steps:
s1, manually assisting an operator in hoisting the pulley 100 in the upper and lower part area 14, inputting ACS instructions on a touch screen, and clamping an inner hole of the pulley 100 by the electric three-jaw 3;
s2, the welding workbench 1 moves the pulley 100 to a welding area 15;
s3, the welding robot 4 performs welding operation on the inner ring and the outer ring of the surface A of the pulley 100;
s4, after welding is completed, the welding workbench 1 moves the pulley 100 to the turnover mechanism 13;
s5, the electric three-jaw 3 loosens the pulley 100, the overturning claw 10 clamps, lifts and overturns the rope groove of the pulley 100 for 180 degrees again and descends;
s6, clamping an inner hole of the pulley 100 by the electric three-jaw 3, and moving the pulley 100 to a welding area 15 by the welding workbench 1;
s7, the welding robot 4 performs welding operation on the inner ring and the outer ring of the surface B of the pulley 100;
s8, after welding is completed, the welding workbench 1 moves the pulley 100 to the upper and lower part area 14;
s9, the electric three-jaw 3 loosens the inner hole of the pulley 100, and the pulley 100 after welding is manually and assisted to be dismounted.
The automatic preparation system operates under full automation of each device, each device operates automatically and continuously strictly according to the preset ACS instruction process sequence and production beats, and a technician can know the production condition of the area through a touch screen or an indicator light on an operating system. If each station is not in a ready state, the automatic position equipment cannot automatically operate even if the selection switch is hit at the moment, and corresponding alarm information is prompted so that an operator can recover in time. The relevant parameters of the welding program, the pulley thickness and the diameter are preset in the control system, and a technician only needs to select the number of the pulley to be welded in the control system, so that parameterized automatic welding is realized, and the product quality is further improved.
Example 1
This embodiment is illustrated with the feeding performed at the welding station 101:
manually assisting the upper and lower part areas 14 to hoist the pulley 100 to be welded onto the welding workbench 1 of the welding workstation 101, enabling the electric three-jaw 3 to clamp the inner hole of the pulley 100, inputting codes of the welding pulley 100 on the touch screen, starting ACS instructions, driving the electric three-jaw 3 to tension outwards until the control system monitors that the set current of the electric three-jaw 3 stops, and moving the motor to drive the welding workbench 1 to drive the pulley 100 to drive on the sliding rail 2 to move to the welding area 15 according to the ACS instructions.
Example 2
This embodiment is illustrated with an inside-outside weld joint on the a-side of the welding station 102 for welding the pulley 100:
when the welding robot 4 in the welding area 15 detects that the welding workbench 1 carries the pulley 100, a welding program corresponding to a code of the pulley 100 is automatically started, the valve 8 and the dust collection device 5 of the welding fume treatment mechanism 300 are started, meanwhile, a rotating motor on the welding workbench 1 is controlled by the welding robot 4 to start rotating, the welding workbench 1 carries the pulley 100 to rotate, the welding robot 4 starts welding while carrying the pulley 100, an inner ring weld joint of the A face of the pulley 100 is welded firstly, then an outer ring weld joint of the A face is welded, at the moment, the valve 8 is closed, an ACS (auto-sensor system) command is triggered after the inner ring weld joint of the A face of the pulley 100 is welded, and the electric three-jaw 3 drives the pulley 100 to travel to the overturning area 16 on the sliding rail 2.
Example 3
This embodiment is illustrated with the welding station 104 flipped:
if the welding table 1 moves to the turning area 16 of the welding station 104 with the pulley 100, the turning truss 9 of the turning area 16 periodically scans the position of the welding table 1 on the welding stations 101, 102, 103, 104, the turning claw 10 moves to the turning area 16 of the welding station 104 along the turning truss 9, the electric three-claw 3 loosens the pulley 100 inwards, the lifting motor 12 drives the turning claw 10 to descend to a preset position, the clamping motor 13 drives the turning claw 10 to clamp the pulley 100 rope groove, the lifting motor 12 drives the turning claw 10 to lift to a preset height, the turning motor 11 drives the turning claw 10 to turn the pulley 100 180 ° (B faces upwards), the lifting motor 12 drives the turning claw 10 to descend to a preset position, the clamping motor 13 drives the turning claw 10 to loosen the pulley 100, the lifting motor 12 drives the turning claw 10 to lift to a preset height, the electric three-claw 3 tightens the inner hole of the pulley 100 outwards until the control system monitors the set current stop of the electric three-claw 3, and the moving motor work drives the welding table 1 to move to the sliding rail 2 to the welding area 15 according to an ACS command.
Example 4
This embodiment is illustrated with the inside-outside weld joint on the B-face of the welding station 102 for welding the pulley 100:
when the welding robot 4 in the welding area 15 detects that the welding workbench 1 carries the pulley 100, a welding program corresponding to a code of the pulley 100 is automatically started, the valve 8 and the dust collection device 5 of the welding fume treatment mechanism 300 are started, meanwhile, a rotating motor on the welding workbench 1 is controlled by the welding robot 4 to start rotating, the welding workbench 1 carries the pulley 100 to rotate, the welding robot 4 starts welding while carrying the pulley 100, the inner ring weld of the B face of the pulley 100 is welded firstly, then the outer ring weld of the B face is welded, at the moment, the valve 8 is closed, the ACS command is triggered after the inner ring weld of the A face of the pulley 100 is welded, and the electric three-jaw 3 drives the pulley 100 to travel to the upper and lower workpiece area 14 on the sliding rail 2.
Example 5
This embodiment is illustrated with the following performed at the welding station 101:
when the upper and lower part areas 14 detect that the welding workbench 1 carries the pulley 100, the electric three-jaw 3 loosens the inner hole of the pulley 100 inwards, the pulley 100 is manually dismounted in an auxiliary manner, and the welding operation of double-sided welding seams of the pulley 100 is completed.
Example 6
In the embodiment, four sets of welding work stations can be combined arbitrarily to finish welding of one pulley according to requirements to explain:
Figure BDA0003635165310000061
the welding pulleys of the same piece can be welded in five different combination modes according to the procedures of feeding I, welding II, turning III and discharging IV. In summary, compared with the arrangement of cast pulleys, the automatic preparation system and the automatic preparation method for welding the pulleys have light weight, even only 1/4 of the cast pulleys, and for a large-scale port machine equipment crane, the dead weight of the arm end pulley is lightened to reduce the overturning moment of the crane, and the adoption of the welded pulleys is significant. The automatic unmanned welding quality is stable and reliable, the primary qualification rate is ensured, and the repair is reduced; the robot welding efficiency is high, the number of workers and the number of workers can be greatly reduced, and the benefits brought by automatic welding are remarkable.
It will be appreciated by persons skilled in the art that the above embodiments are provided for illustration only and not for limitation of the invention, and that variations and modifications of the above described embodiments are intended to fall within the scope of the claims of the invention as long as they fall within the true spirit of the invention.

Claims (3)

1. An automated preparation system for welded pulleys of a large port machinery equipment crane, comprising:
the welding workstation is provided with a plurality of sets for realizing double-sided inner and outer circle welding seams of the welding pulley;
the turnover mechanism is arranged at one side of the welding workstation and used for turning over the pulley on the welding workstation;
the welding fume treatment mechanism is used for treating fume generated by the welding workstation;
the central control PLC is used for controlling the operation of the welding workstation, the welding fume treatment mechanism and the turnover mechanism;
a touch screen for inputting ACS operation instructions and monitoring the state of the welding workstation,
the four sets of welding work stations are arranged in parallel and share one set of turnover mechanism, the four sets of welding work stations are combined arbitrarily as required to finish the welding of one pulley,
the welding work stations all comprise a welding work table, a sliding rail arranged on the welding work table, an electric three-jaw arranged on the sliding rail and moving along the sliding rail, and a welding robot arranged on one side of the welding work table,
the turnover mechanism comprises a turnover truss and turnover claws arranged on the turnover truss;
the turnover claw is provided with a turnover motor, a lifting motor and a clamping motor,
each welding workstation is provided with a piece loading and unloading area, a welding area and a turnover area;
the upper and lower part areas correspond to one end of the sliding rail, the welding area corresponds to the welding robot, the overturning area corresponds to the other end of the sliding rail and also corresponds to the overturning mechanism,
each device automatically and continuously operates according to the preset ACS instruction process sequence and production beats,
the automated preparation system for the welded pulley performs the following steps:
s1, hoisting the pulley by an operator in the upper and lower part areas, placing the pulley on the welding workbench, inputting an ACS instruction on the touch screen, and clamping the pulley by an electric three-jaw on the welding workbench;
s2, the welding workbench moves the pulley to the welding area;
s3, the welding robot performs welding operation on the inner ring and the outer ring of the surface A of the pulley;
s4, the welding workbench moves the pulley to the turnover mechanism;
s5, the electric three-jaw loosens the pulley, the turnover claw clamps, lifts and turns over the pulley for 180 degrees again, and then descends;
s6, clamping the pulley by the electric three-jaw, and moving the pulley to the welding area;
s7, the welding robot performs welding operation on the inner ring and the outer ring of the surface B of the pulley;
s8, the welding workbench moves the pulley to the upper and lower part areas;
s9, unloading the pulley after welding is completed, and finishing the preparation of the pulley.
2. The automated preparation system of welded pulleys of claim 1, wherein: the welding fume treatment mechanism comprises a dust hood arranged above the welding workstation and a dust collection device communicated with the dust hood;
valves are arranged on the dust collecting covers.
3. An automated preparation method of a welding pulley for a large harbor machine crane, characterized in that the following steps are performed by using the automated preparation system of a welding pulley according to claim 1 or 2:
s1, hoisting the pulley by an operator in the upper and lower part areas, placing the pulley on the welding workbench, inputting an ACS instruction on the touch screen, and clamping the pulley by an electric three-jaw on the welding workbench;
s2, the welding workbench moves the pulley to the welding area;
s3, the welding robot performs welding operation on the inner ring and the outer ring of the surface A of the pulley;
s4, the welding workbench moves the pulley to the turnover mechanism;
s5, the electric three-jaw loosens the pulley, the turnover claw clamps, lifts and turns over the pulley for 180 degrees again, and then descends;
s6, clamping the pulley by the electric three-jaw, and moving the pulley to the welding area;
s7, the welding robot performs welding operation on the inner ring and the outer ring of the surface B of the pulley;
s8, the welding workbench moves the pulley to the upper and lower part areas;
s9, unloading the pulley after welding is completed, and finishing the preparation of the pulley.
CN202210499944.2A 2022-05-09 2022-05-09 Automatic preparation system and method for welding pulley Active CN114871611B (en)

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CN202210499944.2A CN114871611B (en) 2022-05-09 2022-05-09 Automatic preparation system and method for welding pulley
PCT/CN2022/097784 WO2023216351A1 (en) 2022-05-09 2022-06-09 Automatic preparation system and method for welded pulley

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