WO2023216351A1 - 一种焊接滑轮的自动化制备系统及方法 - Google Patents
一种焊接滑轮的自动化制备系统及方法 Download PDFInfo
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- WO2023216351A1 WO2023216351A1 PCT/CN2022/097784 CN2022097784W WO2023216351A1 WO 2023216351 A1 WO2023216351 A1 WO 2023216351A1 CN 2022097784 W CN2022097784 W CN 2022097784W WO 2023216351 A1 WO2023216351 A1 WO 2023216351A1
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- welding
- pulley
- workbench
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- 238000002360 preparation method Methods 0.000 title claims abstract description 33
- 238000000034 method Methods 0.000 title description 10
- 238000003466 welding Methods 0.000 claims abstract description 191
- 230000007246 mechanism Effects 0.000 claims abstract description 34
- 238000007514 turning Methods 0.000 claims abstract description 21
- 239000003496 welding fume Substances 0.000 claims abstract description 5
- 210000000078 claw Anatomy 0.000 claims description 26
- 239000000428 dust Substances 0.000 claims description 14
- 239000000779 smoke Substances 0.000 claims description 12
- 238000012544 monitoring process Methods 0.000 claims description 3
- 239000003517 fume Substances 0.000 abstract 1
- 238000004519 manufacturing process Methods 0.000 description 6
- 238000010586 diagram Methods 0.000 description 5
- 229910000831 Steel Inorganic materials 0.000 description 3
- 239000000463 material Substances 0.000 description 3
- 239000010959 steel Substances 0.000 description 3
- 230000007547 defect Effects 0.000 description 2
- 230000008569 process Effects 0.000 description 2
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 description 1
- 229910000677 High-carbon steel Inorganic materials 0.000 description 1
- 229910052799 carbon Inorganic materials 0.000 description 1
- 238000005266 casting Methods 0.000 description 1
- 238000010276 construction Methods 0.000 description 1
- 238000005516 engineering process Methods 0.000 description 1
- 239000007789 gas Substances 0.000 description 1
- 238000003754 machining Methods 0.000 description 1
- 239000002184 metal Substances 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 238000010791 quenching Methods 0.000 description 1
- 230000000171 quenching effect Effects 0.000 description 1
- 230000008439 repair process Effects 0.000 description 1
- 230000033764 rhythmic process Effects 0.000 description 1
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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
- B23K31/00—Processes relevant to this subclass, specially adapted for particular articles or purposes, but not covered by only one of the preceding main groups
- B23K31/02—Processes 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
-
- 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
- B23K37/04—Auxiliary devices or processes, not specially adapted to a procedure covered by only one of the preceding main groups for holding or positioning work
- B23K37/047—Auxiliary 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
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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]
Definitions
- the present invention relates to a pulley preparation technology, and more specifically, to an automated preparation system and method for welding a pulley.
- Pulleys made by conventional casting processes consume a lot of energy and cause serious pollution, and it is difficult to avoid metal shrinkage defects in key parts of the rope grooves; the material utilization rate of forged pulleys is low, the cost of blank production and machining is high, and the overall production cost is high; the forming of welded pulleys
- the main method is to assemble and weld the ring segment outer ring, web, support tube and ring segment inner ring.
- the web, support tube and ring segment inner ring can be made of low-strength steel.
- the ring segment outer ring is made of steel grade with high carbon content. Different steel grades can reduce weight and production costs, but the high-carbon steel of the rope groove obtains higher surface hardness through quenching, further improving the wear resistance and practicality of the welded pulley.
- the purpose of the present invention is to provide an automated preparation system and method for welding pulleys, which can improve work efficiency and stabilize product welding quality.
- an automated preparation system for welding pulleys includes:
- a flip mechanism located on one side of the welding workstation, is used to flip the pulley on the welding workstation 180°;
- a welding smoke treatment mechanism used to treat the smoke generated by the welding workstation
- Central control PLC used to control the operation and monitoring of the welding workstation, the welding smoke treatment mechanism and the turning mechanism;
- Touch screen for inputting work instructions and monitoring the status of the welding workstation.
- the welding workstations there are four sets of the welding workstations, which share one set of the turning mechanism.
- the four sets of the welding workstations can be arbitrarily combined as needed to complete the welding of a pulley.
- the welding workstations are arranged in parallel and share a set of the turning mechanism.
- the welding workstations include a welding workbench, a slide rail provided on the welding workbench, an electric three-claw provided on the welding workbench and moving along the slide rail, and a Welding robot on one side of the welding table.
- the flipping mechanism includes a flipping truss and a flipping claw provided on the flipping truss;
- the turning claw is equipped with a turning motor, a lifting motor and a clamping motor.
- the welding workstation is provided with an upper and lower parts area, a welding area and a turning area;
- the upper and lower parts areas correspond to one end of the slide rail
- the welding area corresponds to the welding robot
- the flipping area corresponds to the other end of the slide rail and also corresponds to the flipping mechanism.
- the welding fume treatment mechanism includes a dust collecting hood located above the welding workstation and a dust suction device connected thereto;
- the dust collecting hood is equipped with a valve, and the opening of the valve is controlled according to the size of the smoke.
- An automated preparation method for welding pulleys using the automated preparation system for welding pulleys to perform the following steps:
- the operator hoists the pulley in the upper and lower parts area, places it on the welding workbench, and inputs instructions on the touch screen, and the electric three claws on the welding workbench clamp the pulley;
- the welding workbench moves the pulley to the welding area
- the welding robot performs welding operations on the inner and outer rings of surface A of the pulley
- the welding workbench then moves the pulley to the turning mechanism
- the welding robot performs welding operations on the inner and outer rings of surface B of the pulley
- the automated preparation system and method for welding pulleys provided by the invention reduce the labor intensity of skilled workers, and automated welding improves the quality of welded pulleys, improves the construction environment, realizes full automation of double-sided welding of pulleys, and further improves production. efficiency.
- Figure 1 is a schematic diagram of the on-site layout of the automated preparation system of the present invention
- Figure 2 is a bottom view of Figure 1;
- Figure 3 is a schematic flow chart of the automated preparation method of the present invention.
- Figure 4 is a schematic diagram of the upper and lower pulleys in the automated preparation method of the present invention.
- FIG. 5 is a schematic diagram of the welding pulley in the automated preparation method of the present invention.
- Figure 6 is a schematic diagram of the turning pulley in the automated preparation method of the present invention.
- Figure 7 is a schematic diagram of the weld on the pulley.
- an automated preparation system for welding pulleys provided by the present invention includes:
- the flipping mechanism 200 is located on one side of the welding workstations 101, 102, 103, and 104, and is used to flip the pulleys 100 on the welding workstations 101, 102, 103, and 104 180°;
- the welding smoke treatment mechanism 300 is used to treat the smoke generated during the operation of the welding workstations 101, 102, 103, and 104;
- the central control PLC is used to control the operation of the welding workstations 101, 102, 103, 104, the turning mechanism 200 and the welding smoke treatment mechanism 300;
- the welding workstations 101, 102, 103, and 104 each include a welding workbench 1, a slide rail 2, an electric three-claw 3, and a welding robot 4.
- the slide rail 2 is installed on the welding workbench 101, 102, 103, 104.
- the electric three-claw 3 is used to clamp the inner hole of the pulley 100, and the electric three-claw 3 moves on the slide rail 2 by moving the motor.
- the welding robot 4 Installed next to the welding workstations 101, 102, 103, and 104, it is used to weld the inner and outer ring welds on both sides (A side and B side) of the pulley 100.
- Welding workstations 101, 102, 103 and 104 form an industrial network with four welding power sources, central control PLC and touch screen.
- the welding program is pre-stored in the robot teaching pendant. After the welding program number is input through the touch screen, the welding robot 4 automatically retrieves the welding program. Afterwards, the welding robot 4 can perform automatic welding.
- the welding fume treatment mechanism 300 includes a dust suction device 5 and a dust collecting hood 6 .
- the number of dust collecting hoods 6 corresponds to the number of welding workstations 101, 102, 103, and 104. They are arranged above the welding position of the welding robot 4, and are connected to the dust collection device 5 through the gas collection pipe 7.
- a valve 8 is installed on each dust collecting hood 6 to control the opening and closing of the dust collecting hood 6 .
- the flip mechanism 200 includes a flip truss 9 and a flip claw 10 installed on the flip truss 9 .
- the flip claw 10 is equipped with a flip motor 11, a lifting motor 12 and a clamping motor 13.
- Upper and lower parts areas 14, welding areas 15 and turning areas 16 are evenly distributed on the welding workbench 101, 102, 103 and 104.
- the upper and lower parts area 14 corresponds to one end of the slide rail 2
- the welding area 15 corresponds to the welding working position of the welding robot 4
- the flipping area 16 corresponds to the other end of the slide rail 2 and also corresponds to the flipping mechanism 200 .
- the turning areas 16 of the welding workbenches 101, 102, 103, and 104 share a set of turning mechanisms 200.
- the present invention also provides an automated preparation method for a welded pulley.
- the automated preparation system for the welded pulley of the present invention is used to perform the following steps:
- the operator manually assists in hoisting the pulley 100 in the upper and lower parts area 14, and inputs the ACS command on the touch screen, and the electric three-claw 3 clamps the inner hole of the pulley 100;
- the welding workbench 1 moves the pulley 100 to the welding area 15;
- the welding robot 4 performs welding operations on the inner and outer rings of surface A of the pulley 100;
- the welding workbench 1 moves the pulley 100 to the turning mechanism 13;
- the electric three-claw 3 clamps the inner hole of the pulley 100, and the welding workbench 1 moves the pulley 100 to the welding area 15;
- the welding robot 4 then performs welding operations on the inner and outer rings of surface B of the pulley 100;
- the welding workbench 1 moves the pulley 100 to the upper and lower parts area 14;
- the electric three-claw 3 loosens the inner hole of the pulley 100, and manually removes the pulley 100 after the welding is completed.
- the automated preparation system of the present invention operates fully automatically on each equipment.
- Each equipment operates automatically and continuously in strict accordance with the preset ACS instruction process sequence and production rhythm. Technicians can understand the production situation in this area through the touch screen or the indicator lights on the operating system. . If each workstation is not in a ready state, even if the selector switch is turned to the automatic position, the equipment will still not be able to operate automatically, and a corresponding alarm message will be prompted so that the operator can recover in time.
- the relevant parameters of the welding procedure, pulley thickness and diameter are preset in the control system. Technicians only need to select the number of the pulley to be welded in the control system to achieve parameterized automated welding and further improve product quality.
- This embodiment is illustrated by loading materials at the welding workstation 101:
- This embodiment is illustrated by using the welding workstation 102 to weld the internal and external welds on surface A of the pulley 100:
- the welding robot 4 in the welding area 15 detects that the welding workbench 1 is carrying the pulley 100, it automatically starts the welding program corresponding to the code of the pulley 100, and starts the valve 8 and the dust suction device 5 of the welding smoke treatment mechanism 300.
- welding The rotating motor on the workbench 1 starts to rotate under the control of the welding robot 4.
- the welding workbench 1 rotates with the pulley 100, and the welding robot 4 starts welding. It first welds the inner ring weld of surface A of the pulley 100, and then welds the outer ring of surface A.
- the valve 8 is closed, and the welding of the inner and outer rings of surface A of the pulley 100 is completed to trigger the ACS command.
- the electric three-claw 3 drives the pulley 100 on the slide rail 2 to the flip area 16.
- This embodiment is illustrated by turning over at the welding workstation 104:
- the flipping truss 9 in the flipping area 16 regularly scans the position of the welding workbench 1 on the welding workbench 101, 102, 103, 104. If the welding workbench 1 travels to the flipping area 16 of the welding workstation 104 with the pulley 100, the flipping claw 10 Travel along the flipping truss 9 to the flipping area 16 of the welding workstation 104. The electric three claws 3 release the pulley 100 inward, the lifting motor 12 drives the flipping claw 10 to drop to the predetermined position, and the clamping motor 13 drives the flipping claw 10 to clamp the pulley 100 rope.
- the lifting motor 12 drives the flip claw 10 to lift to a predetermined height
- the flip motor 11 drives the flip claw 10 to flip the pulley 100 180° (B side upward)
- the lifting motor 12 drives the flip claw 10 to drop to a predetermined position
- the clamping motor 13 drives
- the flip claw 10 releases the pulley 100
- the lifting motor 12 drives the flip claw 10 to lift to a predetermined height.
- the electric three-claw 3 tightens the inner hole of the pulley 100 outward until the control system detects that the set current of the electric three-claw 3 has stopped. Press ACS According to the command, the mobile motor drives the welding workbench 1 to drive the welding workbench 1 with the pulley 100 on the slide rail 2 to the welding area 15.
- This embodiment is illustrated by welding the internal and external welds on surface B of the pulley 100 at the welding workstation 102:
- the welding robot 4 in the welding area 15 detects that the welding workbench 1 is carrying the pulley 100, it automatically starts the welding program corresponding to the code of the pulley 100, and starts the valve 8 and the dust suction device 5 of the welding smoke treatment mechanism 300.
- welding The rotating motor on the workbench 1 starts to rotate under the control of the welding robot 4.
- the welding workbench 1 rotates with the pulley 100, and the welding robot 4 starts welding. It first welds the inner ring weld of surface B of the pulley 100, and then welds the outer ring of surface B.
- the valve 8 is closed, and the welding of the inner and outer rings of surface A of the pulley 100 is completed to trigger the ACS command.
- the electric three-claw 3 drives the pulley 100 on the slide rail 2 to the upper and lower parts area 14.
- This embodiment is illustrated by unloading materials at the welding workstation 101:
- the electric three claws 3 release the inner hole of the pulley 100 inward, and the pulley 100 is manually removed to complete the welding operation of the double-sided weld of the pulley 100.
- the same piece of welded pulley can be welded in five different combinations according to the processes of loading I, welding II, flipping III and unloading IV.
- the use of the automated preparation system and method of the present invention for pulley welding is lighter than the cast pulley, even only 1/4 of the cast pulley.
- reducing the dead weight of the arm end pulley can To reduce the overturning moment of the crane, it is important to use welded pulleys.
- the quality of automated unmanned welding is stable and reliable, ensuring first-time pass rate and reducing repairs; robot welding is highly efficient, and the type and number of operators can be significantly reduced.
- the benefits brought by automated welding are significant.
Abstract
本发明公开了一种焊接滑轮的自动化制备系统，包括：焊接工作站，设有数套，用以实现焊接滑轮的双面内外圈焊缝；翻转机构，设于所述焊接工作站一侧，用以对所述焊接工作站上所述滑轮进行翻转；焊接烟尘处理机构，用以对所述焊接工作站产生的烟尘进行处理；中控PLC，用以控制所述焊接工作站、所述焊接烟尘处理机构和所述翻转机构的运行；触摸屏，用以输入作业指令。本发明还公开了一种焊接滑轮的自动化制备方法，该自动化制备方法采用一种焊接滑轮的自动化制备系统以实现。本发明能够提高工作效率，稳定产品焊接质量。
Description
本发明涉及滑轮的制备技术，更具体地说，涉及一种焊接滑轮的自动化制备系统及方法。
常规的铸造工艺制作的滑轮能耗大，污染严重，关键部位绳槽难以避免存在金属收缩类缺陷；锻造滑轮材料利用率低，毛坯制作以及机械加工成本高，总体制作成本高昂；焊接滑轮的成形方法主要有环段外圈、腹板、支撑管和环段内圈拼装焊接而成，腹板、支撑管和环段内圈可用低强度钢，环段外圈高碳量的钢铁牌号，采用不同的钢铁牌号，可减轻重量，降低生产成本，但绳槽的高碳量钢通过淬火获得较高的表面硬度，进一步提高焊接滑轮的耐磨性和实用性。
发明内容
针对现有技术中存在的上述缺陷，本发明的目的是提供一种焊接滑轮的自动化制备系统及方法，能够提高工作效率，稳定产品焊接质量。
为实现上述目的，本发明采用如下技术方案：
一方面，一种焊接滑轮的自动化制备系统，包括：
焊接工作站，设有数套，用以实现焊接滑轮双面内外圈焊缝的焊接；
翻转机构，设于所述焊接工作站一侧，用以对所述焊接工作站上所述滑轮进行180°翻转；
焊接烟尘处理机构，用以对所述焊接工作站产生的烟尘进行处理；
中控PLC，用以控制所述焊接工作站、所述焊接烟尘处理机构和所述翻转机构的运行和监控；
触摸屏，用以输入作业指令和监控所述焊接工作站的状态。
较佳的，所述焊接工作站设有四套，共用一套所述翻转机构，四套所述焊接工作站可按需任意组合完成一件滑轮的焊接。
较佳的，所述焊接工作站采用并联布置，共用一套所述翻转机构。
较佳的，所述焊接工作站均包括焊接工作台、设于所述焊接工作台上的滑轨、设于所述焊接工作台上并沿所述滑轨移动的电动三爪和设于所述焊接工作台一侧的焊接机器人。
较佳的，所述翻转机构包括翻转桁架和设于所述翻转桁架上的翻转爪；
所述翻转爪上配有翻转电机、提升电机和夹紧电机。
较佳的，所述焊接工作站上设有上下件区域、焊接区域和翻转区域；
所述上下件区域对应所述滑轨的一端，所述焊接区域对应所述焊接机器人，所述翻转区域对应所述滑轨的另一端并还对应所述翻转机构。
较佳的，所述焊接烟尘处理机构包括设于所述焊接工作站上方的集尘罩和与其相连通的吸尘装置；
所述集尘罩上均设有阀门，按烟尘的大小来控制所述阀门的开度。
一种焊接滑轮的自动化制备方法，采用所述的焊接滑轮的自动化制备系统执行以下步骤：
S1、作业员在所述上下件区域吊装所述滑轮，放置于焊接工作台，并在所述触摸屏上输入指令，由所述焊接工作台上的电动三爪夹紧所述滑轮；
S2、所述焊接工作台将所述滑轮移动至所述焊接区域；
S3、所述焊接机器人对所述滑轮的A面内外圈进行焊接作业；
S4、所述焊接工作台再将所述滑轮移动至所述翻转机构；
S5、所述电动三爪松开所述滑轮，由所述翻转爪将所述滑轮夹紧、提升并再翻转180°后下降；
S6、由所述焊接工作台夹紧所述滑轮，并将所述滑轮移动至所述焊接区域；
S7、所述焊接机器人对所述滑轮的B面内外圈进行焊接作业；
S8、所述焊接工作台再将所述滑轮移动至所述上下件区域；
S9、卸掉焊接完成后的所述滑轮，完成所述滑轮的制备。
本发明所提供的一种焊接滑轮的自动化制备系统及方法，减轻技术工人的劳动强度，自动化焊接提高了焊接滑轮的质量，改善了施工环境，实现了滑轮双面焊接的全自动化，进一步提高生产效率。
图1是本发明自动化制备系统的现场布置示意图；
图2是图1的仰视图；
图3是本发明自动化制备方法的流程示意图；
图4是本发明自动化制备方法中上下滑轮的示意图；
图5是本发明自动化制备方法中焊接滑轮的示意图；
图6是本发明自动化制备方法中翻转滑轮的示意图；
图7是滑轮上焊缝的示意图。
为了能更好地理解本发明的上述技术方案，下面结合附图和实施例进一步说明本发明的技术方案。
结合图1和图2所示，本发明所提供的一种焊接滑轮的自动化制备系统，包括：
四套焊接工作站101、102、103、104，采用并联布置，用以实现焊接滑轮100的双面内外圈焊缝；
翻转机构200，设于焊接工作站101、102、103、104一侧，用以对焊接工作站101、102、103、104上滑轮100进行180°的翻转；
焊接烟尘处理机构300，用以对焊接工作站101、102、103、104作业时产生的烟尘进行处理；
中控PLC，用以控制焊接工作站101、102、103、104、翻转机构200和焊接烟尘处理机构300的运行动作；
触摸屏，技术人员通过触摸屏输入各种作业指令。
焊接工作站101、102、103、104均包括焊接工作台1、滑轨2、电动三爪3和焊接机器人4。滑轨2安装在焊接工作台101、102、103、104上，电动三爪3用以夹紧滑轮100的内孔，并通过移动电机使电动三爪3在滑轨2上移动，焊接机器人4安装在焊接工作站101、102、103、104的旁边，用以对滑轮100的双面(A面和B面)内外圈焊缝进行焊接。
焊接工作站101、102、103、104与四台焊接电源、中控PLC和触摸屏组成工业网络，焊接程序预存在机器人示教器内，通过触摸屏输入焊接程序号后，焊接机 器人4自动调取焊接程序后，焊接机器人4即可进行自动焊接。
焊接烟尘处理机构300包括吸尘装置5和集尘罩6。集尘罩6的数量与焊接工作站101、102、103、104的数量对应，设置在焊接机器人4进行焊接位置的上方，并再通过集气管道7与吸尘装置5相连通。每个集尘罩6上均安装了阀门8，以控制集尘罩6的启闭。
翻转机构200包括翻转桁架9和安装在翻转桁架9上的翻转爪10。
翻转爪10上配有翻转电机11、提升电机12和夹紧电机13。
焊接工作台101、102、103、104上均布有上下件区域14、焊接区域15和翻转区域16。上下件区域14对应滑轨2的一端，焊接区域15对应焊接机器人4的焊接工作位置，翻转区域16对应滑轨2的另一端并还对应翻转机构200。焊接工作台101、102、103、104的翻转区域16共用一套翻转机构200。
结合图3至图7所示，本发明还提供了一种焊接滑轮的自动化制备方法，采用本发明焊接滑轮的自动化制备系统执行以下步骤：
S1、作业员在上下件区域14人工辅助吊装滑轮100，并在触摸屏上输入ACS指令，由电动三爪3夹紧滑轮100的内孔；
S2、焊接工作台1将滑轮100移动至焊接区域15；
S3、焊接机器人4对滑轮100的A面内外圈进行焊接作业；
S4、焊接完成后，焊接工作台1再将滑轮100移动至翻转机构13；
S5、电动三爪3松开滑轮100，由翻转爪10将滑轮100绳槽处夹紧、提升并再翻转180°后下降；
S6、由电动三爪3夹紧滑轮100的内孔，焊接工作台1将滑轮100移动至焊接区域15；
S7、焊接机器人4再对滑轮100的B面内外圈进行焊接作业；
S8、焊接完成后，焊接工作台1再将滑轮100移动至上下件区域14；
S9、电动三爪3松开滑轮100的内孔,人工辅助卸掉焊接完成后的滑轮100。
本发明自动化制备系统是在各设备全自动下运行，各设备严格按预设的ACS指令工艺顺序和生产节拍自动连续运行，技术人员可通过触摸屏或操作系统上的指示灯了解本区域的生产情况。如果各个工位并未处于就绪状态，即使此时选择开关打到自动位置设备仍不能自动运转，并提示相应报警信息，以便操作者及时恢复。焊 接程序、滑轮厚度和直径的相关参数预设在控制系统中，技术人员只需在控制系统中选择需要焊接滑轮的编号，实现参数化自动化焊接，进一步提高产品质量。
实施例1
本实施例以在焊接工作站101进行上料加以说明：
人工辅助在上下件区域14将需要焊接的滑轮100吊装至焊接工作站101的焊接工作台1上，使电动三爪3夹紧滑轮100的内孔，在触摸屏上输入焊接滑轮100的代码，启动ACS指令，驱动电动三爪3向外张紧，直至控制系统监测到电动三爪3的设定电流停止，按ACS指令，移动电机工作驱动焊接工作台1带着滑轮100在滑轨2上行驶至焊接区域15。
实施例2
本实施例以在焊接工作站102进行焊接滑轮100的A面内外焊缝加以说明：
焊接区域15的焊接机器人4检测到焊接工作台1带着滑轮100时，自动启动滑轮100的代码所对应的焊接程序，并启动焊接烟尘处理机构300的阀门8和吸尘装置5，同时，焊接工作台1上旋转电机由焊接机器人4控制开始旋转，焊接工作台1带着滑轮100一边旋转，焊接机器人4一边开始焊接，先焊接滑轮100的A面内圈焊缝，再焊接A面外圈焊缝，此时阀门8关闭，滑轮100的A面内外圈焊缝焊完触发ACS指令，电动三爪3带着滑轮100在滑轨2上行驶至翻转区域16。
实施例3
本实施例以在焊接工作站104进行翻转加以说明：
翻转区域16的翻转桁架9定期扫描焊接工作台101、102、103、104上焊接工作台1的位置，若焊接工作台1带着滑轮100行驶至焊接工作站104的翻转区域16时，翻转爪10沿翻转桁架9行驶至焊接工作站104的翻转区域16，电动三爪3向内松开滑轮100，提升电机12驱动翻转爪10下降至预定位置，夹紧电机13驱动翻转爪10夹紧滑轮100绳槽，提升电机12驱动翻转爪10提升至预定高度，翻转电机11驱动翻转爪10将滑轮100翻转180°(B面向上)，提升电机12驱动翻转爪10下降至预定位置，夹紧电机13驱动翻转爪10松开滑轮100，提升电机12驱动翻转爪10提升至预定高度，电动三爪3向外张紧滑轮100内孔，直至控制系统监测到电动三爪3的设定电流停止，按ACS指令，移动电机工作驱动焊接工作台1带着滑轮100在滑轨2上行驶至焊接区域15。
实施例4
本实施例以在焊接工作站102进行焊接滑轮100的B面内外焊缝加以说明：
焊接区域15的焊接机器人4检测到焊接工作台1带着滑轮100时，自动启动滑轮100的代码所对应的焊接程序，并启动焊接烟尘处理机构300的阀门8和吸尘装置5，同时，焊接工作台1上旋转电机由焊接机器人4控制开始旋转，焊接工作台1带着滑轮100一边旋转，焊接机器人4一边开始焊接，先焊接滑轮100的B面内圈焊缝，再焊接B面外圈焊缝，此时阀门8关闭，滑轮100的A面内外圈焊缝焊完触发ACS指令，电动三爪3带着滑轮100在滑轨2上行驶至上下件区域14。
实施例5
本实施例以在焊接工作站101进行下料加以说明：
上下件区域14检测到焊接工作台1带着滑轮100时，电动三爪3向内松开滑轮100内孔，人工辅助卸下滑轮100，完成滑轮100双面焊缝的焊接作业。
实施例6
本实施例以四套焊接工作站可按需任意组合完成一件滑轮的焊接加以说明：
同一件的焊接滑轮按上料Ⅰ、焊接Ⅱ、翻转Ⅲ、下料Ⅳ工序，有五种不同的组合方式可以完成焊接。综上所述，采用本发明自动化制备系统及方法进行滑轮焊接，相比整理铸造滑轮质量轻，甚至只有铸造滑轮的1/4，对于大型港机设备起重机来 说，减轻臂端滑轮的自重可使起重机的倾覆力矩减小，采用焊接滑轮意义重要。采用自动化无人焊接质量稳定可靠，保证一次合格率，减少返修；机器人焊接效率高，操作工的工种和人数均可大幅减少，自动化焊接带来的效益显著。
本技术领域中的普通技术人员应当认识到，以上的实施例仅是用来说明本发明，而并非用作为对本发明的限定，只要在本发明的实质精神范围内，对以上所述实施例的变化、变型都将落在本发明的权利要求书范围内。
Claims (7)
- 一种焊接滑轮的自动化制备系统，其特征在于，包括：焊接工作站，设有数套，用以实现焊接滑轮的双面内外圈焊缝；翻转机构，设于所述焊接工作站一侧，用以对所述焊接工作站上所述滑轮进行翻转；焊接烟尘处理机构，用以对所述焊接工作站产生的烟尘进行处理；中控PLC，用以控制所述焊接工作站、所述焊接烟尘处理机构和所述翻转机构的运行；触摸屏，用以输入作业指令和监控所述焊接工作站的状态。
- 根据权利要求1所述的焊接滑轮的自动化制备系统，其特征在于：所述焊接工作站设有四套，采用并联布置，共用一套所述翻转机构。
- 根据权利要求2所述的焊接滑轮的自动化制备系统，其特征在于：所述焊接工作站均包括焊接工作台、设于所述焊接工作台上的滑轨、设于所述滑轨上并沿所述滑轨移动的电动三爪和设于所述焊接工作台一侧的焊接机器人。
- 根据权利要求3所述的焊接滑轮的自动化制备系统，其特征在于：所述翻转机构包括翻转桁架和设于所述翻转桁架上的翻转爪；所述翻转爪上配有翻转电机、提升电机和夹紧电机。
- 根据权利要求3所述的焊接滑轮的自动化制备系统，其特征在于：所述焊接工作站上设有上下件区域、焊接区域和翻转区域；所述上下件区域对应所述滑轨的一端，所述焊接区域对应所述焊接机器人，所述翻转区域对应所述滑轨的另一端并还对应所述翻转机构。
- 根据权利要求3所述的焊接滑轮的自动化制备系统，其特征在于：所述焊接烟尘处理机构包括设于所述焊接工作站上方的集尘罩和与其相连通的吸尘装置；所述集尘罩上均设有阀门。
- 一种焊接滑轮的自动化制备方法，其特征在于，采用如权利要求1-6之一所述的焊接滑轮的自动化制备系统执行以下步骤：S1、作业员在所述上下件区域吊装所述滑轮，放置于所述焊接工作台，并在所述触摸屏上输入指令，由所述焊接工作台上的电动三爪夹紧所述滑轮；S2、所述焊接工作台将所述滑轮移动至所述焊接区域；S3、所述焊接机器人对所述滑轮的A面内外圈进行焊接作业；S4、所述焊接工作台再将所述滑轮移动至所述翻转机构；S5、所述电动三爪松开所述滑轮，由所述翻转爪将所述滑轮夹紧、提升并再翻转180°后下降；S6、由所述电动三爪夹紧所述滑轮，并将所述滑轮移动至所述焊接区域；S7、所述焊接机器人对所述滑轮的B面内外圈进行焊接作业；S8、所述焊接工作台再将所述滑轮移动至所述上下件区域；S9、卸掉焊接完成后的所述滑轮，完成所述滑轮的制备。
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