With the high welding quality requirements, the gradual improvement of domestic labor costs and the continuous improvement of the labor environment, the emergence of robotic automatic welding workstations with efficient dust removal systems has emerged. Since 2007, Xugong Group, a leading domestic engineering machinery company, has started to apply robotic automated welding and quickly promoted it in various key structural components. Automated welding operations are replaced by robotic welding stations or welding special machines instead of welding workers, which not only reduces the labor intensity of workers, but also improves the working environment, while achieving consistent and consistent weld quality. In the long run, although the one-time investment cost of robotic welding is large, the service life of a welding station is at least 10 years. Compared with the ever-increasing labor cost, robotic automatic welding is more economical.
The welding robot is strictly a six-axis integrated robot, and it cannot work independently. It needs to be equipped with welding system, arc welding software control system, workpiece clamping and displacement system, high-efficiency dust removal system and other equipment to form a welding robot workstation. At present, most of the domestic automated welding system suppliers are purchasing foreign brand robots, such as ABB, KUKA, REIS, ClOOS, ARCMAN, etc. The welding power supply is different according to user requirements. Common brands include FRONIUS, EMW, Panasonic, SENERC, etc. Steel structures such as machines and fixtures are generally developed on their own, and the position of the to-be-welded workpiece, weight, structural features, and weld form are set to support the tonnage, torque, and fixture form. For structural parts with high welding deformation requirements, it is necessary to consider adding anti-deformation measures on the corresponding fixtures, and most of them adopt the hydraulic cylinder compression at the possible deformation position for pre-deformation. For some larger structural parts, it is required to use two sets of welding robots for welding with external shafts. The number of linkage shafts is more than 19 axes, as shown in Figure 2. In terms of positioner, it is set to double station, one station is used for robotic automatic welding, and the other station is used for manual repair welding where the robot cannot weld.
The large number of applications of automated welding workstations puts higher demands on the corresponding operators. It requires operators not only to be familiar with welding knowledge, but also to master the programming language of robot control systems, to understand arc tracking during automatic welding, and to find before welding. Bit principle. At present, most of the construction machinery companies in China are difficult to have the above-mentioned skills and quality, and they still rely on equipment suppliers to solve problems. The expensive welding station has a powerful function that is only less than 60% developed. This also puts forward new requirements for some specialists and technical schools. In the training of skilled personnel, it is necessary to pay attention to the training of the robot control system, programming language, arc welding software system and other common troubleshooting methods.
Compared with the robot welding workstation, the welding machine is easy to operate, low in price, easy to maintain, and highly reliable in equipment, and is favored by welding craftsmen. The welding special machine is mostly used for long straight welds with a single weld form, and the welding gun does not need to be oscillated during the welding process. For the less demanding weld structure, it can be self-made, and the welding system and the linear motion mechanism can be combined to realize the special machine function; for the workpiece with high weld quality and working environment and need to rotate and displace during the welding process, Refer to the model of the robot workstation, with the positioner, dust removal system, preheating system, etc., as shown in Figure 3.
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