CN111702416A - Automatic welding method for high-speed rail sleeper beam fabrication hole - Google Patents

Automatic welding method for high-speed rail sleeper beam fabrication hole Download PDF

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Publication number
CN111702416A
CN111702416A CN202010523652.9A CN202010523652A CN111702416A CN 111702416 A CN111702416 A CN 111702416A CN 202010523652 A CN202010523652 A CN 202010523652A CN 111702416 A CN111702416 A CN 111702416A
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Prior art keywords
welding
sleeper beam
height
welding gun
camera
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Chinese (zh)
Inventor
李鹏一
程远
胡冬双
唐凯
董巍
徐龙
吴晓
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Nanjing Yingnigema Industrial Automation Technology Co ltd
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Nanjing Yingnigema Industrial Automation Technology Co ltd
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Priority to CN202010523652.9A priority Critical patent/CN111702416A/en
Priority to PCT/CN2020/104925 priority patent/WO2021248649A1/en
Publication of CN111702416A publication Critical patent/CN111702416A/en
Priority to CN202110574756.7A priority patent/CN113385887A/en
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23P—METAL-WORKING NOT OTHERWISE PROVIDED FOR; COMBINED OPERATIONS; UNIVERSAL MACHINE TOOLS
    • B23P15/00—Making specific metal objects by operations not covered by a single other subclass or a group in this subclass
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B08—CLEANING
    • B08B—CLEANING IN GENERAL; PREVENTION OF FOULING IN GENERAL
    • B08B7/00—Cleaning by methods not provided for in a single other subclass or a single group in this subclass
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B08—CLEANING
    • B08B—CLEANING IN GENERAL; PREVENTION OF FOULING IN GENERAL
    • B08B7/00—Cleaning by methods not provided for in a single other subclass or a single group in this subclass
    • B08B7/0035—Cleaning by methods not provided for in a single other subclass or a single group in this subclass by radiant energy, e.g. UV, laser, light beam or the like
    • B08B7/0042—Cleaning by methods not provided for in a single other subclass or a single group in this subclass by radiant energy, e.g. UV, laser, light beam or the like by laser
    • 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
    • B23K26/00—Working by laser beam, e.g. welding, cutting or boring
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K9/00—Arc welding or cutting
    • B23K9/04—Welding for other purposes than joining, e.g. built-up welding

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  • Engineering & Computer Science (AREA)
  • Physics & Mathematics (AREA)
  • Mechanical Engineering (AREA)
  • Optics & Photonics (AREA)
  • Plasma & Fusion (AREA)
  • Laser Beam Processing (AREA)

Abstract

The invention relates to an automatic welding method for a fabrication hole of a high-speed rail sleeper beam, which integrates three processes of reverse reconstruction, electric arc welding and laser cleaning, wherein the three processes correspond to a 3D camera, a welding gun head and a laser cleaning head, a quick replacement device of a robot tool can realize automatic switching of the welding gun, the laser cleaning head and the 3D camera in cooperation with an additive manufacturing process, and the welding gun, the laser cleaning head and the 3D camera are protected from being taken out at wrong time through a locking structure, so that the reliability of the processes is ensured. The sleeper beam is positioned and fixed on the fixing seat, the transplanting track controls the sleeper beam to advance according to a preset rhythm, and after three procedures of complete reverse reconstruction, arc welding and laser cleaning are completed for one time, the machined sleeper beam is sent out of the electric arc material increase workstation, and the next sleeper beam to be machined is sent into the electric arc material increase workstation, so that the execution efficiency is optimized.

Description

Automatic welding method for high-speed rail sleeper beam fabrication hole
Technical Field
The invention relates to the field of electric arc additive, in particular to an automatic welding method for a high-speed rail sleeper beam fabrication hole.
Background
Additive Manufacturing (AM) is also called as "solid freeform Manufacturing", "3D printing technology", and the like, and is a Manufacturing method of "bottom-up" material accumulation, which is an emerging Manufacturing technology for Manufacturing solid parts by stacking materials layer by layer based on a discrete-stacking principle based on mathematical modeling, compared with the conventional subtractive Manufacturing (machining) technology. Through the development of the last century, the additive manufacturing technology realizes the rapid manufacturing of organic materials, inorganic non-metallic materials and metal materials. For metal materials, additive manufacturing technologies are classified according to heat sources and can be divided into: the manufacturing method comprises the following steps of laser additive manufacturing, electric arc additive manufacturing, electron beam additive manufacturing and the like, wherein raw materials generally comprise two forms of welding wires and metal powder.
A set of workstation is designed to high-speed railway sleeper beam fabrication hole, compares and has apparent advantage in traditional manual welding.
In the prior art, a single welding gun robot is generally used for welding according to a preset track, and subsequent procedures such as cleaning are performed after the welding is completed. The working mode can improve the efficiency only in a limited way and can not automatically compensate for the actual defects of the workpiece in a self-adaptive way.
Disclosure of Invention
The purpose of the invention is as follows: the automatic welding method for the process holes of the high-speed rail sleeper beam is provided to solve the problems in the prior art.
The technical scheme is as follows: a high-speed rail sleeper beam fabrication hole automatic welding method is based on the following equipment and comprises the following steps: the electric arc material adding workstation is arranged on one side of the middle section of the transplanting workstation; the transplanting work station comprises a transplanting track capable of feeding bidirectionally, a sleeper beam fixing seat is arranged on the transplanting track, and the head and the tail of a sleeper beam are positioned and clamped on the fixing seat at preset intervals;
the method comprises the following steps:
step 1, manually hoisting a sleeper beam to a transplanting workstation, positioning and clamping the sleeper beam on a fixed seat, and pressing the sleeper beam through a plurality of lower pressing plates;
step 2, after the sleeper beam is clamped, starting a transplanting workstation, and transmitting the positioned and fixed sleeper beam to a working area by a transplanting track;
step 3, setting the current workpiece coordinates, driving the industrial robot to a quick-change device of a robot tool at first, accurately driving the industrial robot to a 3D camera after the industrial robot is in place, continuing to slowly descend until two quick-change lock heads are engaged when a mechanical arm of the industrial robot is positioned right above the 3D camera, driving a rotating part to rotate to separate from a movable part after the engagement is finished, and continuing to start the industrial robot to enable the 3D camera to separate from a fixed part of the 3D camera and continue to be driven to the position above a sleeper beam;
step 4, starting a visual scanning part by the 3D camera, analyzing outline data, compensating and correcting defects, reversely reconstructing a model, setting slicing parameters by a computer, generating a robot track path, and setting printing and welding process parameters;
step 5, the industrial robot drives the 3D camera to return to the quick change device of the robot tool, the 3D camera is placed on the fixing part by repeating the content in the step 3, the welding gun head is switched, and the 3D camera continues to return to the position above the sleeper beam;
step 6, starting laser welding, repeating the content of the step 3 after welding is finished, placing the welding gun heads back on the fixed part, switching the welding gun heads into laser cleaning heads, and continuously returning to the position above the sleeper beam for interlayer laser cleaning;
and 7, manually hoisting the welded workpiece out of the workstation for heat treatment, and repeating the steps 1 to 6 to complete the processing of other industries.
In a further embodiment, the arc additive workstation integrates three procedures of reverse reconstruction, arc welding and laser cleaning; each sleeper beam is pressed by a plurality of lower pressing plates, and the lower pressing plates are pressed at the head and the tail of the sleeper beam and at the middle sections of the sleeper beam avoiding the process holes.
In a further embodiment, the electric arc material increase workstation comprises a safety protection room enclosing a designated working area, the safety protection room is located on two sides of a transplanting track and is provided with a rolling door, the transplanting track penetrates through the rolling door, a robot tool quick-changing device is respectively arranged at a position, close to the rolling door, in the safety protection room, the robot tool quick-changing device is located on one side of the transplanting track, and a plurality of industrial robots are arranged between the robot tool quick-changing devices.
In a further embodiment, the quick-change device for the robot tool comprises a support frame, a quick-change plate fixed on one side of the upper part of the support frame, and fixing seats respectively arranged on the quick-change plate; the both sides of fixing base are fixed with revolving cylinder respectively, revolving cylinder's output is fixed with the rotation portion that extends out, the end of rotation portion is fixed with the direct contact site with the quick change tool contact that corresponds.
In a further embodiment, the number of the fixed seats is three, the welding gun heads, the laser cleaning heads and the 3D cameras are respectively arranged on the fixed seats, one side of each of the welding gun heads, the laser cleaning heads and the 3D cameras is fixedly provided with a section of movable seat matched with the fixed seat, and when the welding gun heads, the laser cleaning heads and the 3D cameras are not replaced, the welding gun heads, the laser cleaning heads and the 3D cameras are clamped on the fixed seats by the movable seats and are transversely pressed by the rotating parts of the rotating cylinders; a quick-change lock head is fixed on the movable seat, and a quick-change lock head is also fixed at the tail end of a mechanical arm of the industrial robot.
In a further embodiment, in the step 6, laser welding uses a welding machine as a heat source and a metal wire as a forming material, and a continuous spiral ascending slicing path is planned for cladding printing, and the process is as follows:
step 6-1, determining technological parameters required by forming a specific metal structural part, wherein the technological parameters comprise a welding program, a wire feeding speed, a printing speed, a slice layer height, a shielding gas type and a flow rate, and the relation among the parameters is as follows:
V×F＝v×f
wherein V represents welding speed, F represents welding seam cross section, V represents wire feeding speed, and F represents welding wire cross section;
step 6-2, the cross section of the welding seam of the workpiece is equivalent to a rectangle, and the following relational expression is satisfied:
F＝ld
in the formula, l represents the equivalent rectangular weld width, and d represents the weld height, i.e. the layer height;
and 6-3, obtaining a relation between the wire feeding speed and the layer height according to the two expressions of the step 6-2 and the step 6-3:
Figure BDA0002532939920000031
in the formula, V represents welding speed, l represents equivalent rectangular welding seam width, d represents welding seam height, namely layer height, and f represents welding wire sectional area;
and 6-4, reading current and voltage values through the wire feeding speed, and further calculating the heat input quantity of each consumed 1mm welding wire at the wire feeding speed:
Figure BDA0002532939920000032
in the formula, U represents an arc voltage, I represents a welding current, V represents a welding speed, and k represents a relative thermal conductivity.
In a further embodiment, the slicing parameter setting and the generation of the continuous spiral-up slicing path in step 4 are performed by a computer as follows:
4-1, slicing the model of the printed workpiece, and dividing the model into a plurality of planes along the Z-axis direction;
step 4-2, searching an adjacent layer, and subtracting a layer with a low relative position from a layer with a high relative position to obtain a layer height; then randomly taking a point on the first layer of slice as a starting point (namely a welding arc starting point), and then calculating the offset height in the Z direction between two adjacent points by using the following formula:
Figure BDA0002532939920000033
wherein d is the vertical height between the starting point and the end point in the same layer; x is the number of points per slice; z is the offset height in the Z direction between points;
4-3, searching a starting point of the next layer, requiring the distance between the point and the last layer of end point to be nearest, and connecting the last layer of end point with the starting point of the layer;
and 4-4, sequentially repeating the steps 4-1 to 4-3 until all path points of the whole workpiece are connected to generate a continuous spiral ascending path.
In a further embodiment, step 4-1 further comprises:
step 4-1a, dividing the model into a plurality of triangular patches along the Z-axis direction to obtain the maximum value and the minimum value of the three-dimensional model in the Z-axis direction, and calculating the total layer number by considering the reserved machining allowance:
Figure BDA0002532939920000041
in the formula, ZmaxRepresenting the maximum value of the three-dimensional model in the direction of the Z-axis, ZminThe minimum value of the three-dimensional model in the Z-axis direction is represented, Δ Z represents the layering height, k is an adjusting coefficient, and Δ Z + k is the sum of the adjusting coefficient on the basis of the preset layering height so as to ensure the machining allowance;
step 4-1b, storing each triangular patch of each layer in the n layers in a dynamic array, and inquiring the triangular patch of each triangular patch
Figure BDA0002532939920000044
Value, if
Figure BDA0002532939920000045
Storing the current triangular patch in the jth group of the dynamic array; if it is
Figure BDA0002532939920000046
Storing the current triangular patch in the j-1 group of the dynamic array; if it is
Figure BDA0002532939920000047
Storing the current triangular patch in the j +1 th group of the dynamic array;
wherein h isjDenotes the height of the jth packet, hj+1And (3) representing the j +1 th grouping height, wherein the height is obtained by adding the product of the layering height and the grouping number after the minimum value and the maximum value of the three-dimensional model in the Z-axis direction take the middle value:
hj＝(Zmin+Zmax)/2+Δz×j
in the formula, ZminRepresenting the minimum of the three-dimensional model in the direction of the Z-axis, ZmaxThe maximum value of the three-dimensional model in the Z-axis direction is represented, Δ Z represents the layering height, and j represents the grouping number;
step 4-4 further comprises the trajectory optimization of the continuous spiral ascent path:
step 4-4a, setting linear velocity v of spiral rising pathc：
vc＝ω(L-v0t)
Where ω denotes an angular velocity of the rotation of the welding gun, L denotes a distance of the interpolation start point from the origin, and v0Denotes radial velocity, L-v0t is the real-time radius of the workpiece, and t represents the welding time;
wherein, the angular velocity ω of the rotation of the welding gun satisfies the following relational expression:
Figure BDA0002532939920000042
in the formula, D represents the welding bead interval of radial movement of the welding gun in the process of completing the formation of a welding bead by matching the heat source with the platform,
Figure BDA0002532939920000043
representing the average value of the radial velocity of the welding gun;
step 4-4b, calculation weldingDeposition velocity v of gunr：
Figure BDA0002532939920000051
In the formula, vcLinear velocity, v, of the spiral rising path0Represents the radial velocity;
4-4c, calculating a welding bead distance, enabling the welding gun to move one welding bead distance in the radial direction, and enabling the heat source to be matched with the platform to complete the formation of one welding bead, wherein the expression of the welding bead distance D is as follows:
Figure BDA0002532939920000052
wherein n represents the number of welding guns, v0Represents the radial velocity, t represents the welding time, ω represents the angular velocity of the rotation of the welding gun, d represents the compensation height;
the compensation height d is determined by interpolation precision and satisfies the following relational expression:
Figure BDA0002532939920000053
in the formula (I), the compound is shown in the specification,
Figure BDA0002532939920000054
the mean value of the radial speed of the welding gun is shown, and t' represents the movement time in the interpolation interval;
step 4-4d, calculating the corrected deposition speed vrepair r：
Figure BDA0002532939920000055
Wherein n represents the number of welding guns, v0Representing the radial velocity, ω representing the angular velocity of the torch rotation, d representing the compensation altitude,
Figure BDA0002532939920000056
the mean value of the radial velocity of the butt welding gun is shown, and D shows that the heat source is matched with the platform to complete a welding seamThe weld bead spacing at which the welding torch is moved radially during the forming process.
Has the advantages that: the invention relates to an automatic welding method for a fabrication hole of a high-speed rail sleeper beam, which integrates three processes of reverse reconstruction, electric arc welding and laser cleaning, wherein the three processes correspond to a 3D camera, a welding gun head and a laser cleaning head, a quick replacement device of a robot tool can realize automatic switching of the welding gun, the laser cleaning head and the 3D camera in cooperation with an additive manufacturing process, and the welding gun, the laser cleaning head and the 3D camera are protected from being taken out at wrong time through a locking structure, so that the reliability of the processes is ensured. The sleeper beam is positioned and fixed on the fixing seat, the transplanting track controls the sleeper beam to advance according to a preset rhythm, and after three procedures of complete reverse reconstruction, arc welding and laser cleaning are completed for one time, the machined sleeper beam is sent out of the electric arc material increase workstation, and the next sleeper beam to be machined is sent into the electric arc material increase workstation, so that the execution efficiency is optimized.
Drawings
Fig. 1 is a perspective view of a workstation of the present invention from one perspective.
Fig. 2 is another perspective view of the workstation of the present invention.
Fig. 3 is a top view of a workstation according to the present invention.
Fig. 4 is a perspective view of an arc additive station in accordance with the present invention.
Fig. 5 is a perspective view of an industrial robot and a robot tool quick-change device according to the present invention.
Fig. 6 is a partial enlarged view of the robotic tool quick-change device of the present invention.
Fig. 7 is a schematic structural view of a workpiece bolster to be machined in the present invention.
Fig. 8 is a flow chart of the operation of the present invention.
FIG. 9 is a model point cloud image reversely reconstructed in the present invention.
The figures are numbered: the automatic laser cleaning device comprises a transplanting workstation 1, a sleeper beam 101, a lower pressing plate 102, a rolling door 2, a safety protection room 3, welding 4, a robot tool quick-changing device 5, a supporting frame 501, a quick-changing plate 502, a fixing seat 503, a rotating cylinder 504, a rotating part 505, a main control cabinet 6, a robot control cabinet 7, an industrial robot 8, a quick-changing lock head 801, a welding gun head 9, a laser cleaning head 10 and a 3D camera 11.
Detailed Description
In the following description, numerous specific details are set forth in order to provide a more thorough understanding of the present invention. It will be apparent, however, to one skilled in the art, that the present invention may be practiced without one or more of these specific details. In other instances, well-known features have not been described in order to avoid obscuring the invention.
The invention relates to an automatic welding method for a high-speed rail sleeper beam fabrication hole, which is based on a transfer type double-robot electric arc 3D printing work station, wherein the work station comprises a transplanting work station 1 and an electric arc additive work station, and the electric arc additive work station integrates three processes of reverse reconstruction, electric arc welding 4 and laser cleaning.
Specifically, the transplanting work station 1 comprises a transplanting track capable of feeding bidirectionally, a fixing seat 503 of the sleeper beam 101 is arranged on the transplanting track, and the head and the tail of the sleeper beam 101 are positioned and clamped on the fixing seat 503 at a preset interval. Each sleeper beam 101 is pressed by a plurality of lower pressing plates 102, and the lower pressing plates 102 are pressed at the head and the tail of the sleeper beam 101 and at the middle sections which avoid the fabrication holes of the sleeper beam 101. The transplanting track controls the sleeper beam 101 to advance according to a preset rhythm, and when three procedures of complete reverse reconstruction, arc welding 4 and laser cleaning are completed, the machined sleeper beam 101 is sent out of the electric arc additive station, and the next sleeper beam 101 to be machined is sent into the electric arc additive station.
Electric arc vibration material disk workstation is including the safety protection room 3 of enclosing appointed work area, safety protection room 3 is located and transplants orbital both sides and seted up rolling slats door 2, it passes to transplant the track rolling slats door 2, the position is close to in the safety protection room 3 the position of rolling slats door 2 is equipped with quick change device of robot utensil 5 respectively, quick change device of robot utensil 5 is located transplant orbital one side, be equipped with a plurality of industrial robot 8 between quick change device of robot utensil 5.
The robot tool quick-change device 5 comprises a support frame 501, a quick-change plate 502 fixed on one side of the upper part of the support frame 501, and fixing seats 503 respectively arranged on the quick-change plate 502; two sides of the fixed seat 503 are respectively fixed with a rotary cylinder 504, an output end of the rotary cylinder 504 is fixed with a rotary part 505 extending out, and a contact part directly contacting with a corresponding quick-change tool is fixed at a tail end of the rotary part 505. The robot tool quick-change device 5 can enable the welding gun, the laser cleaning head 10 and the 3D camera 11 to be matched with the additive manufacturing process, and automatic switching is achieved. The number of the fixing seats 503 is three, the welding gun heads 9, the laser cleaning heads 10 and the 3D cameras 11 are respectively arranged on the fixing seats 503, one side of each of the welding gun heads 9, the laser cleaning heads 10 and the 3D cameras 11 is fixedly provided with a section of movable seat matched with the fixing seat 503, and when the welding gun heads 9, the laser cleaning heads 10 and the 3D cameras 11 are not replaced, the movable seats are clamped on the fixing seats 503 and transversely pressed by the rotating parts 505 of the rotating cylinders 504; a quick-change lock head 801 is fixed on the movable seat, and the quick-change lock head 801 is also fixed at the tail end of the mechanical arm of the industrial robot 8. The locking structure can prevent the welding gun, the laser cleaning head 10 and the 3D camera 11 from being taken out at wrong time, and ensure the reliability of the process.
When the working area is being processed, the roller shutter door 2 is closed, and after the processing is completed, the roller shutter door 2 is opened, and the sleeper beam 101 is sent out through the transplanting track. And a welding machine, a laser cleaning power supply, a master control cabinet 6 and a robot control cabinet 7 which are connected with an industrial robot 8 are arranged on one side of the electric arc additive work station.
The specific working process of the invention is as follows: firstly, the sleeper beam 101 is manually hoisted to the transplanting workstation 1, the sleeper beam 101 is positioned and clamped on the fixed seat 503, and the sleeper beam 101 is pressed through the lower pressing plates 102.
After the sleeper beam 101 is clamped, the transplanting workstation 1 is started, and the transplanting track transmits the positioned and fixed sleeper beam 101 to a working area;
then, the current workpiece coordinate is set, the industrial robot 8 is firstly driven to the quick-change device 5 of the robot tool, and then accurately driven to the 3D camera 11 after being in place, when the mechanical arm of the industrial robot 8 is positioned right above the 3D camera 11, the industrial robot continues to slowly descend until the two quick-change lock heads 801 are engaged, after the engagement is finished, the rotating cylinder 504 drives the rotating part 505 to rotate and separate from the movable part, and the industrial robot 8 continues to start, so that the 3D camera 11 separates from the fixed part of the rotating part, and continues to be driven to the upper part of the bolster 101.
And then, starting a visual scanning part by the 3D camera 11, analyzing the profile data, compensating and correcting the defects, reversely reconstructing the model, setting slicing parameters by a computer, generating a robot track path, and setting the process parameters of printing and welding 4.
Then, the industrial robot 8 drives the 3D camera 11 to return to the robot tool quick-change device 5, places the 3D camera 11 back on the fixing portion, switches to the welding gun head 9, and continues to return to above the bolster 101.
And starting the laser welding 4 after returning to the upper part of the sleeper beam 101, placing the welding gun head 9 on the fixed part after the welding 4 is finished, switching to the laser cleaning head 10, and continuing returning to the upper part of the sleeper beam 101 for interlayer laser cleaning.
And (4) manually hoisting the workpiece after the welding is finished, taking the workpiece out of the workstation for heat treatment, and finishing the processing of other industries.
The laser welding takes a welding machine as a heat source and metal wires as forming materials, a continuous spiral ascending slicing path is planned for cladding and printing, and the process is as follows:
1) selecting a welding wire and a base plate required by forming a specific metal structural part, and determining process parameters required by forming the specific metal structural part, wherein the process parameters comprise a welding program, a wire feeding speed, a printing speed, a slicing layer height, a shielding gas type and a shielding gas flow, and the relationship among the parameters is as follows:
the welding speed is proportional to the wire feeding speed and can be expressed by the relation (1)
V×F＝v×f………………………………(1)
V: welding speed;
f: cross sectional area of weld
v: wire feed speed
f: cross section of welding wire
The welding seam section of the workpiece is equivalent to a rectangle, then
F＝ld……………………………(2)
Wherein, l: equivalent rectangular weld width;
d: weld height (layer height)
The relation between the wire feeding speed and the layer height is obtained by the formulas (1) and (2), and is shown in the formula (3):
Figure BDA0002532939920000081
through the wire feed speed, can read out electric current and voltage value on control panel, and then calculate the heat input amount of every consumption 1mm welding wire under this wire feed speed:
Figure BDA0002532939920000082
wherein, U: an arc voltage;
i: welding current;
v: welding speed;
k: relative thermal conductivity;
in the electric arc additive manufacturing process, the control of heat input is extremely important, a welding seam is not formed due to too low heat, a workpiece is not fused, and the workpiece collapses due to too high heat, so that the heat input suitable for various wire materials can be deduced by combining the relationship between the performance of the wire materials and the interlayer temperature in the printing process, and further, technological parameters such as wire feeding speed, welding speed, high interlayer and the like are determined.
2) Wiping the polished and leveled substrate with absolute ethyl alcohol or acetone, and fixing the substrate on a workbench to ensure the substrate to be level;
3) the generation of the continuous spiral ascending slice path is as follows:
firstly, slicing an STL model of a workpiece to be printed, wherein the existing STL model slicing algorithms are numerous, the STL model is processed by adopting the STL slicing algorithm based on the geometric characteristics of a triangular patch, and the model is divided into a plurality of planes along the Z-axis direction;
secondly, searching an adjacent layer, and subtracting a layer with a low relative position from a layer with a high relative position to obtain a layer height;
then randomly taking a point on the first layer of slice as a starting point (namely a welding arc starting point), and then calculating the offset height in the Z direction between two adjacent points by using the following formula:
Figure BDA0002532939920000091
wherein d is the vertical height between the starting point and the end point in the same layer;
x is the number of points per slice;
z is the offset height in the Z direction between points.
More specifically, the slicing process is as follows:
dividing the model into a plurality of triangular surface patches along the Z-axis direction to obtain the maximum value and the minimum value of the three-dimensional model in the Z-axis direction, and calculating the total layer number by considering the reserved machining allowance:
Figure BDA0002532939920000092
in the formula, ZmaxRepresenting the maximum value of the three-dimensional model in the direction of the Z-axis, ZminThe minimum value of the three-dimensional model in the Z-axis direction is represented, Δ Z represents the layering height, k is an adjusting coefficient, and Δ Z + k is the sum of the adjusting coefficient on the basis of the preset layering height so as to ensure the machining allowance;
then each triangular patch of each of the n layers is stored in a dynamic array, and the query of each triangular patch is carried out
Figure BDA0002532939920000093
Value, if
Figure BDA0002532939920000094
Storing the current triangular patch in the jth group of the dynamic array; if it is
Figure BDA0002532939920000095
Storing the current triangular patch in the j-1 group of the dynamic array; if it is
Figure BDA0002532939920000096
Storing the current triangular patch in the j +1 th group of the dynamic array;
wherein h isjDenotes the height of the jth packet, hj+1And (3) representing the j +1 th grouping height, wherein the height is obtained by adding the product of the layering height and the grouping number after the minimum value and the maximum value of the three-dimensional model in the Z-axis direction take the middle value:
hj＝(Zmin+Zmax)/2+Δz×j
in the formula, ZminRepresenting the minimum of the three-dimensional model in the direction of the Z-axis, ZmaxThe maximum value of the three-dimensional model in the Z-axis direction is represented, Δ Z represents the layering height, and j represents the grouping number.
And then searching the starting point of the next layer, requiring the distance between the point and the last layer of end point to be the closest, and connecting the last layer of end point with the starting point of the layer, thereby realizing the continuity of the track between the two layers and avoiding arc blowout in the printing process.
All path points of the whole workpiece are connected in sequence by the method to generate a continuous spiral ascending path, so that continuous arc additive manufacturing of the workpiece is realized.
4) The welding gun moves according to the generated continuous spiral path under the drive of the robot, meanwhile, the technological parameters are determined according to the method in the step 1), the single welding seam is printed on the substrate, and the height of the welding gun from the substrate is gradually increased according to the continuous spiral path in the printing process. The continuous spiral path is combined with the technological parameters calculated according to the heat input in the step 1), so that the dry extension of the welding wire in the printing process is not changed, the arc extinction is avoided in the whole printing process, and the metal structural member with good structural performance is finally formed.
As a preferred scheme, the central control machine further optimizes the track of the continuous spiral ascending path:
firstly, the linear velocity v of the spiral rising path is setc：
vc＝ω(L-v0t)
Where ω denotes the angle of rotation of the welding gunSpeed, L represents the distance of the interpolation starting point from the origin, v0Denotes radial velocity, L-v0t is the real-time radius of the workpiece, and t represents the welding time;
wherein, the angular velocity ω of the rotation of the welding gun satisfies the following relational expression:
Figure BDA0002532939920000101
in the formula, D represents the welding bead interval of radial movement of the welding gun in the process of completing the formation of a welding bead by matching the heat source with the platform,
Figure BDA0002532939920000102
representing the average value of the radial velocity of the welding gun;
then calculating the deposition velocity v of the welding torchr：
Figure BDA0002532939920000103
In the formula, vcLinear velocity, v, of the spiral rising path0Represents the radial velocity;
and then calculating the welding bead distance, wherein the welding gun moves one welding bead distance in the radial direction, and the heat source matching platform completes the formation of one welding bead, wherein the expression of the welding bead distance D is as follows:
Figure BDA0002532939920000104
wherein n represents the number of welding guns, v0Represents the radial velocity, t represents the welding time, ω represents the angular velocity of the rotation of the welding gun, d represents the compensation height;
the compensation height d is determined by interpolation precision and satisfies the following relational expression:
Figure BDA0002532939920000111
in the formula (I), the compound is shown in the specification,
Figure BDA0002532939920000112
the mean value of the radial speed of the welding gun is shown, and t' represents the movement time in the interpolation interval;
subsequently, a corrected deposition speed v is calculatedrepair r：
Figure BDA0002532939920000113
Wherein n represents the number of welding guns, v0Representing the radial velocity, ω representing the angular velocity of the torch rotation, d representing the compensation altitude,
Figure BDA0002532939920000114
and D represents the welding bead distance of the radial movement of the welding gun in the process of finishing forming one welding bead by matching the heat source with the platform.
When the welding work is carried out, the avoiding surface needs to be calculated in advance, and a welding gun nozzle and the root of a welding gun of the welding gun are prevented from colliding with the side wall of the workpiece. The minimum diameter of the original welding gun nozzle is 22mm, and the welding gun nozzle is specially made due to the narrow space at the bottom of the workpiece, and the original diameter of 22mm is changed into the current diameter of 13 mm; the problem that the welding gun at the root part cannot reach is solved by the aid of the measures, the workpiece is subjected to multi-layer and multi-pass welding, and the workpiece can collide and generate arc deflection when being welded to the upper layers, so that the welding gun is required to monitor the collision radius of the welding gun at the position where the self track is located at any time.
The welding gun track avoidance is achieved by increasing eight avoidance surfaces for avoidance, the peripheral outline is divided, the virtual surface is controlled through software, the principle is that the collision radius of the welding gun is detected, the virtual surface is created by referring to the center line of the gun head, avoidance angles can be set at different positions for avoidance, the avoidance angles are automatically avoided according to the distance close to the outer edge of the workpiece, and the welding gun conversion angle is 5-15 degrees.
As noted above, while the present invention has been shown and described with reference to certain preferred embodiments, it is not to be construed as limited thereto. Various changes in form and detail may be made therein without departing from the spirit and scope of the invention as defined by the appended claims.

Claims (8)

1. A high-speed rail sleeper beam fabrication hole automatic welding method is characterized by comprising the following steps:
based on the following devices, comprising: the electric arc material adding workstation is arranged on one side of the middle section of the transplanting workstation; the transplanting work station comprises a transplanting track capable of feeding bidirectionally, a sleeper beam fixing seat is arranged on the transplanting track, and the head and the tail of a sleeper beam are positioned and clamped on the fixing seat at preset intervals;
the method comprises the following steps:
step 1, manually hoisting a sleeper beam to a transplanting workstation, positioning and clamping the sleeper beam on a fixed seat, and pressing the sleeper beam through a plurality of lower pressing plates;
step 2, after the sleeper beam is clamped, starting a transplanting workstation, and transmitting the positioned and fixed sleeper beam to a working area by a transplanting track;
step 3, setting the current workpiece coordinates, driving the industrial robot to a quick-change device of a robot tool at first, accurately driving the industrial robot to a 3D camera after the industrial robot is in place, continuing to slowly descend until two quick-change lock heads are engaged when a mechanical arm of the industrial robot is positioned right above the 3D camera, driving a rotating part to rotate to separate from a movable part after the engagement is finished, and continuing to start the industrial robot to enable the 3D camera to separate from a fixed part of the 3D camera and continue to be driven to the position above a sleeper beam;
step 4, starting a visual scanning part by the 3D camera, analyzing outline data, compensating and correcting defects, reversely reconstructing a model, setting slicing parameters by a computer, generating a robot track path, and setting printing and welding process parameters;
step 5, the industrial robot drives the 3D camera to return to the quick change device of the robot tool, the 3D camera is placed on the fixing part by repeating the content in the step 3, the welding gun head is switched, and the 3D camera continues to return to the position above the sleeper beam;
step 6, starting laser welding, repeating the content of the step 3 after welding is finished, placing the welding gun heads back on the fixed part, switching the welding gun heads into laser cleaning heads, and continuously returning to the position above the sleeper beam for interlayer laser cleaning;
and 7, manually hoisting the welded workpiece out of the workstation for heat treatment, and repeating the steps 1 to 6 to complete the processing of other industries.
2. The automatic welding method for the fabrication hole of the high-speed rail sleeper beam according to claim 1, characterized in that: the electric arc material increase workstation integrates three procedures of reverse reconstruction, electric arc welding and laser cleaning; each sleeper beam is pressed by a plurality of lower pressing plates, and the lower pressing plates are pressed at the head and the tail of the sleeper beam and at the middle sections of the sleeper beam avoiding the process holes.
3. The automatic welding method for the fabrication hole of the high-speed rail sleeper beam according to claim 1, characterized in that: the electric arc vibration material disk workstation is including the safety protection room of enclosing appointed work area, the safety protection room is located and has been transplanted orbital both sides and seted up the rolling slats door, it passes to transplant the track the rolling slats door, the position in the safety protection room is close to the position of rolling slats door is equipped with the quick change device of robot utensil respectively, the quick change device of robot utensil is located transplant orbital one side, be equipped with a plurality of industrial robot between the quick change device of robot utensil.
4. The automatic welding method for the fabrication hole of the high-speed rail sleeper beam according to claim 3, characterized in that: the quick-change device of the robot tool comprises a support frame, a quick-change plate fixed on one side of the upper part of the support frame and fixing seats respectively arranged on the quick-change plate; the both sides of fixing base are fixed with revolving cylinder respectively, revolving cylinder's output is fixed with the rotation portion that extends out, the end of rotation portion is fixed with the direct contact site with the quick change tool contact that corresponds.
5. The automatic welding method for the fabrication hole of the high-speed rail sleeper beam according to claim 4, characterized in that: the device comprises three fixed seats, a welding gun head, a laser cleaning head and a 3D camera, wherein the welding gun head, the laser cleaning head and the 3D camera are respectively arranged on the fixed seats, one side of the welding gun head, the laser cleaning head and the 3D camera is fixedly provided with a section of movable seat matched with the fixed seats, and when the welding gun head, the laser cleaning head and the 3D camera are not replaced, the welding gun head, the laser cleaning head and the 3D camera are clamped on the fixed seats by the movable seats and are transversely pressed by a rotating part of a rotating cylinder; a quick-change lock head is fixed on the movable seat, and a quick-change lock head is also fixed at the tail end of a mechanical arm of the industrial robot.
6. The automatic welding method for the fabrication hole of the high-speed rail sleeper beam according to claim 1, characterized in that: in the step 6, laser welding takes a welding machine as a heat source and metal wires as forming materials, and a continuous spiral ascending slicing path is planned for cladding and printing, wherein the process is as follows:
step 6-1, determining technological parameters required by forming a specific metal structural part, wherein the technological parameters comprise a welding program, a wire feeding speed, a printing speed, a slice layer height, a shielding gas type and a flow rate, and the relation among the parameters is as follows:
V×F＝v×f
wherein V represents welding speed, F represents welding seam cross section, V represents wire feeding speed, and F represents welding wire cross section;
step 6-2, the cross section of the welding seam of the workpiece is equivalent to a rectangle, and the following relational expression is satisfied:
F＝ld
in the formula, l represents the equivalent rectangular weld width, and d represents the weld height, i.e. the layer height;
and 6-3, obtaining a relation between the wire feeding speed and the layer height according to the two expressions of the step 6-2 and the step 6-3:
Figure FDA0002532939910000021
in the formula, V represents welding speed, l represents equivalent rectangular welding seam width, d represents welding seam height, namely layer height, and f represents welding wire sectional area;
and 6-4, reading current and voltage values through the wire feeding speed, and further calculating the heat input quantity of each consumed 1mm welding wire at the wire feeding speed:
Figure FDA0002532939910000031
in the formula, U represents an arc voltage, I represents a welding current, V represents a welding speed, and k represents a relative thermal conductivity.
7. The automatic welding method for the fabrication hole of the high-speed rail sleeper beam according to claim 1, characterized in that: in the step 4, the computer sets slicing parameters and generates a continuous spiral ascending slicing path, and the process is as follows:
4-1, slicing the model of the printed workpiece, and dividing the model into a plurality of planes along the Z-axis direction;
step 4-2, searching an adjacent layer, and subtracting a layer with a low relative position from a layer with a high relative position to obtain a layer height; then randomly taking a point on the first layer of slice as a starting point (namely a welding arc starting point), and then calculating the offset height in the Z direction between two adjacent points by using the following formula:
Figure FDA0002532939910000032
wherein d is the vertical height between the starting point and the end point in the same layer; x is the number of points per slice; z is the offset height in the Z direction between points;
4-3, searching a starting point of the next layer, requiring the distance between the point and the last layer of end point to be nearest, and connecting the last layer of end point with the starting point of the layer;
and 4-4, sequentially repeating the steps 4-1 to 4-3 until all path points of the whole workpiece are connected to generate a continuous spiral ascending path.
8. The automatic welding method for the fabrication hole of the high-speed rail sleeper beam according to claim 7, characterized in that: step 4-1 further comprises:
step 4-1a, dividing the model into a plurality of triangular patches along the Z-axis direction to obtain the maximum value and the minimum value of the three-dimensional model in the Z-axis direction, and calculating the total layer number by considering the reserved machining allowance:
Figure FDA0002532939910000033
in the formula, ZmaxRepresenting the maximum value of the three-dimensional model in the direction of the Z-axis, ZminThe minimum value of the three-dimensional model in the Z-axis direction is represented, Δ Z represents the layering height, k is an adjusting coefficient, and Δ Z + k is the sum of the adjusting coefficient on the basis of the preset layering height so as to ensure the machining allowance;
step 4-1b, storing each triangular patch of each layer in the n layers in a dynamic array, and inquiring the triangular patch of each triangular patch
Figure FDA0002532939910000034
Value, if
Figure FDA0002532939910000035
Storing the current triangular patch in the jth group of the dynamic array; if it is
Figure FDA0002532939910000036
Storing the current triangular patch in the j-1 group of the dynamic array; if it is
Figure FDA0002532939910000037
Storing the current triangular patch in the j +1 th group of the dynamic array;
wherein h isjDenotes the height of the jth packet, hj+1And (3) representing the j +1 th grouping height, wherein the height is obtained by adding the product of the layering height and the grouping number after the minimum value and the maximum value of the three-dimensional model in the Z-axis direction take the middle value:
hj＝(Zmin+Zmax)/2+Δz×j
in the formula, ZminRepresenting the minimum of the three-dimensional model in the direction of the Z-axis, ZmaxRepresents the maximum value of the three-dimensional model in the Z-axis direction, Δ Z represents the layering height, j represents the grouping number；
Step 4-4 further comprises the trajectory optimization of the continuous spiral ascent path:
step 4-4a, setting linear velocity v of spiral rising pathc：
vc＝ω(L-v0t)
Where ω denotes an angular velocity of the rotation of the welding gun, L denotes a distance of the interpolation start point from the origin, and v0Denotes radial velocity, L-v0t is the real-time radius of the workpiece, and t represents the welding time;
wherein, the angular velocity ω of the rotation of the welding gun satisfies the following relational expression:
Figure FDA0002532939910000041
in the formula, D represents the welding bead interval of radial movement of the welding gun in the process of completing the formation of a welding bead by matching the heat source with the platform,
Figure FDA0002532939910000042
representing the average value of the radial velocity of the welding gun;
4-4b, calculating the deposition speed v of the welding gunr：
Figure FDA0002532939910000043
In the formula, vcLinear velocity, v, of the spiral rising path0Represents the radial velocity;
4-4c, calculating a welding bead distance, enabling the welding gun to move one welding bead distance in the radial direction, and enabling the heat source to be matched with the platform to complete the formation of one welding bead, wherein the expression of the welding bead distance D is as follows:
Figure FDA0002532939910000044
wherein n represents the number of welding guns, v0Represents the radial velocity, t represents the welding time, ω represents the angular velocity of the rotation of the welding gun, d represents the compensation height;
the compensation height d is determined by interpolation precision and satisfies the following relational expression:
Figure FDA0002532939910000045
in the formula (I), the compound is shown in the specification,
Figure FDA0002532939910000046
the mean value of the radial speed of the welding gun is shown, and t' represents the movement time in the interpolation interval;
step 4-4d, calculating the corrected deposition speed vrepair r：
Figure FDA0002532939910000051
Wherein n represents the number of welding guns, v0Representing the radial velocity, ω representing the angular velocity of the torch rotation, d representing the compensation altitude,
Figure FDA0002532939910000052
and D represents the welding bead distance of the radial movement of the welding gun in the process of finishing forming one welding bead by matching the heat source with the platform.
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