CN113579539A

CN113579539A - Automatic welding production line device for upper mast and lower mast

Info

Publication number: CN113579539A
Application number: CN202110974671.8A
Authority: CN
Inventors: 公茂震; 赵映龙; 冯瑶
Original assignee: Beijing Institute of Computer Technology and Applications
Current assignee: Beijing Institute of Computer Technology and Applications
Priority date: 2021-08-24
Filing date: 2021-08-24
Publication date: 2021-11-02

Abstract

The invention discloses an automatic welding production line device for an upper mast and a lower mast, which comprises an inner welding line welding unit, an outer welding line welding unit, a heavy-load manipulator, a welding clamp and an electrical control system, wherein the inner welding line welding unit is connected with the outer welding line welding unit; the inner welding line welding unit and the outer welding line welding unit respectively comprise a positioner head part, a positioner tail part and a welding robot, the positioner tail part is arranged on a positioner ground rail, the welding robot is arranged on a robot installation C-shaped frame, the lower part of the robot installation C-shaped frame is arranged on the robot ground rail, and welding clamps are respectively arranged on the positioner head part and the positioner tail part; the heavy-duty manipulator is arranged on a heavy-duty manipulator ground rail through a heavy-duty manipulator slewing mechanism. Welding jig compresses tightly the module and centering including pushing down to be equipped with 360 turning device. The automatic operation of the upper mast welding production line and the lower mast welding production line can be realized, a robot is used for replacing a welder, and the manual participation degree in the production process is reduced so as to weaken the uncontrollable property brought to the product by subjective factors. The information and intelligent production is realized, and the production process is controlled comprehensively.

Description

Automatic welding production line device for upper mast and lower mast

Technical Field

The invention relates to welding equipment of a port machine, in particular to an automatic welding production line device for upper masts and lower masts.

Background

At present, in the machining and manufacturing process of the small port machine, the mode of manual welding operation is mostly adopted for production. The upper mast and the lower mast are important parts of a pile driver in the field of engineering machinery, are large in size, are formed by welding a plurality of plates, are complex in welding structure, are mainly welded by traditional manual welding at present, and have the defects of low machining efficiency, large influence on welding quality due to human factors and high difficulty in controlling welding quality. The manual welding mode is difficult to control all aspects of production in the whole line, thereby influencing the productivity and increasing the reject ratio.

With the increasing of the productivity level, the quality requirements of users on related products are higher and higher, the structural design is more and more complex, and the quantity requirements are larger and larger, so that the unstable factors of limited production speed, difficult control of welding quality and the like caused by the change of the emotion of welding workers in the traditional manual operation, and the defect of poor accessibility of the manual processing of welding seams of partial structures are more and more exposed.

In view of the above, the invention is especially provided to introduce an automatic device, so as to effectively make up for the deficiency of manual operation.

Disclosure of Invention

The invention aims to provide an automatic welding production line device for upper and lower masts.

The purpose of the invention is realized by the following technical scheme:

the invention discloses an automatic welding production line device for upper and lower masts, which comprises an inner welding line welding unit, an outer welding line welding unit, a heavy-duty manipulator, a welding clamp and an electric control system, wherein the inner welding line welding unit is connected with the outer welding line welding unit;

the inner welding line welding unit and the outer welding line welding unit respectively comprise a positioner head part, a positioner tail part and a welding robot, the positioner head part is fixed on a positioner connecting seat, a positioner ground rail is arranged on the positioner connecting seat, the positioner tail part is arranged on the positioner ground rail, the welding robot is arranged on a robot installation C-shaped frame, the lower part of the robot installation C-shaped frame is arranged on the robot ground rail, a dust removal system and a welding power supply are arranged on the robot installation C-shaped frame, and the welding fixture is respectively arranged on the positioner head part and the positioner tail part;

the heavy-duty manipulator is arranged on one side of the inner welding line welding unit and one side of the outer welding line welding unit.

According to the technical scheme provided by the invention, the automatic welding production line device for the upper mast and the lower mast, which is provided by the embodiment of the invention, introduces automatic equipment into the traditional manual industry, reduces the participation of workers, guides the work of an operator, reduces the influence of subjective factors on the product quality, fills the emerging technologies of information industries such as intelligent manufacturing, Internet of things and the like into the operation process while meeting the basic function and flexibility of the traditional manual operation, promotes the flow of information on the whole production line, thereby realizing the standardized operation mode of 'one-time programming and multiple-time production', meeting the increasing demands on the product quality and productivity, realizing the advantages of controllable processing process, higher production speed, stable product quality and the like, and realizing the quantitative control on various aspects of the production process.

Drawings

FIG. 1 is a schematic layout of an automated welding line apparatus with upper and lower masts according to an embodiment of the present invention;

FIG. 2 is a schematic structural diagram of an inner weld joint welding unit according to an embodiment of the present invention;

FIG. 3 is a schematic structural diagram of an outer weld joint welding unit according to an embodiment of the present invention;

FIG. 4 is a schematic structural diagram of a heavy robot according to an embodiment of the present invention;

FIG. 5 is a schematic diagram of relative positions of the positioner and the tooling fixture in the embodiment of the invention;

FIG. 6 is a schematic structural diagram of a welding fixture according to an embodiment of the present invention;

FIG. 7 is a schematic view of a production flow of an automatic production line device for internal and external welding of upper and lower masts according to an embodiment of the present invention.

In the figure:

1. the welding robot comprises a positioner head part, 2 a robot ground rail, 3 a welding robot, 4 a robot installation C-shaped frame, 5 a dust removal system, 6 a welding power supply, 7 a positioner tail part, 8 a positioner ground rail, 9 a positioner connecting seat, 10 and a welding fixture;

11. the method comprises the following steps of (1) heavy manipulator grippers, 12 heavy manipulator C-shaped frames, 13 heavy manipulator slewing mechanisms, 14 heavy manipulator ground rails, 15 upper masts and lower masts to be welded;

16. centering compresses tightly the mounting panel, 17, compresses tightly the mounting panel down, 18, compresses tightly the module down, 19, compresses tightly the motor down, 20, compresses tightly the pressure head down, 21, centering compresses tightly the motor, 22, centering compresses tightly the pressure head, 23, centering compresses tightly the module.

Detailed Description

The embodiments of the present invention will be described in further detail below. Details which are not described in detail in the embodiments of the invention belong to the prior art which is known to the person skilled in the art.

The invention discloses an automatic welding production line device for upper and lower masts, which has the preferred specific implementation mode that:

the welding device comprises an inner welding line welding unit, an outer welding line welding unit, a heavy-duty manipulator, a welding clamp and an electrical control system;

The heavy-duty manipulator comprises a heavy-duty manipulator C-shaped frame, heavy-duty manipulator grippers are arranged on the heavy-duty manipulator C-shaped frame, a heavy-duty manipulator swing mechanism is arranged at the bottom of the heavy-duty manipulator C-shaped frame, and the heavy-duty manipulator swing mechanism is arranged on a heavy-duty manipulator ground rail.

Welding jig compresses tightly the mounting panel including the centering of fixing compressing tightly the mounting panel lower part down, compress tightly the mounting panel down and be equipped with down the compacting die set, compress tightly the motor down and compress tightly the head down, the centering compresses tightly to be equipped with the centering on the mounting panel and compresses tightly the pressure head with the centering.

And 360-degree turnover devices are respectively arranged between the welding fixture and the positioner head and between the welding fixture and the positioner tail.

The electric control system comprises a heavy manipulator control unit, a welding robot control unit and a positioner control unit;

the intelligent control system also comprises a PLC, an HMI, an electrical control cabinet, a control cable, a wire slot, a button operation box, a three-color alarm lamp, a buzzer and a comparator.

The invention discloses an intelligent welding upper and lower mast device, which is a set of automatic welding intelligent manufacturing system aiming at mast products. The automatic operation of the upper mast welding production line and the lower mast welding production line is realized, a robot is used for replacing a welder, and the manual participation degree in the production process is reduced so as to weaken the uncontrollable property brought to the product by subjective factors. The information and intelligent production is realized, and the production process is controlled comprehensively.

The specific embodiment is as follows:

as shown in fig. 1, the welding line device for inner and outer welding seams of the upper and lower masts (hereinafter referred to as welding line) is an intelligent manufacturing equipment set for automatic welding operation, so as to realize comprehensive automatic welding of mast products. The production line comprises an outer welding line welding unit, an inner welding line welding unit, a heavy-duty manipulator, a dust removal system and the like, wherein the inner welding line robot workstation and the outer welding line robot workstation share one set of robot walking guide rail. The three units realize signal interaction in a bus mode, so that automatic feeding, automatic welding and automatic discharging in a production line are realized.

The hardware parts of the inner and outer welding seam welding units are respectively composed of a set of positioner head parts, a positioner tail part, a set of welding fixture, a set of robot installation C-shaped frame, a welding robot, a welding power supply, a dust removal system and other main components, the welding work of the inner and outer welding seams of the upper and lower masts is completed, and workpieces are transferred by heavy-duty mechanical arms between two stations.

The automatic welding production line device for the upper mast and the lower mast comprises the following functions:

the production line establishes a PLC real-time data acquisition system, acquires key working parameters of equipment, process data and other information, uploads the information to a manufacturing execution system of the first party by the PLC, realizes automatic data acquisition, receives statistics, analysis and decision results of the manufacturing execution system of the first party, and realizes intelligent control of the production process;

the production line can realize the quick production switching of products with different specifications and models, and the average model changing time is less than 20 minutes; can be compatible with collinear flexible production of at least 10 types of products.

The automatic and manual switching mode is provided, the safe entry of personnel is ensured in the manual mode, and the workpiece inspection and operation can be manually carried out;

the control system of the production line can realize automatic control, has an interlocking function to prevent misoperation, and can display and process equipment alarm;

the production line is provided with a plurality of emergency stop buttons at the positions of the positioner, the operating platform and the like, so that operators can conveniently and rapidly stop the production line at the nearby position of the workpiece when danger occurs;

the production line has a warning function. For example, a warning is given to the danger by a buzzer, an indicator lamp, or the like;

the production line has a perception function for the safety of the surrounding environment. For example, with interlocks, safety light curtains and the like have a perception of the behavior of entering into the hazardous area. After sensing dangerous behaviors, the power is quickly and automatically cut off, and a movement mechanism automatically and emergently stops;

the production line has the functions of arc tracking and contact locating, the problem that welding cannot be performed due to the incoming deviation of parts to be welded can be avoided, and the intelligent level of the whole production line is greatly improved.

The following describes each unit separately:

(1) inner weld welding unit

As shown in fig. 2, the inner weld joint welding unit is composed of a set of positioner head, a positioner tail, a set of welding fixture, a set of robot installation C-shaped frame, a welding robot, a welding power supply, a dust removal system and other main components, wherein the positioner is fixed by the positioner head, the tail is provided with a walking ground rail, mast products with different lengths can be welded, and the fixture adopts a structure that left and right side plates are centered and clamped, and a flange plate is pressed and clamped downwards to fix a workpiece between the positioner head and the tail; the centering clamping and the pressing clamping are both realized by a motor controlled by torque. This unique actual thinking has guaranteed promptly that the focus of being welded piece remains at the machine center of shifting all the time, has ensured equipment again and can the not mast of co-altitude size of centre gripping, has increased equipment stability and reliability in the operation process on the one hand, and the another party can reduce the machine power take off ability of shifting, saves equipment purchasing cost. The position changing machine can turn over by +/-90 degrees to match, so that all inner welding lines are ensured to be positioned at good welding positions as much as possible, and the stable quality of a welding product is favorably ensured.

The outer welding seam welding robot is fixedly arranged on the C-shaped frame, and the C-shaped frame is used for walking on the guide rail to cover all welding seam positions.

(2) Outer weld seam welding unit

As shown in fig. 3, the outer weld seam welding unit is composed of a set of positioner head, a positioner tail, a set of welding fixture, a set of robot installation C-shaped frame, a welding robot, a welding power supply, a dust removal system and other main components, wherein the positioner is fixed by the positioner head, the tail is provided with a walking ground rail, mast products with different lengths can be welded, and the fixture adopts a structure that left and right side plates are centered and clamped, and a flange plate is pressed and clamped downwards to fix a workpiece between the positioner head and the tail; the centering clamping and the pressing clamping are both realized by a motor controlled by torque. This unique actual thinking has guaranteed promptly that the focus of being welded piece remains at the machine center of shifting all the time, has ensured equipment again and can the not mast of co-altitude size of centre gripping, has increased equipment stability and reliability in the operation process on the one hand, and another party can reduce the machine power take off ability of shifting, has saved equipment purchase cost. The position changing machine can turn over by +/-90 degrees to match, so that all inner welding lines are ensured to be positioned at good welding positions as much as possible, and the stable quality of a welding product is favorably ensured.

(3) Heavy-duty mechanical arm

As shown in fig. 4, the heavy-duty manipulator is composed of a ground rail, a gripper, a C-shaped frame and a swing mechanism, and a complete set of heavy-duty manipulator is formed together, the heavy-duty manipulator grabs the upper mast part and the lower mast part to be welded, and conveys the masts to the inner welding seam welding unit along the ground rail, after the welding unit completes the inner welding seam of the masts, the heavy-duty manipulator is controlled through bus communication to convey the completed weldment to the outer welding seam unit, and after the outer welding seam unit completes welding, the heavy-duty manipulator grabs the weldment and conveys the weldment to the next process.

The heavy manipulator gripper adopts a private clothes motor clamping mode, is stable and reliable, and can perform accurate position control. Meanwhile, the swing mechanism is installed on the heavy manipulator C-shaped base frame, so that the inner and outer welding seam welding robots, the robot C-shaped frame, the positioner and other mechanisms can be conveniently collided in the conveying process, and the flexibility of the equipment is improved. The heavy manipulator ground rail covers the inner welding line and the outer welding line by the length, so that the transportation range is effectively ensured.

(4) Welding jig and machine of shifting

As shown in figure 5, the welding fixture is arranged on a head-tail positioner, a workpiece can be clamped under the driving of the positioner to rotate for + -360 degrees, the workpiece to be welded is positioned at a proper position, the flexibility of the equipment is improved, and the stability of the product quality is guaranteed.

The head and the tail of the positioner are arranged on a base which is subjected to finish machining, so that the concentricity of the head and the tail of the positioner is ensured.

The tail part of the positioner is provided with a ground rail which moves back and forth, and the flexibility of the positioner is improved by privately covering the distance of the motor controller moving back and forth, so that the positioner can adapt to upper mast pieces and lower mast pieces with different lengths.

The left and right sets of welding tools are respectively provided, each set of welding tools is identical in structure and is respectively installed on rotating mechanisms at two ends of a head-tail positioner, a positioner driving motor is a robot external shaft motor and controls the positioner to rotate by +/-360 degrees, so that an upper mast and a lower mast of a part to be welded are driven to rotate and are positioned at a proper welding position, and the stability and the welding manufacturability of welding quality are ensured.

As shown in fig. 6, the welding jig is composed of a lower pressing motor, a lower pressing module, a lower pressing head, a centering pressing motor, a centering pressing head, a centering pressing module, a lower pressing mounting plate, and a centering pressing mounting plate.

The welding fixture has the functions of centering clamping and downward pressing, wherein the centering clamping ensures that the gravity center of the welding piece and the rotation center of the positioner are positioned on the same diameter, the minimum eccentric moment generated when the positioner rotates is ensured, and the service life and the stability of the positioner are improved.

The centering driving force of the welding fixture is a servo motor, so that the clamping stability can be effectively controlled, the moving distance of the chuck can be accurately controlled, and the possibility of equipment damage is further reduced.

(5) Electrical control system

The electric control system mainly comprises a robot control program, a bare machine program, a PLC (programmable logic controller) and an HMI (human machine interface), an electric control cabinet, a control cable, a wire casing, a button operation box, a three-color alarm lamp and a buzzer.

On the demonstrator, the process path can be set visually and conveniently, and the process path can be stored and called at any time.

The time for starting work, the standby time and the downtime are recorded, and meanwhile, the operation record and the alarm record of a user can be recorded.

The intelligent alarm system has an abnormal diagnosis alarm function, and when control system components, robots and the like are abnormal, the red indicator lamp is turned on and a buzzer is given out for alarm, so that fault information is provided.

The control system and the robot system are integrated, communication and linkage of related actions are carried out between the control system and the robot system through interfaces, the welding function is completed together, the formula function is achieved, and all parameter settings can be completed only by inputting product numbers.

The system has the functions of manual selection and automatic selection, can be manually participated in the manual mode, and can automatically complete the welding operation by the robot in the automatic mode. And is provided with a power on/off and indication button and an emergency stop button, and can be stopped emergently when an accident occurs.

The welding process and parameters (welding program) can be conveniently set for each workpiece, the welding program can be stored and called at any time, and the automatic welding of the workpieces is completed according to the welding program selected by an operator during working. On the comparator, the welding condition and parameters can be visually monitored and welding records can be extracted at any time.

During the assembly of the welded workpieces, errors can be caused inevitably, the consistency of the position and the width of a welding seam is not high, and in the welding process, the deformation generated by the welding seam which is welded firstly can act on the workpieces, so that the welding seam which is welded later deviates from the position of the assembly. In order to ensure the welding quality, the production line has the welding functions of welding starting point locating, welding seam tracking and the like, and the practicability of the equipment to welding products is further improved.

(6) The production flow structure is as follows:

the production flow structure of the production line is shown in fig. 7.

The technical scheme of the invention brings beneficial effects

The invention designs an automatic production line device for internal and external welding of upper and lower masts aiming at the upper and lower mast products of a pile machine by replacing the traditional manual production mode with automatic operation. It brings the benefits that:

the automation of welding operation is realized, and the manual participation degree in a production line is weakened, so that the uncontrollable property of a product caused by subjective factors is reduced, the product quality is improved, the reject ratio is reduced, and the product competitiveness of a device user is increased;

the production line is in modular design, the units are relatively independent and are mutually associated, so that the respective tasks can be independently completed, the units can be mutually associated through bus communication, the seamless connection among the units of the whole production line is realized, the automation degree is high, the labor cost is reduced, the labor intensity of workers is reduced, and the production environment is improved;

all working time, maintenance and fault points of the production line can be displayed in an HMI mode, so that equipment faults can be eliminated in time, the utilization rate of the equipment is tracked, data basis is provided for equipment use products and production management, and the management cost is greatly reduced;

the production line adopts the flexible thin 6-axis robot commonly used at present to effectively cooperate with the positioner and the welding jig of self-service research and development, and equipment intelligent degree is high and flexible good, provides the guarantee to the qualified and steady quality product of welding, has reduced equipment user's product failure rate, increases trade core competitiveness.

The equipment has simple operation interface and complete functions, a plurality of parameters influencing the product quality are submerged in an electrical program, the equipment is not needed in the using process, the whole product can be welded by supporting one-key starting, the technical threshold of the equipment user is reduced, and the production efficiency is improved;

the equipment is provided with a dust removal system, so that the influence of smoke generated by welding on the environment is effectively prevented, and the national energy-saving and environment-friendly requirements are met.

The technical key points of the invention are as follows:

the welding production line device for the inner and outer welding seams of the upper mast and the lower mast comprises an outer welding seam welding unit, an inner welding seam welding unit, a heavy-duty manipulator, a dust removal system and the like, and has the following advantages: the automation degree is high, the operation is simple, the flexibility is good, and the energy is saved and the environment is protected;

the positioner of the welding production line device for the inner and outer welding seams of the upper mast and the lower mast adopts a tail moving structure, is suitable for welding mast products, is not only suitable for one product, but also suitable for welding mast products with the same structure and different sizes, adopts an external shaft of a robot for driving, can perform coordinated motion with a welding robot in the actual welding process, greatly reduces the waiting time of equipment procedures, and fully exerts the working smoothness of the equipment;

the welding production line device for the inner and outer welding seams of the upper mast and the lower mast is provided with a self-help developed heavy-load manipulator mechanism, and a traveling guide rail of the heavy-load manipulator covers the whole production line, so that the upper and lower workpieces are smooth and are carried out fully automatically;

the welding fixture of the welding production line device for the inner and outer welding seams of the upper mast and the lower mast adopts a servo motor centering clamping and upper pressing structure, so that the eccentricity of a welding part is guaranteed to be the lowest on one hand, the inertia moment of the rotation of the positioner is reduced, and the service life of equipment is prolonged. On the other hand, the lower pressing mechanism is added, so that the stability of the welding part in 360-degree rotation on the positioner is ensured;

the inner and outer welding seam welding production line devices of the upper mast and the lower mast are provided with dust removal systems, so that the influence of smoke generated by welding on the environment is effectively prevented, and the national energy-saving and environment-friendly requirements are met;

the welding production line device for the inner and outer welding seams of the upper mast and the lower mast adopts a field bus mode to carry out interaction and interlocking on the stroke information of the welding and transporting units, and has the functions of mistake prevention and fool prevention;

the overall color of the welding production line device for the inner and outer welding lines of the upper mast and the lower mast is beige, the cover of the movable part is yellow, and the electrical cabinet is red, so that the appearance is beautiful, concise, elegant and striking;

the electrical control system of the welding production line device for the inner and outer welding lines of the upper mast and the lower mast has two modes of manual operation and automatic operation, is strong in adaptability, can transmit data with an upper computer of a user of the device, and can facilitate the user to carry out production management and capacity evaluation.

The above description is only for the preferred embodiment of the present invention, but the scope of the present invention is not limited thereto, and any changes or substitutions that can be easily conceived by those skilled in the art within the technical scope of the present invention are included in the scope of the present invention. Therefore, the protection scope of the present invention shall be subject to the protection scope of the claims.

Claims

1. An automatic welding production line device for upper and lower masts is characterized by comprising an inner welding seam welding unit, an outer welding seam welding unit, a heavy-load manipulator, a welding clamp and an electrical control system;

2. The upper and lower mast automated welding line apparatus of claim 1, wherein the heavy-duty robot comprises a heavy-duty robot C-shaped frame, the heavy-duty robot C-shaped frame is provided with a heavy-duty robot gripper, the bottom of the heavy-duty robot C-shaped frame is provided with a heavy-duty robot swing mechanism, and the heavy-duty robot swing mechanism is arranged on a heavy-duty robot ground rail.

3. The upper and lower mast automated welding line apparatus of claim 2, wherein the welding fixture comprises a centering clamping mounting plate fixed to a lower portion of the lower clamping mounting plate, the lower clamping mounting plate having a lower clamping module, a lower clamping motor and a lower clamping head mounted thereon, the centering clamping mounting plate having a centering clamping module, a centering clamping motor and a centering clamping head mounted thereon.

4. The upper and lower mast automated welding line apparatus of claim 3, wherein a 360 ° turnover device is provided between the welding fixture and the positioner head and the positioner tail, respectively.

5. An upper and lower mast automated welding line apparatus according to any one of claims 1 to 4, wherein the electrical control system includes a heavy robot control unit, a welding robot control unit and a positioner control unit;