CN114346500B - Automatic welding method and controller - Google Patents
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Abstract
The embodiment of the invention provides an automatic welding method and a controller, wherein the automatic welding method is applied to a welding workstation, and the welding workstation comprises: a positioning system and a welding system; the automatic welding method comprises the following steps: controlling the positioning system to fix the workpiece to be welded on a welding station; and after the positioning system fixes the workpiece to be welded on the welding station, controlling the welding system to weld the workpiece to be welded. The embodiment of the invention can realize automatic control of the welding process and complete penetration of one-time welding, reduce welding deformation, improve welding speed, reduce welding wire consumption, cancel two procedures of groove milling and backing welding, reduce equipment, personnel and field, save the time of the two procedures of groove milling and backing welding and the time of transferring and waiting for driving caused by the two procedures, has less welding spatter and only needs one person to watch.
Description
Technical Field
The invention relates to the technical field of welding, in particular to an automatic welding method and a controller.
Background
The welding technology in the prior art has the following defects particularly for welding long cylindrical workpieces with the length of more than 9 meters or lower plates and plates with the wall thickness of 10 millimeters: the butt welding seam of the long thin-wall component cannot realize complete penetration of one welding, automatic welding is difficult to realize, the number of processes needing manual participation is large, the quality of the welding seam is difficult to guarantee, the welding defect of incomplete penetration is easy to generate, the back surface is difficult to be welded, the problems of unstable quality of the back surface of the welding seam, low efficiency and the like exist in manual backing welding, the common MAG welding efficiency is low, the welding bottleneck becomes a boom capacity improving bottleneck, the existing boom is manually backing welded and then is automatically welded to cover the surface, the process time is long, the welding filling amount is large, welding deformation is easy to cause, the postwelding deformation amount of the boom is mostly more than 5 mm, typical wave type destabilization deformation is difficult to correct after welding, the previous process needs a groove milling process, the groove milling process occupies equipment, sites and personnel, and the time for dumping and waiting for travelling crane among the processes needs a large amount of time, the efficiency of the whole production line is influenced, and a large amount of sites are occupied, the welding wire usage is large, and the amount of welding wire is large, and the splashing is large. Therefore, it is urgently needed to provide a technical solution to solve the above technical problems in the prior art.
Disclosure of Invention
An embodiment of the invention aims to provide an automatic welding method and a controller, and solves the technical problems in the prior art.
In order to achieve the above object, a first aspect of the present invention provides an automatic welding method applied to a welding station, the welding station including: a positioning system and a welding system; the automatic welding method comprises the following steps: controlling a positioning system to fix a workpiece to be welded on a welding station; and after the positioning system fixes the workpiece to be welded on the welding station, controlling the welding system to weld the workpiece to be welded.
In an embodiment of the invention, the workpiece to be welded is a cylindrical workpiece.
In an embodiment of the present invention, a positioning system includes: the automatic back lining device, the transverse centering and positioning mechanism, the longitudinal positioning mechanism, the top pressing mechanism and the roller assembly line are arranged on the machine frame; control positioning system will wait to weld the work piece and fix at the welding station, include: controlling the automatic backing pad device to leave the roller assembly line, controlling the transverse centering and positioning mechanism to return to a zero position, and controlling the welding system to be in a safe position; after the workpiece to be welded reaches a welding station on the roller assembly line, controlling the automatic backing pad device to return to the roller assembly line; controlling a transverse centering and positioning mechanism to transversely center and position the workpiece to be welded according to the width of the workpiece to be welded and returning to a zero position; controlling a longitudinal positioning mechanism to longitudinally center and position the workpiece to be welded according to the length of the workpiece to be welded; controlling the transverse centering and positioning mechanism to perform transverse centering and positioning on the workpiece to be welded again according to the width; controlling the longitudinal positioning mechanism to perform longitudinal centering positioning on the workpiece to be welded again according to the length; controlling the automatic backing pad device to be contacted with the back of the welding position of the workpiece to be welded according to the model of the workpiece to be welded; and controlling the top pressing mechanism to press and tightly attach the workpiece to be welded according to the thickness of the workpiece to be welded.
In an embodiment of the present invention, the automatic welding method further includes: after the welding of the workpiece to be welded is finished, the automatic backing pad device, the transverse centering and positioning mechanism and the longitudinal positioning mechanism are controlled to leave the roller assembly line, and the top pressing mechanism is controlled to ascend.
In an embodiment of the present invention, a welding system comprises: a plasma welding machine, a gas shielded welding machine and a welding robot; control welding system treats welding workpiece and welds, includes: selecting the operation number of the plasma welding machine according to the type of the workpiece to be welded; sending the model to a welding robot so that the welding robot selects a program taught in advance according to the model, moves the program to a welding start position of a workpiece to be welded and selects the current, the voltage and the channel number of the gas shielded welding machine according to the program; after the welding robot moves to the welding position of the workpiece to be welded, sending an arc starting signal of the plasma welding machine to the plasma welding machine so as to control the arc starting of the plasma welding machine; and after the plasma welding machine successfully arcs, sending an arc-starting success signal of the plasma welding machine to the welding robot so that the welding robot sends an arc-starting signal of the gas-shielded welding machine to control the arc-starting of the gas-shielded welding machine.
In an embodiment of the invention, the welding station further comprises a preheating system; control welding system treats the welding workpiece and welds, still includes: judging whether the workpiece to be welded needs to be preheated or not according to the model of the workpiece to be welded; and if the workpiece to be welded needs to be preheated, controlling the preheating system to preheat the workpiece to be welded.
In an embodiment of the present invention, a preheating system includes: the heating mechanism, the lifting translation mechanism and the rotating mechanism; control system of preheating treats welding workpiece and preheats, includes: controlling the rotating mechanism to rotate, lift and translate the mechanism according to the model of the workpiece to be welded so as to realize the rotation of the heating mechanism; after the rotating mechanism rotates to a preset position, controlling the rotating mechanism to stop moving; controlling the lifting translation mechanism to lift and/or translate the heating mechanism according to the model of the workpiece to be welded; after the lifting translation mechanism reaches the surface of the workpiece to be welded, controlling the lifting translation mechanism to stop running; controlling a heating mechanism to detect the temperature of a welding position of a workpiece to be welded; when the temperature is lower than a set value, controlling the heating mechanism to heat the welding position of the workpiece to be welded; after the temperature reaches a set value, controlling a heating mechanism to preserve heat; and when the temperature exceeds a set value, controlling the heating mechanism to stop heating the welding position of the workpiece to be welded.
In an embodiment of the present invention, an automatic back cushion apparatus includes: the device comprises a height adjusting mechanism, a backing pad trolley, a rope winding and unwinding mechanism and a guide rope mechanism; controlling an automatic backing pad device to be in contact with the back surface of a welding position of a workpiece to be welded according to the model of the workpiece to be welded, comprising: controlling the height adjusting mechanism to adapt to the height of the workpiece to be welded according to the model of the workpiece to be welded; controlling a rope retracting and releasing mechanism to pull a backing pad trolley according to the model of the workpiece to be welded so as to enable the backing pad trolley to adapt to the welding walking speed of the welding robot; and controlling the guide rope mechanism to tighten the backing pad trolley according to the model of the workpiece to be welded so as to avoid the position deviation when the backing pad trolley travels.
In the embodiment of the invention, the welding workstation further comprises a lifting type chain positioner; the automatic welding method further comprises: and after the workpiece to be welded reaches the welding workstation, controlling the lifting type chain positioner to lift and/or turn over the workpiece to be welded.
A second aspect of the present invention provides a controller configured to perform the automatic welding method of the foregoing embodiment.
According to the embodiment of the invention, through the technical scheme, automatic control of the welding process and complete penetration of one-time welding can be realized, welding deformation is reduced, the welding speed is improved, the using amount of welding wires is reduced, two processes of groove milling and backing welding are cancelled, equipment, personnel and fields are reduced, the time of the two processes of groove milling and backing welding and the time of transferring and waiting for driving caused by the two processes are saved, welding spatter is less, and only one person is needed to watch.
Additional features and advantages of embodiments of the invention will be set forth in the detailed description which follows.
Drawings
The accompanying drawings, which are included to provide a further understanding of the embodiments of the invention and are incorporated in and constitute a part of this specification, illustrate embodiments of the invention and together with the description serve to explain the embodiments of the invention without limiting the embodiments of the invention. In the drawings:
FIG. 1 is a schematic flow diagram of an automated welding method 100 in accordance with an embodiment of the present invention;
FIG. 2A is a diagram illustrating a manual debugging screen of a backing pad according to an embodiment of the present invention;
FIG. 2B is a diagram illustrating a manual debugging screen of the centering system according to an embodiment of the present invention;
FIG. 2C is a diagram of a product parameter setting screen according to an embodiment of the present invention;
FIG. 2D is a single step screen diagram according to an embodiment of the present invention; and
FIG. 2E is a diagram of an auto-screen according to an embodiment of the present invention.
Detailed Description
The following detailed description of embodiments of the invention refers to the accompanying drawings. It should be understood that the detailed description and specific examples, while indicating embodiments of the invention, are given by way of illustration and explanation only, not limitation.
As shown in FIG. 1, in an embodiment of the present invention, an automated welding method 100 is provided for use in a welding station. Wherein, the welding workstation includes: a positioning system and a welding system. The automated welding method 100 includes the steps of:
step S110: and controlling a positioning system to fix the workpiece to be welded at the welding station. And
step S130: and after the positioning system fixes the workpiece to be welded on the welding station, controlling the welding system to weld the workpiece to be welded.
Specifically, the positioning system includes, for example: the automatic back cushion device comprises an automatic back cushion device, a transverse centering and positioning mechanism, a longitudinal positioning mechanism, a top pressing mechanism and a roller assembly line. Accordingly, the positioning system is controlled to fix the workpiece to be welded at the welding station, i.e. step S110 comprises the following sub-steps, for example:
(a1) And controlling the automatic backing pad device to leave the roller production line, controlling the transverse centering positioning mechanism to return to a zero position, and controlling the welding system to be in a safe position.
(a2) And after the workpiece to be welded reaches the welding station on the roller assembly line, controlling the automatic backing pad device to return to the roller assembly line.
(a3) And controlling a transverse centering and positioning mechanism to transversely center and position the to-be-welded workpiece according to the width of the to-be-welded workpiece and returning to a zero position.
(a4) And controlling a longitudinal positioning mechanism to longitudinally center and position the workpiece to be welded according to the length of the workpiece to be welded.
(a5) And controlling the transverse centering and positioning mechanism to perform transverse centering and positioning on the workpiece to be welded again according to the width.
(a6) And controlling the longitudinal positioning mechanism to perform longitudinal centering positioning on the workpiece to be welded again according to the length.
(a7) And controlling the automatic backing pad device to be in contact with the back of the welding position of the workpiece to be welded according to the model of the workpiece to be welded. And
(a8) And controlling the top pressing mechanism to press and tightly attach the workpiece to be welded according to the thickness of the workpiece to be welded.
Further, the automatic welding method 100, for example, further includes:
step S150: after the welding of the workpiece to be welded is finished, the automatic backing pad device, the transverse centering and positioning mechanism and the longitudinal positioning mechanism are controlled to leave the roller assembly line, and the top pressing mechanism is controlled to ascend.
Specifically, the welding system includes, for example: plasma welding machine, gas shielded welding machine and welding robot. Accordingly, the welding system is controlled to weld the workpiece to be welded, i.e. step S130 includes the following sub-steps:
(b1) And selecting the operation number of the plasma welding machine according to the type of the workpiece to be welded.
(b2) And sending the model to the welding robot so that the welding robot selects a program taught in advance according to the model, moves the program to the welding position of the workpiece to be welded and selects the current, the voltage and the channel number of the gas shielded welding machine according to the program.
(b3) And after the welding robot moves to the welding position of the workpiece to be welded, sending an arc starting signal of the plasma welding machine to the plasma welding machine so as to control the arc starting of the plasma welding machine. And
(b4) And after the plasma welding machine successfully arcs, sending an arc-striking success signal of the plasma welding machine to the welding robot so that the welding robot sends an arc-striking signal of the gas shielded welding machine to control the arc-striking of the gas shielded welding machine.
Further, the welding station for example also comprises a preheating system. Accordingly, the welding system is controlled to weld the workpiece to be welded, that is, step S130 further includes the sub-steps of:
(b5) And judging whether the workpiece to be welded needs to be preheated or not according to the model of the workpiece to be welded.
And
(b6) And if the workpiece to be welded needs to be preheated, controlling the preheating system to preheat the workpiece to be welded.
The preheating system can adopt medium frequency induction heating, although the invention is not limited thereto, and the preheating system can also adopt various methods such as high frequency, ceramic, cutting torch heating and the like.
Specifically, the preheating system includes, for example: heating mechanism, lift translation mechanism and rotary mechanism. Accordingly, the preheating system is controlled to preheat the workpiece to be welded, that is, (b 6) includes, for example:
(b61) And controlling the rotating mechanism to rotate, lift and translate the mechanism according to the model of the workpiece to be welded so as to realize the rotation of the heating mechanism. The rotation mechanism includes, for example, a variable frequency motor and a position detection device such as a limit switch sensor.
(b62) And after the rotating mechanism rotates to the preset position, controlling the rotating mechanism to stop moving.
(b63) And controlling the lifting translation mechanism to lift and/or translate the heating mechanism according to the model of the workpiece to be welded. The lifting translation mechanism is fixedly provided with a heating mechanism. The lifting translation mechanism comprises, for example, a variable frequency motor and a position detection device such as a limit switch sensor.
(b64) And after the lifting translation mechanism reaches the surface of the workpiece to be welded, controlling the lifting translation mechanism to stop running.
(b65) And controlling the heating mechanism to detect the temperature of the welding position of the workpiece to be welded.
(b66) And when the temperature is lower than a set value, controlling the heating mechanism to heat the welding position of the workpiece to be welded.
(b67) And after the temperature reaches a set value, controlling the heating mechanism to preserve heat. And
(b68) And when the temperature exceeds a set value, controlling the heating mechanism to stop heating the welding position of the workpiece to be welded.
The heating mechanism includes, for example, a heating coil and a temperature sensor. The heating coil is, for example, a medium-frequency heating coil, but the embodiment of the invention is not limited thereto.
Detecting the temperature of a welding position of a workpiece to be welded by controlling a heating mechanism; when the temperature is lower than a set value, controlling the heating mechanism to heat the welding position of the workpiece to be welded; after the temperature reaches a set value, controlling a heating mechanism to preserve heat; and when the temperature exceeds a set value, the heating mechanism is controlled to stop heating the welding position of the workpiece to be welded, so that automatic preheating control and feedback can be realized, and the temperature can be accurately controlled.
Specifically, the automatic backing pad device includes, for example: the device comprises a height adjusting mechanism, a backing pad trolley, a rope winding and unwinding mechanism and a guide rope mechanism. Accordingly, the automatic backing pad device is controlled to be in contact with the back surface of the welding position of the workpiece to be welded according to the model of the workpiece to be welded, that is, (a 7) includes, for example:
(a71) And controlling the height adjusting mechanism to adapt to the height of the workpiece to be welded according to the model of the workpiece to be welded. The height adjusting mechanism includes, for example, a servo motor.
(a72) And controlling the rope retracting and releasing mechanism to pull the backing pad trolley according to the model of the workpiece to be welded so as to enable the backing pad trolley to adapt to the welding walking speed of the welding robot. The rope retracting mechanism comprises a servo motor, for example. The backing pad cart includes, for example, a copper plate, a permanent magnet, and a cooling device. And
(a73) And controlling the guide rope mechanism to tighten the backing pad trolley according to the model of the workpiece to be welded so as to avoid the position deviation when the backing pad trolley travels. In particular, for example, the guide ropes on the back-cushion carriage are tensioned.
The automatic back cushion device is, for example, a steel-rope-drawn automatic back cushion device. In other embodiments, the automated backing pad apparatus may be replaced with a self-propelled lift car.
Further, the welding workstation for example still includes over-and-under type chain positioner. Accordingly, the automatic welding method 100, for example, further includes: and after the workpiece to be welded reaches the welding workstation, controlling the lifting type chain positioner to lift and/or turn over the workpiece to be welded.
Specifically, the workpiece to be welded is, for example, a cylindrical workpiece. The cylindrical workpiece has, for example, a regular pattern or other irregular pattern having a circular or quadrangular cross section.
Further, the welding workstation may also include, for example, a MAG power supply, a laser tracker, a walking gantry assembly, a plasma welding power supply, and a safety shield system.
In other embodiments, the combination of plasma hybrid welding of a plasma welder and a gas shield welder in a welding system may also be replaced with a combination of a laser welder and a gas shield welder, i.e., the plasma welder may be replaced with a laser welder. Accordingly, the plasma welding power supply may be replaced with a corresponding laser welding power supply.
In an embodiment of the present invention, there is further provided a controller configured to perform the automatic welding method 100 according to any one of the preceding embodiments. The detailed functions and details of the automatic welding method can be referred to the related description of the foregoing embodiments, and are not repeated herein.
In conclusion, the embodiment of the invention can realize automatic control of the welding process and complete penetration of one-time welding, reduce welding deformation, improve welding speed, reduce welding wire consumption, cancel two processes of groove milling and backing welding, reduce equipment, personnel and field, save time of the two processes of groove milling and backing welding and time of transferring and waiting for driving caused by the two processes, reduce welding spatter and only need one person to watch.
The automatic welding method 100 and the controller of the embodiment of the invention can be used for realizing the self-adaptive welding of various cylindrical workpieces with the length of more than 9 meters, can also be used for realizing the butt welding of a lower plate with the wall thickness of 10 millimeters or less and a plate, can be formed by one-time welding, ensures the complete penetration of a welding seam, has small heat input in the welding process, ensures the special quality requirement of high-strength steel welding, has small welding deformation, and solves the industrial problem that the butt welding seam of a long thin-wall member cannot realize the complete penetration of one-step welding.
The embodiment of the invention also provides a plasma composite welding production line which comprises 2 workstations. A single workstation comprising: the welding robot system, walking portal frame assembly, automatic backing device, transverse centering positioning mechanism, longitudinal positioning mechanism, roller support frame, top pressing mechanism, plasma composite welding equipment, MAG power supply, laser tracker, preheating system, electric control system, safety protection system and the like, and all parts of the workstation cooperate to realize automatic control of the welding process.
The safety protection system comprises, for example, a fence, a protective curtain between two stations, etc. The welding robot system, the plasma composite welding equipment, the MAG power supply, the laser tracker, the preheating system and the electric control system are arranged on the walking portal frame assembly. The 2 workstations all comprise the structures, and one workstation also comprises a lifting type chain positioner.
The electrical control system uses PLC as a core, and is provided with a total PLC electric control cabinet which comprises the PLC. The parameters are input into the total PLC electric control cabinet, the total PLC electric control cabinet carries out operation according to a preset logic program, the preset logic program is realized by operation software for example, and the output of the total PLC electric control cabinet is used for completing the control of all parts except the welding robot system and the laser tracker.
The welding robot system includes a welding robot. The general PLC electric control cabinet sends a signal to the welding robot system, and the laser tracker controls the laser to be turned on and off according to a signal butt joint program sent by the general PLC electric control cabinet.
The total PLC electric control cabinet comprises a PLC integrated controller. In the actual production welding process, in order to complete complex welding tasks of different workpieces, relevant parameters of all parts of a workstation need to be matched, and the matching is implemented through a PLC centralized controller. The PLC centralized controller has the characteristics of simple and convenient programming, visual interface, convenience in maintenance, strong anti-interference capability and the like.
And each functional module and each switching element are reasonably installed in the PLC centralized controller through a wire slot. The PLC centralized controller uses PLC as a core and mainly comprises a circuit breaker, a contactor, a thermal relay protector, a switching power supply and a servo motor driver.
The process flow and control logic of the plasma composite production line are as follows.
The welding process flow of the first workstation is as follows: the electric control system controls the automatic back lining device to leave the roller assembly line, the transverse centering positioning mechanism returns to a zero position, and the welding robot is in a safe position. A workpiece is placed on a roller assembly line formed by roller supporting frames, a feeding button is started, the workpiece flows to a welding station, after the workpiece reaches the welding station, an electric control system controls an automatic backing pad device to return to the roller assembly line, and the electric control system controls a transverse centering positioning mechanism to start centering the workpiece and then return to a zero position; then the electrical control system controls the longitudinal positioning mechanism to start correcting the workpiece, after the longitudinal positioning mechanism is in place, the electrical control system controls the transverse centering positioning mechanism to tightly press and transversely position the workpiece again, the electrical control system controls the cylinder of the longitudinal positioning mechanism to tightly press and longitudinally position the workpiece, the electrical control system controls the automatic backing pad device to be in place, the automatic backing pad device is in contact with the back of the welding position of the workpiece after being in place, and the electrical control system controls the top pressing mechanism to start pressing and tightly adhering the workpiece; judging whether a preheating system is started or not according to the type of the workpiece by the electric control system, and starting welding by the welding robot; after welding one side, the welding robot moves to the other side station of the same work station for welding, the other side station is used for placing another workpiece, the same work station can be used for placing two workpieces simultaneously, the next workpiece can be fed to wait for welding when one workpiece is fed to be welded, and the welding robot can always weld to improve the efficiency. When only one workpiece of one workstation needs to be welded, the step that the welding robot moves to the other side station to weld is not needed; the electric control system controls the automatic backing pad device, the transverse centering and positioning mechanism and the longitudinal positioning mechanism to move away, controls the top pressing mechanism to ascend, waits for the second workstation to send a feeding signal, and then the workpiece flows into the second workstation; and the circulation is carried out, so that the high-efficiency and high-automation operation is realized.
It is also worth mentioning that for workpieces with a relatively thin wall thickness, for example a wall thickness of less than 5 mm, a top hold-down mechanism may be used to secure them in order to prevent large deformations that may occur during welding. For workpieces with wall thickness greater than 5 mm, the workpiece can be fixed without using a top pressing mechanism.
The welding process flow of the second workstation is as follows: and sending a feeding signal, controlling the automatic backing pad device to leave the roller assembly line by an electrical control system, returning the transverse centering and positioning mechanism to a zero position, and enabling the welding robot to be in a safe position. The workpiece flows into the second workstation from the first workstation, and after the workpiece is in place, the lifting type chain positioner starts to lift and turn over the workpiece; after the workpiece is turned over in place, the workpiece is lowered onto a roller assembly line; the workpiece is placed on the roller assembly line, the workpiece flows to the welding station, after the workpiece reaches the welding station, the electric control system controls the automatic backing pad device to return to the roller assembly line, and the electric control system controls the transverse centering and positioning mechanism to start centering the workpiece and then return to a zero position; then the electrical control system controls the longitudinal positioning mechanism to start correcting the workpiece, after the longitudinal positioning mechanism is in place, the electrical control system controls the transverse centering positioning mechanism to tightly press and transversely position the workpiece again, the electrical control system controls the cylinder of the longitudinal positioning mechanism to tightly press and longitudinally position the workpiece, the electrical control system controls the automatic backing pad device to be in place, the automatic backing pad device is in contact with the back of the welding position of the workpiece after being in place, and the electrical control system controls the top pressing mechanism to start pressing and tightly adhering the workpiece; judging whether a preheating system is started or not according to the model number of the workpiece by the electric control system, and starting welding by the welding robot; after one side is welded, the welding robot moves to the other side station of the same workstation for welding; the electric control system controls the automatic backing pad device, the transverse centering and positioning mechanism and the longitudinal positioning mechanism to move away, controls the top pressing mechanism to ascend, waits for the second workstation to send a feeding signal, and then the workpiece flows into the second workstation; and the circulation is carried out, so that the high-efficiency and high-automation operation is realized. The workpiece flows out of the second workstation; and the circulation is carried out, so that the high-efficiency and high-automation operation is realized.
The plasma composite welding equipment comprises a plasma welding machine and a gas shielded welding machine, and the control logic of the plasma welding machine and the gas shielded welding machine is as follows: after the workpiece is placed on a roller assembly line formed by roller supporting frames, the automatic back lining device, the longitudinal positioning mechanism, the transverse centering positioning mechanism, the top pressing mechanism and the preheating system are automatically prepared according to the type of the workpiece. The electrical control system sends the model of the workpiece to the welding robot. The welding robot selects a program taught in advance according to the model of the workpiece and automatically moves to a workpiece welding part according to the program, the welding robot sends a position signal to the electrical control system, the electrical control system sends a plasma welding machine arcing signal to the plasma welding machine, after the plasma welding machine arcs successfully, the plasma welding machine arcs and sends a plasma welding machine arcing success signal to the electrical control system, the electrical control system receives the plasma welding machine arcing success signal and feeds the plasma welding machine arcing success signal back to the welding robot, and after the welding robot receives the plasma welding machine arcing success signal, the welding robot sends a gas-shielded welding machine arcing signal to the gas-shielded welding machine to realize the control of the welding machine and finish the process of automatically welding the workpiece by plasma composite welding.
The automatic back pad device includes, for example, a left back pad and a right back pad. The left and right backing pads, for example, each include: the device comprises a height adjusting mechanism, a rope winding and unwinding mechanism, a backing pad trolley and a guide rope mechanism. The height adjusting mechanism and the rope winding and unwinding mechanism both comprise servo motors, the backing pad trolley comprises a copper plate, a permanent magnet and a cooling device, the guide rope mechanism comprises a variable frequency motor, and the variable frequency motor provides power to realize winding and unwinding of the guide rope. The control logic for the automatic back cushion device is: after a workpiece is placed on a roller assembly line, the electric control system controls the height adjusting mechanism to automatically adapt to the height of the workpiece according to the model of the workpiece so as to confirm a welding point of the welding robot in the Z direction, controls the rope retracting mechanism to pull the back cushion trolley to adapt to the welding walking speed of the welding robot according to the model of the workpiece, and controls the guide rope mechanism to pre-tension the guide rope on the back cushion trolley according to the model of the workpiece so as to finish the operation of preventing the back cushion trolley mechanism from shifting when walking.
The longitudinal positioning mechanism includes, for example, a left longitudinal mechanism and a right longitudinal mechanism. The left longitudinal mechanism and the right longitudinal mechanism realize a longitudinal accurate positioning function by a servo motor. The control logic of the longitudinal positioning mechanism is as follows: when the workpiece is placed on the roller assembly line, the electric control system automatically adjusts the X-direction welding starting point of the longitudinal positioning welding robot of the longitudinal positioning mechanism according to the length of the workpiece.
The transverse centering and positioning mechanism comprises four centering mechanisms, for example, and each centering mechanism realizes a transverse accurate positioning function by a servo motor. The control logic of the transverse centering and positioning mechanism is as follows: when the workpiece is placed on the roller assembly line, the electric control system automatically adjusts the welding start point in the Y direction of the transverse positioning and positioning mechanism of the transverse centering and positioning mechanism according to the width of the workpiece.
The top hold-down mechanism comprises a hydraulic pump motor and a hydraulic device. The control logic of the top pressing mechanism is as follows: after the workpiece is placed on the roller production line, the electric control system automatically controls the welding workpiece to be pressed by the top pressing mechanism according to the thickness of the workpiece, and the workpiece is prevented from deforming in the welding process.
The control logic of the welding robot system is as follows: after the workpiece is placed on the roller production line, the electric control system selects the operation number of the plasma welding machine, namely the JOB number according to the model of the workpiece, the electric control system sends the model of the workpiece to the welding robot through the TCP, and the welding robot automatically selects a program which is taught in advance according to the model of the workpiece, selects the current, the voltage and the channel number of the gas shielded welding machine, and realizes welding.
The preheating system mainly comprises a heating mechanism, a lifting translation mechanism and a rotating mechanism. The heating mechanism comprises a heating coil and a temperature feedback unit, the temperature feedback unit comprises a temperature sensor, the lifting translation mechanism comprises a variable frequency motor and a position detection unit, and the rotating mechanism comprises a variable frequency motor and a position detection unit. The position detection unit includes, for example, a limit switch sensor. The preheating system comprises the following components and control logics: after a workpiece is placed on a roller assembly line, according to the model of the workpiece, an electrical control system controls a rotating mechanism to automatically rotate a lifting translation mechanism, a heating mechanism is fixedly installed on the lifting translation mechanism, the rotating lifting translation mechanism can drive the heating mechanism to rotate, a limit switch sensor of the rotating mechanism detects whether the heating mechanism is rotated in place, and when the heating mechanism rotates in place, the rotating mechanism is automatically stopped to move. After the heating mechanism is rotated to the position by the rotating mechanism, the lifting translation mechanism drives the heating mechanism to automatically move left and right and/or up and down, a limit switch sensor is mounted at the head of the lifting translation mechanism, and when the lifting translation mechanism reaches the surface of a workpiece, the limit switch sensor of the lifting translation mechanism detects that the workpiece is in place, and the lifting translation mechanism is automatically stopped. After the lifting translation mechanism stops operating, the temperature sensor detects the temperature of the welding position of the workpiece, such as the temperature around the welding seam, in a range of 50 mm on the two sides of the welding seam, the heating mechanism starts a PID temperature adjusting function, when the temperature detected by the temperature sensor is lower than a set value, the heating coil continues heating, when the temperature detected by the temperature sensor reaches the set value, the heating coil enters a heat preservation state, and when the temperature detected by the temperature sensor exceeds the set value, the heating is stopped. The preheating system may be specifically, for example, an intermediate frequency preheating system.
The control modes of the plasma composite welding production line comprise manual control, single-step control and automatic control. The manual control is used for teaching workpieces, and the main function of the teaching device is to respectively teach a welding robot a Z-direction welding point, an X-direction welding point and a Y-direction welding point according to different workpiece models. The single-step control is semi-automatic control, and all actions are carried out step by step through keys on the touch screen. And automatically controlling one key to realize the welding function of the welding robot.
The operation of the manual control is described in detail below.
(1) And teaching starting welding points of the welding robot in the X direction.
After the workpiece is placed on a roller assembly line, the moving speed of a longitudinal mechanism is set at a speed setting position in a longitudinal positioning unit of a backing pad manual debugging picture shown in figure 2A, a left longitudinal advance key or a left longitudinal retreat key is clicked, the left longitudinal mechanism is moved to the workpiece and is close to the workpiece, a right longitudinal advance key or a right longitudinal retreat key is clicked, after the right longitudinal mechanism is moved to the workpiece, a backing pad longitudinal cylinder extension key is clicked in other units, the workpiece is extended to be close to the top through a cylinder, a positioning iron block at the end of the left longitudinal mechanism is abutted to the workpiece, the actual position of left and right longitudinal positioning is recorded and is placed in the workpiece parameter corresponding to a product parameter setting picture shown in figure 2C, and welding point teaching in the X direction of the welding robot is completed.
(2) And teaching a welding point of the welding robot in the Z direction.
After a workpiece is placed on a roller assembly line, the lifting speed of a back pad is set at a speed setting position in a back pad unit of a back pad manual debugging picture, a left back pad lifting key or a left back pad descending key is clicked, the left back pad is moved to a workpiece inner cylinder, a right back pad lifting key or a right back pad descending key is clicked, the right back pad is moved to the workpiece inner cylinder, the lifting actual positions of the left back pad and the right back pad are recorded in workpiece parameters corresponding to a product parameter setting picture, and welding point teaching in the Z direction of a welding robot is completed.
(3) And teaching a welding point in the Y direction of the welding robot.
After a workpiece is placed on a roller assembly line, the speeds of servo motors of four centering mechanisms are set at the set speed positions in the centering 1, centering 2, centering 3 and centering 4 units of a manual debugging picture of a centering system shown in fig. 2B, a 'loosening' or 'clamping' button is clicked, the corresponding centering mechanism is moved to the position of an outer cylinder of the workpiece, keys of 'stretching out of a centering cylinder 1' and 'stretching out of a centering cylinder 2' are clicked, the workpiece is stretched out and clamped through the corresponding cylinder of the centering mechanism, the actual positions of the servo motors of the centering 1 to the centering 4 are recorded in workpiece parameters corresponding to a product parameter setting picture, and the teaching of welding spots in the Y direction of a welding robot is completed.
The operation of the single-step control is described in detail below.
(1) After the workpiece is placed on the roller assembly line, the workpiece model is input in a station model selection column in a single-step picture as shown in fig. 2D, the line number is selected and input into an A surface, a B surface or an AB surface, and the parameter calling in the X, Y, Z direction of the welding robot starting point of the taught workpiece is completed.
(2) Clicking a 'longitudinal servo forward to workpiece position' button, and automatically moving the left longitudinal mechanism and the right longitudinal mechanism to preset positions to complete the positioning of the X-direction position of the welding point of the welding robot.
(3) Clicking a 'centering servo clamping' button, synchronously actuating servo motors of all centering mechanisms to preset positions, then clicking 'centering cylinders to stretch out', completely stretching out the cylinders of all the centering mechanisms, clamping workpieces, and completing the positioning of the welding robot in the Y-direction welding point.
(4) And clicking 'lifting servo operation to a workpiece position', judging whether the back cushion is lifted or lowered by the lifting servo motors of the left back cushion and the right back cushion according to the current actual position and preset data, and linking with a traction rope during lifting to finish the Z-direction position positioning of the welding starting point of the welding robot.
(5) Clicking 'longitudinally retreats to the robot safety point', the left longitudinal mechanism and the right longitudinal servo motor retreat to the predefined original point positions, giving way to the welding space of the welding robot, synchronously unwinding the left traction rope and the right traction rope, and synchronously unwinding the guide rope.
(6) And clicking the 'welded backing pad', wherein a servo motor of the left longitudinal mechanism runs to a welding starting point on the left side of the workpiece, so that the backing pad trolley is conveniently connected.
The operation of the automatic control is described in detail below.
(1) Inputting the workpiece model in the B-station model selection column in the automatic picture as shown in FIG. 2E, selecting and inputting the line number into the A surface, the B surface or the AB surface, and completing the parameter calling in the X, Y, Z direction of the welding point of the welding robot of the taught workpiece.
(2) A feeding button of a control cabinet is pressed, a transverse air cylinder of the left back cushion automatically extends out, and a lifting servo motor of the left back cushion moves to a workpiece position which is defined in advance; and the longitudinal mechanism of the right back cushion and the lifting servo motor of the right back cushion move to a predefined workpiece, the servo motors of all the centering mechanisms retract automatically, the air cylinders of all the centering mechanisms retract automatically, and the air cylinders of all the longitudinal mechanisms retract automatically to prepare for feeding. And meanwhile, the lifting servo motors of the left back pad and the right back pad complete the Z-direction position positioning of the welding robot.
(3) The feeding motor starts to be started quickly and automatically, when the workpiece moves to the deceleration sensor, the feeding motor runs to the stop sensor at a slow speed, and the feeding motor stops automatically to finish feeding.
(4) The transverse cylinder of the left back cushion automatically retracts, and the longitudinal mechanism of the right back cushion moves to the safety position of the welding robot to prepare for the centering mechanism to position the welding robot in the Y direction.
(5) All the centering mechanisms move to positions according to preset position points, clamp workpieces and extend out of the air cylinder, and Y-direction position positioning of the welding robot is completed. All centering mechanisms retract into the cylinder in preparation for X-direction positioning of the longitudinal mechanism.
(6) And the left longitudinal mechanism and the right longitudinal mechanism automatically run to the preset workpiece position, and the air cylinder of the longitudinal mechanism automatically extends out to prop against the workpiece, so that the X-direction positioning of the welding robot is completed.
(7) And the cylinder of the centering mechanism automatically extends out to fix the workpiece.
(8) After the guide rope and the traction rope are hung manually, according to the 'confirmation of hanging rope' on the automatic picture, the electric control system automatically judges whether the top pressing mechanism is pressed or not according to the model of the workpiece and the welding process requirement, the pressing oil cylinder of the top pressing mechanism automatically operates, and the top pressing mechanism automatically presses the workpiece.
(9) The longitudinal mechanism of the left back liner automatically moves to a workpiece, the traction rope servo motor of the right back liner automatically and synchronously takes up the rope, the guide rope motor automatically takes up the rope, the back liner trolley automatically sucks the inner side of the workpiece, the back liner trolley manually detects whether the back liner trolley sucks the workpiece or not, and the next step is carried out by pressing a key of 'the back liner clings to the workpiece'.
(10) The longitudinal mechanism of the left back liner automatically operates to a safety point of the welding robot, the traction rope servo motor of the left back liner synchronously releases the rope, and the guide rope motor automatically and synchronously releases the rope.
(11) The robot welding and fool-proof functions are started, and the welding robot automatically starts a welding program. According to the type of a workpiece, the electric control system controls the heating mechanism to rotate and move until the heating mechanism reaches the surface of the workpiece, the limit switch sensor is triggered to stop running, the welding robot moves to a taught position and sends an in-place signal to the electric control system, the electric control system sends a plasma welding machine arcing signal to the plasma welding machine, the plasma welding machine arcing success signal is sent to the electric control system after the plasma welding machine arcs successfully, the electric control system sends a plasma welding machine arcing success signal to the welding robot, the welding robot starts the gas shielded welding machine after receiving the plasma welding machine arcing success signal, a backing pad trolley moving signal and the welding robot moving speed are sent to the electric control system, and the electric control system controls the backing pad trolley to automatically move synchronously with the welding robot.
(12) When the welding robot sends a welding completion signal, the backing pad trolley stops running, and the left longitudinal mechanism automatically moves to the workpiece to prepare for the backing pad trolley.
(13) The servo motors of the left and right traction ropes are linked to release the ropes, the backing pad trolley moves to the sensor on the left longitudinal mechanism, stops running and receives the backing pad trolley.
(14) Manually detaching the ropes, pressing a 'detached rope confirmation' button on an automatic picture after the ropes are detached, enabling all the longitudinal mechanisms to return to the original point, enabling all the centering mechanisms to return to the original point, and enabling the cylinders of all the centering mechanisms to retract.
(15) And the transverse cylinders of the left back cushion and the right back cushion retract to wait for calling and feeding at the next station.
(16) The next station calls for feeding, and the roller bed motor of the previous station automatically operates to complete the discharging action.
(17) The next cycle is started.
The plasma composite welding production line provided by the embodiment of the invention can realize automatic control of the welding process and complete penetration of one-time welding, reduces welding deformation, improves welding speed, reduces the consumption of welding wires, cancels two procedures of groove milling and backing welding, reduces equipment, personnel and field, saves the time of the two procedures of groove milling and backing welding and the time of transferring and waiting for driving caused by the two procedures, has less welding spatter, and only needs one person to watch the whole production line. The method can be used for self-adapting to various cylindrical workpieces with the length of more than 9 meters, can also be used for realizing butt welding of a lower plate with the wall thickness of more than 10 millimeters and a plate, can be formed by one-step welding, ensures complete penetration of a welding line, has small heat input in the welding process, ensures special quality requirements of high-strength steel welding, has small welding deformation, and solves the industrial problem that the butt welding line of a long thin-wall component cannot realize complete penetration of one-step welding.
It is to be noted that the terms "comprises," "comprising," or any other variation thereof, are intended to cover a non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements does not include only those elements but may include other elements not expressly listed or inherent to such process, method, article, or apparatus. Without further limitation, an element defined by the phrase "comprising a … …" does not exclude the presence of another identical element in a process, method, article, or apparatus that comprises the element.
The above are merely examples of the present invention, and are not intended to limit the present invention. Various modifications and alterations to this invention will become apparent to those skilled in the art. Any modification, equivalent replacement, improvement, etc. made within the spirit and principle of the present invention should be included in the scope of the claims of the present invention.
Claims (7)
1. An automated welding method, applied to a welding station, said welding station comprising: positioning system and welding system, the positioning system includes: automatic back of body liner device, horizontal centering positioning mechanism, vertical positioning mechanism, top hold-down mechanism and cylinder assembly line, weldment work station still includes the system of preheating, the system of preheating includes: the heating mechanism, the lifting translation mechanism and the rotating mechanism; the automatic welding method comprises the following steps:
controlling the automatic back-lining device to leave the roller assembly line, controlling the transverse centering and positioning mechanism to return to a zero position, and controlling the welding system to be in a safe position;
after the workpieces to be welded reach the welding station on the roller assembly line, controlling the automatic back cushion device to return to the roller assembly line;
controlling the transverse centering and positioning mechanism to transversely center and position the workpiece to be welded according to the width of the workpiece to be welded and returning to a zero position;
controlling the longitudinal positioning mechanism to longitudinally center and position the workpiece to be welded according to the length of the workpiece to be welded;
controlling the transverse centering and positioning mechanism to perform transverse centering and positioning on the workpiece to be welded again according to the width;
controlling the longitudinal positioning mechanism to perform longitudinal centering positioning on the workpiece to be welded again according to the length;
controlling the automatic backing pad device to be in contact with the back of the welding position of the workpiece to be welded according to the model of the workpiece to be welded;
controlling the top pressing mechanism to press and tightly attach the workpiece to be welded according to the thickness of the workpiece to be welded; and
after the positioning system fixes the workpiece to be welded on the welding station, controlling the welding system to weld the workpiece to be welded;
the automatic welding method further comprises the following steps:
judging whether the workpiece to be welded needs to be preheated or not according to the model of the workpiece to be welded;
if the workpiece to be welded needs to be preheated, controlling the preheating system to preheat the workpiece to be welded;
wherein the controlling the preheating system to preheat the workpiece to be welded includes:
controlling the rotating mechanism to rotate the lifting translation mechanism according to the model of the workpiece to be welded so as to realize the rotation of the heating mechanism;
after the rotating mechanism rotates to a preset position, controlling the rotating mechanism to stop moving;
controlling the lifting translation mechanism to lift and/or translate the heating mechanism according to the model of the workpiece to be welded;
after the lifting translation mechanism reaches the surface of the workpiece to be welded, controlling the lifting translation mechanism to stop running;
controlling the heating mechanism to detect the temperature of the welding position of the workpiece to be welded;
when the temperature is lower than a set value, controlling the heating mechanism to heat the welding position of the workpiece to be welded;
after the temperature reaches the set value, controlling the heating mechanism to carry out heat preservation; and
and when the temperature exceeds the set value, controlling the heating mechanism to stop heating the welding position of the workpiece to be welded.
2. The automatic welding method of claim 1, wherein the workpiece to be welded is a cylindrical workpiece.
3. The automated welding method of claim 1, further comprising:
after the welding of the workpieces to be welded is finished, the automatic backing pad device, the transverse centering and positioning mechanism and the longitudinal positioning mechanism are controlled to leave the roller assembly line, and the top pressing mechanism is controlled to ascend.
4. The automated welding method of claim 1, wherein the welding system comprises: a plasma welding machine, a gas shielded welding machine and a welding robot; the controlling the welding system to weld the workpieces to be welded includes:
selecting the operation number of the plasma welding machine according to the type of the workpiece to be welded;
sending the model to the welding robot so that the welding robot selects a program taught in advance according to the model, moves the program to a welding position of the workpiece to be welded and selects the current, the voltage and the channel number of the gas shielded welding machine according to the program;
after the welding robot moves to the welding position of the workpiece to be welded, sending an arc starting signal of a plasma welding machine to the plasma welding machine so as to control the arc starting of the plasma welding machine; and
and after the plasma welding machine successfully arcs, sending a plasma welding machine successful arc striking signal to the welding robot so that the welding robot sends an arc striking signal of the gas shielded welding machine to control the arc striking of the gas shielded welding machine.
5. The automated welding method of claim 4, wherein the automated backing pad apparatus comprises: the device comprises a height adjusting mechanism, a backing pad trolley, a rope winding and unwinding mechanism and a guide rope mechanism; the controlling of the automatic backing pad device to contact the back of the welding position of the workpiece to be welded according to the model of the workpiece to be welded includes:
controlling the height adjusting mechanism to adapt to the height of the workpiece to be welded according to the model of the workpiece to be welded;
controlling the rope retracting and releasing mechanism to pull the backing pad trolley according to the model of the workpiece to be welded so as to enable the backing pad trolley to adapt to the welding walking speed of the welding robot; and
and controlling the guide rope mechanism to tighten the back gasket trolley according to the model of the workpiece to be welded so as to avoid position deviation when the back gasket trolley travels.
6. The automated welding method of any of claims 1 to 5, wherein the welding station further comprises an elevating chain positioner; the automatic welding method further comprises the following steps:
and after the workpiece to be welded reaches the welding workstation, controlling the lifting type chain positioner to lift and/or overturn the workpiece to be welded.
7. A controller configured to perform the automated welding method of any of claims 1 to 6.
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| CN202922070U (en) * | 2012-09-11 | 2013-05-08 | 武汉和越装备技术有限公司 | Welding robot workstation |
| CN103659132B (en) * | 2013-12-04 | 2015-11-04 | 中联重科股份有限公司 | Lifting type chain position changing machine and lifting position changing method of workpiece |
| CN104708236B (en) * | 2013-12-12 | 2016-05-18 | 中联重科股份有限公司 | Robot welding workstation |
| CN107570899A (en) * | 2017-06-28 | 2018-01-12 | 中联重科股份有限公司 | Welding method and welding device for carrying out the welding method |
| CN110449795A (en) * | 2019-09-03 | 2019-11-15 | 湖南蓝天机器人科技有限公司 | Backing for automatic welding production line pads tooling |
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Application publication date: 20220415 Assignee: Zoomlion Heavy Industry Science and Technology Co.,Ltd. Assignor: ZOOMLION HEAVY INDUSTRY SCIENCE&TECHNOLOGY Co.,Ltd. Contract record no.: X2023980044881 Denomination of invention: Automatic welding methods and controllers Granted publication date: 20230331 License type: Common License Record date: 20231030 Application publication date: 20220415 Assignee: Hunan ZOOMLION Crawler Crane Co.,Ltd. Assignor: ZOOMLION HEAVY INDUSTRY SCIENCE&TECHNOLOGY Co.,Ltd. Contract record no.: X2023980044887 Denomination of invention: Automatic welding methods and controllers Granted publication date: 20230331 License type: Common License Record date: 20231030 Application publication date: 20220415 Assignee: Hunan Zoomlion engineering hoisting equipment Co.,Ltd. Assignor: ZOOMLION HEAVY INDUSTRY SCIENCE&TECHNOLOGY Co.,Ltd. Contract record no.: X2023980044882 Denomination of invention: Automatic welding methods and controllers Granted publication date: 20230331 License type: Common License Record date: 20231030 |