CN117259985B - Laser splice welding door ring and production process thereof - Google Patents
Laser splice welding door ring and production process thereof Download PDFInfo
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- CN117259985B CN117259985B CN202311481610.3A CN202311481610A CN117259985B CN 117259985 B CN117259985 B CN 117259985B CN 202311481610 A CN202311481610 A CN 202311481610A CN 117259985 B CN117259985 B CN 117259985B
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- 238000003466 welding Methods 0.000 title claims abstract description 206
- 238000004519 manufacturing process Methods 0.000 title claims abstract description 49
- 239000000463 material Substances 0.000 claims abstract description 52
- 239000011248 coating agent Substances 0.000 claims abstract description 21
- 238000000576 coating method Methods 0.000 claims abstract description 21
- 238000010438 heat treatment Methods 0.000 claims abstract description 10
- 238000005422 blasting Methods 0.000 claims abstract description 8
- 238000003856 thermoforming Methods 0.000 claims abstract description 5
- 238000003698 laser cutting Methods 0.000 claims abstract description 4
- 238000001514 detection method Methods 0.000 claims description 46
- 238000000034 method Methods 0.000 claims description 22
- 230000007306 turnover Effects 0.000 claims description 18
- 230000008569 process Effects 0.000 claims description 17
- 230000033001 locomotion Effects 0.000 claims description 16
- HCHKCACWOHOZIP-UHFFFAOYSA-N Zinc Chemical compound [Zn] HCHKCACWOHOZIP-UHFFFAOYSA-N 0.000 claims description 9
- 229910052725 zinc Inorganic materials 0.000 claims description 9
- 239000011701 zinc Substances 0.000 claims description 9
- 238000012546 transfer Methods 0.000 claims description 8
- 238000001816 cooling Methods 0.000 claims description 3
- 239000012636 effector Substances 0.000 claims description 3
- 238000007747 plating Methods 0.000 claims description 2
- 230000009286 beneficial effect Effects 0.000 abstract description 12
- 238000013461 design Methods 0.000 abstract description 8
- 238000005260 corrosion Methods 0.000 abstract description 5
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- 230000007613 environmental effect Effects 0.000 abstract description 2
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- 239000000047 product Substances 0.000 description 16
- 230000002787 reinforcement Effects 0.000 description 13
- 230000005540 biological transmission Effects 0.000 description 11
- 238000001179 sorption measurement Methods 0.000 description 8
- CSDREXVUYHZDNP-UHFFFAOYSA-N alumanylidynesilicon Chemical compound [Al].[Si] CSDREXVUYHZDNP-UHFFFAOYSA-N 0.000 description 7
- 230000000670 limiting effect Effects 0.000 description 7
- 239000000945 filler Substances 0.000 description 6
- 230000000007 visual effect Effects 0.000 description 6
- 230000000712 assembly Effects 0.000 description 5
- 238000000429 assembly Methods 0.000 description 5
- 230000005587 bubbling Effects 0.000 description 4
- 238000009434 installation Methods 0.000 description 4
- 238000012545 processing Methods 0.000 description 4
- 241000252254 Catostomidae Species 0.000 description 2
- 239000010953 base metal Substances 0.000 description 2
- 230000002860 competitive effect Effects 0.000 description 2
- 238000005516 engineering process Methods 0.000 description 2
- 230000010354 integration Effects 0.000 description 2
- 238000011084 recovery Methods 0.000 description 2
- 230000003014 reinforcing effect Effects 0.000 description 2
- 239000002699 waste material Substances 0.000 description 2
- 229910000831 Steel Inorganic materials 0.000 description 1
- 230000009471 action Effects 0.000 description 1
- 230000006978 adaptation Effects 0.000 description 1
- 229910052782 aluminium Inorganic materials 0.000 description 1
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 description 1
- 239000003518 caustics Substances 0.000 description 1
- 238000011161 development Methods 0.000 description 1
- 238000007599 discharging Methods 0.000 description 1
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- 238000002309 gasification Methods 0.000 description 1
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Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K26/00—Working by laser beam, e.g. welding, cutting or boring
- B23K26/20—Bonding
- B23K26/21—Bonding by welding
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K26/00—Working by laser beam, e.g. welding, cutting or boring
- B23K26/36—Removing material
- B23K26/38—Removing material by boring or cutting
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K26/00—Working by laser beam, e.g. welding, cutting or boring
- B23K26/70—Auxiliary operations or equipment
- B23K26/702—Auxiliary equipment
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- Engineering & Computer Science (AREA)
- Physics & Mathematics (AREA)
- Optics & Photonics (AREA)
- Plasma & Fusion (AREA)
- Mechanical Engineering (AREA)
- Laser Beam Processing (AREA)
Abstract
The invention relates to a laser splice welding door ring and a production process thereof, belonging to the technical field of door ring production. The laser splice welding door ring comprises a plurality of plates, wherein a plurality of plates are sequentially connected end to form a door ring structure with at least one door opening, a part of plates are zinc-plated plates, and the rest of plates are bare plates. The production process of the laser splice welding door ring comprises laser splice welding, patch plate spot welding, heating the welding door ring, precooling, thermoforming, removing allowance by laser cutting and shot blasting. The invention realizes the connection between different coating plates, can realize that the vehicle body meets different environmental corrosion resistance requirements, and realizes better vehicle body design through material selection; the invention combines the advantages of two materials, not only can improve the durability of the door ring, but also is beneficial to reducing the cost and meeting the market demand, and can ensure the stability of the product quality and the production cost while realizing mass production.
Description
Technical Field
The invention relates to a laser splice welding door ring and a production process thereof, belonging to the technical field of door ring production.
Background
In today's highly competitive automotive industry, automotive manufacturers are facing tremendous challenges. In order to remain competitive in the marketplace, they must continually search for new ways to reduce costs.
With the development of light weight, integration and integration of car body design, car manufacturers are focusing on innovative designs such as an integrated door ring structure, and the integrated door ring structure design is a very effective car light weight design, and can remarkably reduce car manufacturing cost and improve performance.
The integral door ring structure integrates a plurality of plates, and can realize the advantages of effectively reducing the weight of the automobile body, improving the safety, reducing the die cost, improving the production efficiency and the like by utilizing advanced technologies such as high-strength steel, laser welding and the like. The design simplifies the production flow, reduces the manufacturing and assembling costs of a plurality of parts, ensures that the production flow is more compact, and improves the production efficiency. Meanwhile, the integrated door ring structure can improve the material utilization rate, reduce the waste of materials, reduce the production cost of enterprises, and is beneficial to environmental protection. In a word, the integrated door ring structural design is an innovative technology with multiple advantages, can meet the light-weight requirement of an automobile, and has the advantages of being higher in strength, higher in material utilization rate, capable of reducing the investment of a front-stage die, capable of reducing the cost of a bicycle and the like.
The integral door ring structure used on the existing high-end vehicle is formed by splicing aluminum-silicon coating plates, however, self-fusion welding is adopted between the aluminum-silicon coating plates, when welding operation is carried out, uneven thermal expansion and shrinkage of the coating can be caused by high temperature, so that the coating is cracked and falls off, and as the melting point of the aluminum-silicon coating is lower than that of a welding material, the aluminum-silicon coating can be melted and flows into a welding seam in the welding process, the welding quality can be reduced, and in order to solve the problem, part of the welding edge coating is peeled off before welding so as to avoid the influence of the coating on the welding quality, but the treatment mode is more complex and the cost is higher.
The low-end vehicle is generally subjected to stricter cost pressure, the integral door ring structure used on the existing low-end vehicle directly adopts an uncoated bare board for splice welding, and the adoption of the uncoated bare board for splice welding can indeed reduce the cost, but the corrosion resistance and the service life of the door ring can be influenced to a certain extent.
In fact, because more moisture and corrosive substances exist in the contact environment between the lower part of the door ring and the ground or the wall surface, the lower part of the door ring is easy to corrode, the upper part of the door ring is basically not corroded, and the performance and the cost cannot be simultaneously achieved by adopting all aluminum-silicon coating plates or all bare plates from the aspects of reducing the cost and improving the quality.
On the premise of not reducing the quality of the automobile, the problems of improving the utilization rate of materials, reducing the waste of the materials and reducing the production cost of enterprises are continuously concerned by automobile manufacturers.
Disclosure of Invention
The present invention aims to provide a new technical solution to improve or solve the technical problems existing in the prior art as described above.
The technical scheme provided by the invention is as follows: a laser splice welding door ring comprises a plurality of plates, wherein a plurality of plates are sequentially connected end to form a door ring structure with at least one door opening, a part of plates are zinc-plated plates, and the rest of plates are bare plates.
Compared with the prior art, the technical scheme provided by the invention has the following beneficial effects:
the invention successfully realizes the connection between different thermoforming materials, adopts zinc plating plate materials with better corrosion resistance at the place with severe use environment of the chassis of the vehicle body, adopts bare plate materials at the place with better environment of the vehicle body, can realize the vehicle body to meet different environment corrosion resistance requirements, and realizes better vehicle body design through material selection.
On the basis of the technical scheme, the invention can be improved as follows.
Further, the patch board is further included, and a part of the bare board is provided with the patch board.
The adoption of the further scheme has the beneficial effects that the structural strength of the door ring can be enhanced, and the collision safety is improved.
Further, the patch plates are welded in a spot welding mode.
Further, adjacent plates are connected in a laser welding mode.
The adoption of the further scheme has the beneficial effects that the zinc coating plate material and the bare plate are welded by laser, the coating does not need to be stripped, the welding is easy to realize, the cost is saved, and the production efficiency is improved.
The production process of the laser splice welding door ring comprises the following steps:
s1, performing laser welding, wherein adjacent plates are spliced and welded together in a laser welding mode;
s2, spot welding patch plates, namely, spot welding the patch plates on corresponding plates to obtain welded door rings;
s3, heating the welding door ring, and transferring the welding door ring into a heating furnace to perform austenitization and prealloying of a surface coating;
s4, precooling, and cooling the welded door ring after heating;
s5, performing thermoforming, namely performing hot stamping on the pre-cooled welded door ring by using a hot stamping die;
s6, removing the allowance by utilizing laser cutting;
s7, shot blasting is carried out on the surface of the door ring by using a shot blasting machine.
The production process of the laser splice welding door ring combines the advantages of two materials, not only can improve the durability of the door ring, but also is beneficial to reducing the cost and meeting the market demand, and can ensure the stability of the product quality and the production cost while realizing mass production.
On the basis of the technical scheme, the invention can be improved as follows.
Further, in step S1, including full-automatic door ring welding production line, full-automatic door ring welding production line includes ground rail and sets up material loading district and the welded zone around the ground rail, be equipped with on the ground rail and follow the piece adjustment positioner that ground rail removed, be equipped with material loading robot, prepositioning platform, truss and install on the truss can follow on the truss reciprocating motion' S end effector, laser welding process includes the following step:
s11, placing a plurality of plates on a pre-positioning table by the feeding robot, and abutting the plates head and tail to form an annular pre-assembled door ring;
s12, the pre-assembled door ring is integrally transferred to a seam adjusting and positioning device through an end pick-up, and a seam between adjacent plates is adjusted to be 0.1-0.5 mm through the seam adjusting and positioning device, so that the plates are clamped and fixed;
s13, moving the seam adjustment positioning device along the ground rail to move the plate with the fixed position into a welding area, wherein a welding robot is arranged in the welding area;
s14, adjusting a welding track of the welding robot, and primarily marking a theoretical welding track on a plate through low-intensity laser of the welding robot;
s15, comparing the deviation of the theoretical welding track and the actual welding seam, wherein the deviation is smaller than a threshold value, welding is carried out, and if the deviation is larger than the threshold value, the process is switched to S14;
s16, detecting a back weld by using a weld detection device.
The adoption of the further scheme has the beneficial effects that a plurality of plates are pre-assembled into the annular pre-assembled door ring through the step S11, so that convenience is provided for the subsequent seam adjustment positioning device; in the step S13, the seam gap between the plates is accurately controlled between 0.1mm and 0.5mm through the seam adjusting and positioning device, the fine adjustment provides ideal welding conditions for the step S15, when the step S15 adopts laser filler wire welding, the seam adjusting and positioning device can adjust the gap between the plates to a size range suitable for the laser filler wire welding, the laser filler wire welding is a high-energy beam processing method, the requirement on the welding gap is very strict, the laser beam can be ensured to fill the metal wire into the welding seam efficiently only when the gap is controlled in a proper range, thereby achieving the high-strength and high-precision welding effect, when the laser self-fluxing welding is adopted, but the cost can be saved, when the self-fluxing welding is carried out, the control of the gap needs to be particularly paid attention, and because a plurality of gaps have accumulated errors when the last welding seam is welded, if the gap is too large, the last welding seam can only be processed through the filler wire welding mode, therefore the adjusting step is critical to the whole manufacturing process, and the quality and the stability of the final product are laid; the welding deviation can be predicted through the step S14 and the step S15, when the deviation is larger than the threshold value, the deviation welding can be avoided through manual or automatic adjustment, scrapping is prevented, and the yield is improved; and detecting the states of the front and back welding seams through the step S16, including problems of flatness, bubbling, cold joint and the like, so as to ensure the quality of products.
Further, in step S11, the splicing seam between adjacent plates is 1 mm-5 mm.
The technical scheme has the beneficial effects that the splicing gap of the annular pre-spliced door ring is controlled within the range of 1-5 mm, and the precision provides convenience for the subsequent splicing gap adjusting and positioning device, so that the gap between the plates can be finely adjusted and optimized.
Further, the full-automatic door ring splice welding production line also comprises a visual guide module, wherein the feeding robot is used for capturing the plate material and then moving to the visual guide module to take a picture and transmitting the picture to the control system, and the control system is used for controlling the feeding robot to adjust the blanking direction to accurately place the plate material on the pre-positioning table after obtaining the picture.
Further, the full-automatic door ring splice welding production line further comprises a back welding seam detection area, a blanking area and a blanking robot, wherein a turn-over machine and welding seam detection equipment are arranged in the back welding seam detection area, the blanking robot moves in the back welding seam detection area and the blanking area, in step S16, the blanking robot transfers a welded door ring product from the splice seam adjusting and positioning device to the turn-over machine, and after the turn-over machine turns over the welded door ring product, the welding seam detection equipment detects a welding seam on the back; and the blanking robot transfers the qualified door ring products after detection to the qualified product area, and transfers the unqualified door ring products after detection to the unqualified product area.
The welding seam detection equipment has the beneficial effects that the welding seam state can be accurately detected by adopting the further scheme, and the problems of flatness, bubbling, cold joint and the like are solved.
Further, the seam adjustment positioning device comprises a working table plate, a vision device frame, positioning electromagnets and an alignment platform, wherein a camera and a light source are installed on the vision device frame, the working table plate and the vision device frame are installed on the ground rail, the vision device frame can move to the upper part of the working table, a plurality of positioning electromagnets and the alignment platform are arranged on the working table plate, the alignment platform is used for realizing movement adjustment of the plate in the X direction and the Y direction and rotation adjustment in the XY plane, and the positioning electromagnets are used for adsorbing and fixing the plate.
Adopt the beneficial effect of above-mentioned further scheme, the quantity of location electro-magnet and counterpoint platform and the quantity looks adaptation of sheet material, the below of every sheet material all is equipped with a counterpoint platform, and the both sides of the piece that two piece adjacent sheet materials formed all are equipped with a location electro-magnet, set up a counterpoint platform below every sheet material, possess and carry out the function of three-way adjustment to every sheet material alone, can ensure the accurate counterpoint of sheet material when the concatenation, and piece both sides set up the electro-magnet and fix a position the sheet material, can ensure the stability of sheet material location, help guaranteeing product quality and production efficiency.
Drawings
In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings that are required to be used in the embodiments or the description of the prior art will be briefly described below, and it is obvious that the drawings in the following description are only embodiments of the present invention, and that other drawings can be obtained according to the provided drawings without inventive effort for a person skilled in the art.
FIG. 1 is a schematic view of a door ring according to the present invention;
FIG. 2 is a flow chart of a production process of the laser splice welded door ring;
FIG. 3 is a flow chart of the laser welding process of the present invention
FIG. 4 is a plan layout view of a fully automatic door ring splice welding line of the present invention;
FIG. 5 is a schematic view of a seam adjusting and positioning device of the present invention mounted on a ground rail;
FIG. 6 is a layout of a positioning electromagnet and alignment platform mounted on a work platen of the present invention;
FIG. 7 is a schematic view of the vision apparatus frame of the present invention moved over a work deck;
FIG. 8 is a schematic perspective view of an alignment platform according to the present invention;
FIG. 9 is a front view of the alignment platform of the present invention;
FIG. 10 is a top view of the alignment stage of the present invention;
FIG. 11 is an exploded view of the alignment platform of the present invention;
FIG. 12 is an exploded view of the alignment platform of the present invention from the bottom view;
FIG. 13 is a schematic view of a turn-up machine according to the present invention;
FIG. 14 is a schematic view of a structure of a turnover of a platform bracket of a turnover machine according to the present invention;
FIG. 15 is a schematic structural view of a detection platform of the present invention with flipping assemblies disposed on both sides thereof;
in the figure, 1, a seam adjusting and positioning device; 11. a work platen; 12. a vision device frame; 121. a camera; 13. positioning an electromagnet; 14. an alignment platform; 15. a grip unit; 151. a support plate; 152. a magnet adsorption cylinder; 16. a base; 17. a drive transmission assembly; 171. a rotating disc; 1711. pushing arms; 172. an X-direction moving disk; 173. a Y-direction moving disk; 174. a turntable support; 1741. a U-shaped frame; 1742. a limit groove; 18. an X-direction movement driving mechanism; 181. a first servo motor; 182. moving the ball screw pair in the X direction; 1821. a first lead screw; 1822. a first nut; 19. a Y-direction movement driving mechanism; 191. a second servo motor; 192. y moves the ball screw pair; 1921. a second lead screw; 1922. a second nut; 20. an XY plane rotation driving mechanism; 201. a third servo motor; 202. rotating the ball screw pair on an XY plane; 2021. a third lead screw; 2022. a third nut; 2. a ground rail; 3. a feeding area; 31. a feeding robot; 32. a visual guidance module; 33. a pre-positioning table; 34. truss; 35. an end effector; 4. a welding area; 41. welding a machine room; 5. a backside weld detection zone; 51. a turn-over machine; 511. a detection platform; 512. a flip assembly; 5121. a support base; 5122. a rotating shaft; 5123. a platform bracket; 5124. a limit bracket; 5125. a suction cup; 52. a weld detection device; 6. a blanking area; 61. discharging trolley; 7. a blanking robot; 8. feeding trolley; 81. a trolley track; 9. a door ring; 91. a column reinforcement plate; 92. h column reinforcing plate; 93. a threshold front end plate; 94. a threshold; 95. a B column reinforcing plate; 96. a column patch board; 97. b post patch board.
Detailed Description
The principles and features of the present invention are described below in connection with examples, which are set forth only to illustrate the present invention and not to limit the scope of the invention.
As shown in fig. 1, the laser splice welding door ring comprises a plurality of plates, wherein the plates are sequentially connected end to form a door ring 9 structure with at least one door opening, a part of the plates are zinc-plated plates, and the rest of the plates are bare plates.
The zinc coating thermal forming material has better corrosion resistance compared with an aluminum-silicon coating material and a bare plate material because the zinc coating has the cathode protection property, and is suitable for being applied to chassis positions with severe working conditions; compared with the aluminum-silicon coating material, the zinc coating material has low cost and can realize the cost reduction of the raw materials; compared with the overlap spot welding of the parts, the door ring 9 structure can improve collision performance, reduce weight, reduce production procedures and equipment investment, improve the quality stability of parts and the like. The splice welded door ring 9 combines the advantages of two materials, not only can improve the durability of the door ring 9, but also is beneficial to reducing the cost and meeting the market demand.
In addition, in the present embodiment, the present invention,
the laser splice welding door ring 9 further comprises a patch board, and a part of the bare board is provided with the patch board.
The patch plates are welded in a spot welding mode.
The adjacent plates are connected in a laser welding mode.
The embodiment of the invention does not limit the laser welding mode, the galvanized plate and the bare plate can be spliced and welded together by adopting the laser welding mode, when the laser filler wire welding is adopted, the welding wire absorbs most of heat to be melted, the base metal absorbs little heat and is basically not melted, the base metal absorbs little heat, the gasification of a galvanized layer is greatly reduced, the influence of zinc vapor on a welding seam is reduced, the welding quality is improved, and therefore, the laser welding can be realized in a mode of not stripping a zinc coating; the laser self-fluxing welding mode can also be adopted, so that the cost can be saved, but when the self-fluxing welding is carried out, special attention is required to control the gaps, and because a plurality of welding gaps have accumulated errors, when the welding is carried out on the last welding seam, if the gaps are too large, the last welding seam needs to be subjected to laser filler wire welding treatment.
For example, as shown in fig. 1, the door ring 9 is formed by connecting an a-pillar reinforcement plate 91, an H-pillar reinforcement plate 92, a threshold front end plate 93, a threshold 94 and a B-pillar reinforcement plate 95 end to end, wherein the a-pillar reinforcement plate 91, the H-pillar reinforcement plate 92 and the B-pillar reinforcement plate 95 are located on a vehicle, and the environment is better and not easy to corrode, so that the a-pillar reinforcement plate 91, the H-pillar reinforcement plate 92 and the B-pillar reinforcement plate 95 adopt bare plates, and the threshold front end plate 93 and the threshold 94 are easy to be scratched and corroded at a position close to a chassis of the vehicle body in the driving process, thereby influencing the service life and safety of the vehicle, the threshold front end plate 93 and the threshold 94 are selectively zinc plated plates, and the B-pillar patch plate 97 is connected at the connection position of the a-pillar reinforcement plate 91 and the H-pillar reinforcement plate 92 in a spot welding manner, and the a-pillar patch plate 96 is connected on the B-pillar reinforcement plate 95 in a spot welding manner, so that the structural strength of the door ring 9 can be enhanced, and the collision safety is increased.
As shown in fig. 2, a production process of the laser tailor-welded door ring 9 comprises the following steps:
s1, performing laser welding, wherein adjacent plates are spliced and welded together in a laser welding mode;
s2, spot welding patch plates, namely, spot welding the patch plates on corresponding plates to obtain welded door rings 9;
s3, heating the welding door ring 9, and transferring the welding door ring 9 into a heating furnace to perform austenitization and prealloying of a surface coating;
s4, precooling, and cooling the welded door ring 9 after heating;
s5, performing thermoforming, namely performing hot stamping on the pre-cooled welding door ring 9 by using a hot stamping die;
s6, removing the allowance by utilizing laser cutting;
and S7, shot blasting, namely performing shot blasting treatment on the surface of the door ring 9 by using a shot blasting machine, so that the surface finish reaches the requirement.
As shown in fig. 3, in step S1, a full-automatic door ring splice welding production line is included, the full-automatic door ring splice welding production line includes a ground rail 2, and a feeding area 3 and a welding area 4 that are disposed around the ground rail 2, a splice adjustment positioning device 1 that can move along the ground rail 2 is disposed on the ground rail 2, a feeding robot 31, a pre-positioning table 33, a truss 34, and an end pick-up 35 that is mounted on the truss 34 and can reciprocate along the truss 34 are disposed in the feeding area 3, and the laser splice welding process includes the following steps:
s11, placing a plurality of plates on a pre-positioning table 33 by the feeding robot 31, and abutting the plates from head to tail to form an annular pre-assembled door ring 9;
s12, the pre-assembled door ring 9 is integrally transferred to the seam adjusting and positioning device 1 through the end pick-up device 35, and the seam between adjacent plates is adjusted to be 0.1-0.5 mm through the seam adjusting and positioning device 1, so that the plates are clamped and fixed;
s13, moving the seam adjusting and positioning device 1 along the ground rail 2 to move the plate with the fixed position into the welding area 4, wherein a welding robot is arranged in the welding area 4;
s14, adjusting a welding track of the welding robot, and primarily marking a theoretical welding track on a plate through low-intensity laser of the welding robot;
s15, comparing the deviation of the theoretical welding track and the actual welding seam, wherein the deviation is smaller than a threshold value, welding is carried out, and if the deviation is larger than the threshold value, the process is switched to S14;
and the welding deviation is predicted in the step S14 and the step S15, and when the deviation is larger than the threshold value, the deviation welding can be avoided, the scrapping is prevented and the yield is improved through manual or automatic adjustment.
S16, detecting a back weld by using the weld detection device 52.
In the step S11, the splicing seam between the adjacent plates is 1 mm-5 mm.
More specifically, the method comprises the steps of,
as shown in fig. 4, the fully automatic door ring splice welding production line comprises a ground rail 2, wherein a splice seam adjusting and positioning device 1 capable of moving along the ground rail 2 is arranged on the ground rail 2, a feeding area 3, a welding area 4, a back weld detection area 5, a blanking area 6 and a blanking robot 7 are also arranged around the ground rail 2, a feeding robot 31, a visual guiding module 32, a pre-positioning table 33, a truss 34 and an end pick-up device 35 which is arranged on the truss 34 and can reciprocate along the truss 34 are arranged in the feeding area 3, the end pick-up device 35 can move between the pre-positioning table 33 and the splice seam adjusting and positioning device 1, the feeding robot 31 is used for grabbing a plate material and moving to the pre-positioning table 33, the visual guiding module 32 is used for guiding the feeding robot 31 to adjust the blanking direction, the end pick-up device 35 is used for grabbing the plate material which is pre-assembled together from the pre-positioning table 33 and then moving to the splice seam adjusting and positioning device 1, and the splice seam adjusting and positioning device 1 is used for adjusting and positioning the splice seam; welding equipment is arranged in the welding area 4, a turn-over machine 51 and welding seam detection equipment 52 are arranged in the back welding seam detection area 5, and the blanking robot 7 moves in the back welding seam detection area 5 and the blanking area 6.
After the feeding robot 31 grabs the plate material, the vision guiding module 32 acquires the grabbing position and guides the feeding robot 31 to adjust the blanking position, then the plate material is accurately placed on the pre-positioning table 33, the end pick-up 35 is used for integrally grabbing the pre-assembled door ring 9 from the pre-positioning table 33 and then transferring the pre-assembled door ring to the seam adjusting and positioning device 1, the seam adjusting and positioning device 1 adjusts the gap width between adjacent plate materials and fixes the adjusted plate material, then the seam adjusting and positioning device 1 moves along the ground rail 2 to transfer the fixed plate material into the welding area 4 for welding, and the ground rail 2 extends from the feeding area 3 to the back weld detection area 5, and the seam adjusting and positioning device 1 moves along the ground rail 2 to move to the feeding area 3, the welding area 4 and the back weld detection area 5; the back weld detection area 5 is internally provided with a turn-over machine 51 and weld detection equipment 52, the blanking robot 7 moves in the back weld detection area 5 and the blanking area 6, the blanking robot 7 transfers the welded door ring 9 from the seam adjustment positioning device 1 to the turn-over machine 51, after the turn-over machine 51 turns over the welded door ring 9, the weld detection equipment 52 detects the weld on the back, the detected product is moved to a qualified product area or a disqualified product area by the blanking robot 7, and a blanking trolley 61 is arranged in the qualified product area and used for conveying the qualified product.
The welding machine room 41 is arranged in the welding area 4, a supporting beam, welding equipment and an exhaust gas recovery system are arranged in the welding machine room 41, the welding equipment is arranged on the supporting beam, the welding equipment is provided with a plurality of degrees of freedom, the welding equipment comprises a frame, a laser welding head, a laser matched with the laser welding head, a weld tracking system, a front weld detecting unit for detecting the state of a weld, a wire feeder matched with the laser welding head, a welding fixture and a double-sided gas protection system are arranged on the frame, the double-sided gas protection system can protect workpieces from oxidation and pollution in the welding process, the welding quality is improved, the weld tracking system monitors the position and the shape of the weld in real time through a sensor, the welding speed and the track are automatically adjusted, the welding quality and the welding efficiency are improved, the wire feeder is used for feeding the welding material into the welding area, the smooth progress of the welding process is ensured, the welding fixture is used for fixing and positioning a plate material, the exhaust gas generated in the welding process is recovered by the exhaust gas recovery system, the environment pollution is avoided, the front state of the front weld detecting unit can be accurately detected, and the front face of the ring 9 is increased, the problems of flatness, the bubbling and the like are solved.
The full-automatic door ring tailor-welding production line further comprises a feeding trolley 8, a trolley track 81 is arranged on the ground of the feeding area 3, and the feeding trolley 8 is slidably mounted on the trolley track 81.
The number of the ground rails 2 is not limited in the embodiment of the present invention, and the number of the ground rails 2 may be one or more, so long as the use requirement can be met, which falls within the protection scope of the present invention. When the full-automatic door ring splice welding production line comprises two ground rails 2, two splice seam adjusting and positioning devices 1 are arranged on the two ground rails 2, and one side of each splice seam adjusting and positioning device 1 is provided with a feeding area 3.
In addition, in the present embodiment, the present invention,
as shown in fig. 5-7, the seam adjusting and positioning device 1 includes a working table 11, a vision device frame 12, positioning electromagnets 13 and an alignment platform 14, wherein the vision device frame 12 and the working table 11 are both installed on the ground rail 2, the vision device frame 12 can move above the working table 11, and a plurality of positioning electromagnets 13 and alignment platforms 14 are disposed on the working table 11. The number of the positioning electromagnets 13 and the alignment platforms 14 are matched with the number of the plates, one alignment platform 14 is arranged below each plate, and two positioning electromagnets 13 are arranged on two sides of a joint formed by two adjacent plates.
In this embodiment, the alignment stage 14 is a three-way alignment stage, and can move the plate material adsorbed on the alignment stage 14 in the X direction and the Y direction, and rotate in the XY plane, and the X, Y direction is referred to in fig. 8. The positioning electromagnet 13 is arranged at the joint between the plates, and can adsorb and fix the plates after the joint is adjusted, so that the stability of the joint in the welding process is ensured. And the two sides of each welding seam position are respectively adsorbed and fixed with the positioning electromagnet 13, so that the seam stability in the welding process is ensured.
The vision device frame 12 is driven to move through a servo motor, the vision device frame 12 is of a light aluminum profile frame structure, the weight of the whole frame is reduced, and the stability of the frame is ensured.
The vision frame 12 mounts a plurality of cameras 121 and a light source. In the embodiment, the camera 121 adopts a CCD camera, the CCD is a short term of a charge coupled device (charge coupled device), the field of view range of the camera 121 can meet the requirement of 0mm-5mm of a seam gap of a hot forming laser splice welding plate, the identification precision of the camera 121 is less than or equal to 3 pixels, and the identification precision of a plate edge is less than or equal to 0.024mm. The characteristic positions of the plates are photographed and imaged through a CCD camera, an industrial lens and a light source, image data are acquired through image processing, image processing is carried out, position operation is carried out to judge the actual positions of the plates, and the actual offset of the plates is calculated through comparison with the previously set reference positions.
As shown in fig. 8-12, the alignment platform 14 includes a base 16, and further includes a gripping unit 15, a driving transmission assembly 17, and a driving mechanism, which are mounted on the base 16, where the gripping unit 15 includes a supporting plate 151 and a plurality of magnet adsorption cylinders 152, the bottom of the supporting plate 151 is connected with the top of the driving transmission assembly 17, the plurality of magnet adsorption cylinders 152 are mounted above the supporting plate 151, the driving mechanism drives the driving transmission assembly 17 to act so as to drive the gripping unit 15 to move or rotate, the driving transmission assembly 17 is an intermediate link for transmitting a driving force to the gripping unit 15, the gripping unit 15 can move in the X direction and the Y direction, and the gripping unit 15 can rotate in the XY plane.
The driving transmission assembly 17 comprises a rotating disc 171, a rotating disc support 174, a Y-direction moving disc 173 and an X-direction moving disc 172 which are sequentially arranged from top to bottom, the X-direction moving disc 172 is installed in a chute of the base 16, the X-direction moving disc 172 can move along the X-axis direction in the chute, but is limited in the Y-axis direction, the top of the X-direction moving disc 172 and the bottom of the Y-direction moving disc 173 are connected together through the chute, the Y-direction moving disc 173 can move along the Y-axis direction, the rotating disc support 174 is installed above the Y-direction moving disc 173 in a circumferential limiting manner, the rotating disc 171 is installed on the rotating disc support 174 in a rotating manner, a pushing arm 1711 is arranged on one side of the rotating disc 171, a U-shaped frame 1741 which is opened towards one side is arranged on the rotating disc support 174, a limiting groove 1742 is formed in the bottom of the U-shaped frame 1741, and the pushing arm 1711 is inserted into the limiting groove 1742. When the X-direction moving tray 172 moves in the X-direction, the rotating tray 171, the turntable support 174, the Y-direction moving tray 173, and the grip unit 15 also move in the X-direction simultaneously, and when the Y-direction moving tray 173 moves in the Y-direction, the X-direction moving tray 172 is stationary, the rotating tray 171, the turntable support 174, and the grip unit 15 move in the Y-direction simultaneously, and the rotating tray 171 can rotate in the XY plane in a limited manner about the central axis due to the limiting action of the limiting groove 1742.
The driving mechanism comprises an X-direction moving driving mechanism 18, a Y-direction moving driving mechanism 19 and an XY plane rotating driving mechanism 20, wherein the X-direction moving driving mechanism 18, the Y-direction moving driving mechanism 19 and the XY plane rotating driving mechanism 20 are arranged around the driving transmission assembly 17, the X-direction moving driving mechanism 18 drives the driving transmission assembly 17 to drive the gripping unit 15 to move along the X direction, the Y-direction moving driving mechanism 19 drives the driving transmission assembly 17 to drive the gripping unit 15 to move along the Y direction, and the XY plane rotating driving mechanism 20 drives the driving transmission assembly 17 to drive the gripping unit 15 to rotate in the XY plane.
The X-direction movement driving mechanism 18, the Y-direction movement driving mechanism 19, and the XY-plane rotation driving mechanism 20 each include a servomotor and a ball screw pair mounted on the servomotor, which converts the rotational movement of the servomotor into a linear movement.
More specifically, the X-direction moving driving mechanism 18 includes a first servomotor 181 and an X-direction moving ball screw pair 182, the X-direction moving ball screw pair 182 includes a first screw 1821 and a first nut 1822 mounted on the first screw 1821, one end of the first screw 1821 is connected to the output shaft of the first servomotor 181, the other end of the first screw 1821 is connected to the X-direction moving disk 172, and the first nut 1822 is connected to the base 16. The process of moving the grip unit 15 in the X-axis direction is as follows: the first servomotor 181 is started, the output shaft of the first servomotor 181 rotates to drive the first screw 1821 to rotate, and the first nut 1822 is connected with the base 16, at this time, the first nut 1822 is fixed, and the first screw 1821 pushes the X-direction moving disk 172 to move along the X-direction, so as to drive the plate on the gripping unit 15 to synchronously move along the X-direction.
The Y-direction movement driving mechanism 19 includes a second servo motor 191 and a Y-direction movement ball screw pair 192, the Y-direction movement ball screw pair 192 includes a second screw 1921 and a second nut 1922 attached to the second screw 1921, one end of the second screw 1921 is connected to an output shaft of the second servo motor 191, the other end of the second screw 1921 is connected to the Y-direction movement disk 173, and the second nut 1922 is connected to the X-direction movement disk 172. The process of moving the grip unit 15 in the Y-axis direction is as follows: the second servo motor 191 is started, the output shaft of the second servo motor 191 rotates to drive the second screw rod 1921 to rotate, and the second nut 1922 is in limit fit with the base 16 in the Y direction, that is, the X-direction moving disc 172 is fixed in the Y direction, at this time, the second nut 1922 is fixed, and the second screw rod 1921 pushes the Y-direction moving disc 173 to move in the Y direction, so as to drive the plate above the gripping unit 15 to synchronously move in the Y direction.
The XY plane rotation driving mechanism 20 includes a third servo motor 201 and an XY plane rotation ball screw pair 202, the XY plane rotation ball screw pair 202 includes a third screw 2021 and a third nut 2022 mounted on the third screw 2021, one end of the third screw 2021 is connected with an output shaft of the third servo motor 201, the other end of the third screw 2021 is hinged to a pushing arm 1711 fixedly connected to the rotating disc 171, a U-shaped frame 1741 with an opening towards one side is provided on the turntable support 174, a limit groove 1742 is provided at the bottom of the U-shaped frame 1741, the pushing arm 1711 is inserted into the limit groove 1742, and an end of the third nut 2022 is fixed on a cross arm of the U-shaped frame 1741. The method of rotating the grip unit 15 on the XY plane is as follows: the third servo motor 201 is started, and since the third nut 2022 is fixedly connected to the U-shaped frame 1741, when the output shaft of the third servo motor 201 rotates, the third nut stretches out along the Y-direction to push the push arm 1711 to rotate in the limiting groove 1742 in a limiting manner, the push arm 1711 rotates with the rotating disc 171, and the gripping unit 15 rotates synchronously in the XY plane.
The gripping unit 15 includes a support plate 151 and a plurality of magnet adsorption cylinders 152, the plurality of magnet adsorption cylinders 152 are installed above the support plate 151, and the top of the driving transmission assembly 17 is connected with the bottom of the support plate 151. The magnet adsorption cylinder 152 comprises a cylinder body and a magnet piston arranged in the cylinder body, the magnet piston divides the cylinder body into an upper cavity and a lower cavity, an upper air hole and a lower air hole are arranged on the cylinder body, the upper air hole is communicated with the upper cavity, and the lower air hole is communicated with the lower cavity. The magnet piston can move up and down in the cylinder body, when the lower air hole is used for inflating the lower cavity, the magnet piston can move upwards, and the upper end of the cylinder can obtain magnetic attraction, so that a plate can be firmly adsorbed, and an adsorption function is realized; when the upper air hole is inflated into the upper cavity, the magnet piston moves downwards, the upper end of the air cylinder loses magnetic attraction, and the function of adsorbing the plate is lost.
As shown in fig. 13-15, the turnover machine 51 includes a detection platform 511 and a turnover assembly 512, the turnover assembly 512 includes a support base 5121, a rotation shaft 5122, a platform support 5123, a limit support 5124 and a plurality of suckers 5125, two ends of the rotation shaft 5122 are mounted on the support base 5121 through bearing blocks, one end of the platform support 5123 is fixed on the rotation shaft 5122, a plurality of suckers 5125 are arranged above the platform support 5123, and the other end of the platform support 5123 can be movably lapped on the limit support 5124. In this embodiment, the number of the overturning assemblies 512 is not limited, the overturning assemblies 512 may be disposed on one side of the detection platform 511, or the overturning assemblies 512 may be disposed on both sides of the detection platform 511, and when the overturning assemblies 512 are disposed on both sides of the detection platform 511, the overturning assembly 512 on one side is used for overturning the door ring 9 to the back side, and the overturning assembly 512 on the other side can overturn the door ring 9 to the front side. The platform bracket 5123 is composed of a plurality of overturning beams which are arranged in a crisscross manner. The detection platform 511 is provided with an installation beam, the welding seam detection equipment 52 is installed on the installation beam, the detection platform 511 is provided with a track, the installation beam can move along the track, the welding seam detection equipment 52 can move along the installation beam, and the welding seam detection equipment 52 can comprehensively detect the welding seam of the door ring 9 which is overturned above the detection platform 511. The turnover machine 51 is at an initial position, one end of the platform support 5123 is lapped above the limit support 5124, when the blanking robot 7 moves the welded door ring 9 from the seam adjustment positioning device 1 to the platform support 5123 of the turnover machine 51, the suction disc 5125 on the platform support 5123 firmly adsorbs the door ring 9, the rotation shaft 5122 rotates to drive the platform support 5123 to overturn above the detection platform 511, the suction disc 5125 releases the door ring 9 to the detection platform 511, the platform support 5123 returns to the initial position, the welding seam detection device 52 moves above the door ring 9 and detects welding seams on the door ring 9, and the welding seam detection device 52 can accurately detect the welding seam state of the back of the door ring 9, including the problems of flatness, bubbling, cold joint and the like.
In step S13, the working method of automatically adjusting the seam of a plurality of plates by using the seam adjusting and positioning device 1 is as follows:
s131, arranging a set of alignment platforms 14 below each plate, and fixing the splice welding plates by using magnet adsorption cylinders 152 on the alignment platforms 14;
s132, the vision device frame 12 moves to the upper part of the working table 11, the camera 121 photographs after reaching the photographing position, the characteristic image data sampling of the splice welding plate is completed, the vision control system performs image processing on the collected image data, performs position operation to judge the actual position of the plate, and calculates the actual offset of the plate by comparing with the previously set reference position;
s133, the servo control system outputs servo pulse signals to a servo motor of the alignment platform 14 according to the offset data output by the vision control system;
s134, driving the corresponding splice welding plate to move to the target position by the alignment platform 14 according to the servo pulse signal output by the servo control system, so as to realize automatic splicing of the splice welding plate and meet the requirement of a target model data splicing gap;
s135, the camera 121 shoots again, and the characteristic image data of the plate material at the joint position are sampled;
s136, acquiring image data through image processing, performing position operation to judge the actual position of the plate, comparing the reference position data of a target product, and completing the joint movement if the target requirement is met; if the target requirement is not met, executing S133 again until the target requirement is met;
s137, after the seam is completed, the positioning electromagnet 13 corresponding to the position of the welding seam adsorbs and fixes the plate material;
s138, the servo motor drives the vision device frame 12 to move to the feeding position.
The full-automatic production line adopts an automatic feeding mode, after the feeding robot 31 grabs the plate, the plate is firstly placed on the pre-positioning table 33 under the guiding action of the visual guiding module 32, so that an annular pre-assembled door ring can be successfully assembled, the splicing gap of the annular pre-assembled door ring is controlled within the range of 1 mm-5mm, the precision provides convenience for the subsequent splicing gap adjusting and positioning device 1, and the gap between the plate materials can be finely adjusted and optimized; the pre-assembled door ring is integrally grabbed from the pre-positioning table 33 through the end pick 35 and then transferred to the splice adjustment positioning device 1, the rapid and automatic splice function of the splice plate is realized through the cooperation of the working table plate 11 and the vision device frame 12, the flexible adjustment of the splice plate material at the splice gap of 0mm-5mm can be realized on the splice adjustment positioning device 1, and the position of the splice plate material can be rapidly and accurately adjusted; the production line also has the functions of detecting and automatically compensating and adjusting the welding seam splicing gap, realizes the closed-loop control of the plate splicing gap, and ensures that the splicing gap of the spliced plate is within +/-0.05 mm.
The production process of the laser splice welding door ring combines the advantages of two materials, not only can improve the durability of the door ring 9, but also is beneficial to reducing the cost and meeting the market demand, and can ensure the stability of the product quality and the production cost while realizing mass production.
The foregoing description of the preferred embodiments of the invention is not intended to limit the invention to the precise form disclosed, and any such modifications, equivalents, and alternatives falling within the spirit and scope of the invention are intended to be included within the scope of the invention.
Claims (5)
1. The production process of the laser splice welding door ring is characterized in that the laser splice welding door ring comprises a plurality of plates, the plates are sequentially connected end to form a door ring structure with at least one door opening, a part of the plates are zinc plating plates, the rest of the plates are bare plates, patch plates are arranged on the bare plates, and the production process of the laser splice welding door ring comprises the following steps:
s1, performing laser welding, wherein adjacent plates are spliced and welded together in a laser welding mode;
s2, spot welding patch plates, namely, spot welding the patch plates on corresponding plates to obtain welded door rings;
s3, heating the welding door ring, and transferring the welding door ring into a heating furnace to perform austenitization and prealloying of a surface coating;
s4, precooling, and cooling the welded door ring after heating;
s5, performing thermoforming, namely performing hot stamping on the pre-cooled welded door ring by using a hot stamping die;
s6, removing the allowance by utilizing laser cutting;
s7, shot blasting is carried out on the surface of the door ring by using a shot blasting machine;
in step S1, including full-automatic door ring welding production line, full-automatic door ring welding production line includes ground rail (2) and sets up material loading district (3) and welding district (4) around ground rail (2), be equipped with on ground rail (2) and follow piece adjustment positioner (1) that ground rail (2) removed, be equipped with material loading robot (31), preposition platform (33), truss (34) and install on truss (34) can follow end effector (35) of truss (34) reciprocating motion, laser welding procedure includes the following steps:
s11, placing a plurality of plates on a pre-positioning table (33) by the feeding robot (31), and abutting the plates from head to tail to form an annular pre-assembled door ring;
s12, integrally transferring the pre-assembled door ring to a seam adjusting and positioning device (1) through an end pick-up (35), adjusting the seam between adjacent plates to 0.1-0.5 mm through the seam adjusting and positioning device (1), and clamping and fixing the plates;
s13, the seam adjustment positioning device (1) moves along the ground rail (2) to move the plate with the fixed position into the welding area (4), and a welding robot is arranged in the welding area (4);
s14, adjusting a welding track of the welding robot, and primarily marking a theoretical welding track on a plate through low-intensity laser of the welding robot;
s15, comparing the deviation of the theoretical welding track and the actual welding seam, wherein the deviation is smaller than a threshold value, welding is carried out, and if the deviation is larger than the threshold value, the process is switched to S14;
s16, detecting a back weld by using a weld detection device (52).
2. The process for producing a laser splice welded door ring according to claim 1, wherein in step S11, the splice joint between adjacent plates is 1 mm-5 mm.
3. The production process of the laser splice welding door ring according to claim 1, wherein the full-automatic door ring splice welding production line further comprises a vision guiding module (32), the feeding robot (31) grabs a plate material and then moves to the vision guiding module (32) to take a picture and transmits the picture to the control system, and the control system controls the feeding robot (31) to adjust the blanking direction to accurately place the plate material on the pre-positioning table (33) after obtaining the picture.
4. The production process of the laser splice welding door ring according to claim 1, wherein the full-automatic door ring splice welding production line further comprises a back welding seam detection area (5), a blanking area (6) and a blanking robot (7), a turn-over machine (51) and welding seam detection equipment (52) are arranged in the back welding seam detection area (5), the blanking robot (7) moves in the back welding seam detection area (5) and the blanking area (6), in step S16, the blanking robot (7) transfers a welded door ring product onto the turn-over machine (51) from the splice seam adjusting and positioning device (1), and after the turn-over machine (51) turns over the welded door ring product, the welding seam detection equipment (52) detects the welding seam on the back; and the blanking robot (7) transfers the qualified door ring products after detection to the qualified product area, and transfers the unqualified door ring products after detection to the unqualified product area.
5. The process for producing the laser splice welding door ring according to claim 1, wherein the splice welding positioning device (1) comprises a working table plate (11), a vision device frame (12), positioning electromagnets (13) and an alignment platform (14), wherein cameras (121) and luminous sources are installed on the vision device frame (12), the working table plate (11) and the vision device frame (12) are installed on the ground rail (2), the vision device frame (12) can be moved to the position above the working table plate (11), a plurality of the positioning electromagnets (13) and the alignment platform (14) are arranged on the working table plate (11), the alignment platform (14) realizes movement adjustment and rotation adjustment in an XY plane of the plate in an X direction and a Y direction, and the positioning electromagnets (13) are used for adsorbing and fixing the plate.
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