The application of robot automatic welding production line in the sheet metal industry

The application of robot automatic welding production line in the sheet metal industry

With the high quality of parts in the sheet metal industry and the increasing improvement of lean production, robot automatic welding technology has been promoted and applied in the industry. In this article, the author will introduce a robot automatic welding production line of LAG Ge Shi International.

The robot automatic welding production line (Figure 1) is mainly used for the automatic welding of the lower beam and the car bottom beam in the elevator industry. When welding, the workpiece is first loaded by manual, cantilever or forklift, and then the lower cross beam or car bottom beam is manually aligned. After assembling, the assembled workpiece can also be adjusted by the rotary positioner to be rotated to the welding station, and the robot welding system can automatically complete the welding of the workpiece.

The robot automatic welding production line is mainly composed of assembling station, assembling fixture, welding station (industrial robot, welding machine, automatic gun cleaning wire cutter, welding tooling, workbench), dust removal system, central control system and safety protection system.

Figure 1 Robot automatic welding production line

Functions and components of robot automatic welding production line

(1) Assemble fixtures. The universal fixture design is used to adjust the fixture manually, which is suitable for welding multi-specification workpieces. The workpiece clamping platform is shown in Figure 2.

(2) Welder. Fronius MIG TPS400i welding machine, equipped with welding gun cleaning and welding wire cutting function. It has an analog control mode, digitally monitors the welding process, and quickly reacts to any changes in the welding process to ensure the ideal welding effect. LSC low-spatter mode and PMC high-performance pulse welding mode can be selected according to actual welding process requirements, and can be upgraded online through U disk form or network.

Figure 2 Workpiece clamping platform

Table 1 Parameters of mobile sliding table

Serial Number Item Parameters Equipment 1 Moving slide table length 8000mm 2 Effective stroke 2000mm 3 Bearing capacity 2000kg 4 Sliding table maximum travel speed 10000mm/min 5 Repeated positioning accuracy ±0.2mm

Table 2 Ground rail parameters of the handling manipulator

Serial number item parameters Equipment 1 ground rail slide table length 8530mm 2 effective stroke 5000mm 3 load capacity 2000kg 4 slide table maximum travel speed 10000mm/min

5 Repeat positioning accuracy ±0.2mm

Table 3 Parameters of welding positioner

Serial Number Item Parameters Equipment 1 Medium and large swing diameter φ1100mm 2 Rated load 1000kg 3 Rated speed 12rpm 4 Repeated positioning accuracy ±1arcmin

5Minimum center height 600mm

(3) Move the sliding table. The parameters of the mobile sliding table are shown in Table 1.

(4) Welding gun. Use world-renowned brand gas shielded welding torch.

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(5) Welding gas. A mixed gas composed of 80% argon and 20% carbon dioxide.

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(6) Welding station. Industrial robots (including welding machines and welding torches) adopt articulated robots from world-renowned brands. The servo slide rail is convenient for the robot to move forwards and backwards, and flexibly weld each part of the workpiece; the welding tooling can realize the accurate and rapid positioning and clamping of the workpiece; the automatic gun cleaning wire cutter can automatically clean the welding slag on the welding gun surface.

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(7) The ground rail of the handling manipulator. The ground rail parameters of the handling manipulator are shown in Table 2.

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(8) Welding positioner. The workpieces that have been assembled and spot welded by the full welding fixture on the welding positioner are then loaded into the full welding fixture to weld all the welding points on the positioner. The welding positioner parameters are shown in Table 3.

(9) Control system. The robot welding line is divided into two levels: central control and online control: central control controls the entire production line; online control controls each robot and welding machine separately.

(10) Dust removal system. The high negative pressure vacuum dust removal device is used to capture the sub-micron welding fume particles generated during the welding process and meet the indoor emission standard.

(11) Safety protection system. The entire production line is equipped with a safety protection system, and personnel are not allowed to enter during the production process. The protective fence is designed in accordance with European standards, beautiful in appearance, safe and reliable. The safety inspection door is equipped with an electronically controlled safety lock. When the door is opened, the machine will automatically stop running and give an audible and visual alarm.

(12) Security. The equipment design conforms to the specifications, and the safety facilities necessary for safe operation are provided and installed.

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Application case of robot welding production line

The following takes the elevator car bottom beam assembly as an example to introduce the typical application case of the robot welding production line:

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(1) Workpiece material and thickness.

Material Q235-A, ST12 cold-rolled plate thickness 2mm, 2.5mm, 3mm; maximum dimensions of workpiece: EMA2 is 2050mm×2225mm (AA×BB=2000mm×2100mm), EMA3 is 2050mm×2185mm (AA×BB=2000mm×2100mm ); The minimum dimensions of the workpiece: EMA2 is 1050mm×1125mm (AA×BB=1000mm×1000mm), EMA3 is 1050mm×1085mm (AA×BB=1000mm×1000mm), the schematic diagram of the workpiece is shown in Figure 3.

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(2) Workpiece analysis.

1) The parts of the workpiece are made of Q235 and ST12 cold-rolled plates, which have good welding performance.

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2) There are many types of workpiece specifications, and it is necessary to solve the problem of fixture versatility in order to adapt to mass automated production.

3) The accuracy of workpiece blanking must meet the requirements of automated welding.

4) There should be no oil rust, moisture, oxide scale, etc. that affect the welding quality within 10mm around the weld of the workpiece.

5) There should be no defect factors such as sagging and burrs that affect positioning on the workpiece.