Korea Hyundai Heavy Industries Robot - Welding application of welding robot

Workstations (Units)

If the workpiece does not need to be dislocated during the entire welding process, the workpiece can be positioned on the table with a fixture, which is the simplest system. However, in actual production, more workpieces need to be dislocated during welding, so that the weld is welded in a better position (attitude). In this case, the positioner and the robot can move separately, that is, the robot is welded after the positioner is displaced; It can also be simultaneous movement, that is, the positioner is disposed while the robot is welded, that is, the positioner and the robot coordinate the movement. At this time, the movement of the positioner and the movement of the robot are compounded, so that the movement of the welding gun relative to the workpiece can not only meet the welding seam trajectory, but also meet the requirements of welding speed and welding gun attitude. In fact, at this time the axis of the positioner has become an integral part of the robot, and this welding robot system can have up to 7-20 axes, or more. The latest robot control cabinet can be a group of two robots working together with 12 axes to coordinate movement. One of them is a welding robot and the other is a handling robot for positioners.

The welding robot workstation is further subdivided, and the following four types can be obtained:

1.1 Box welding robot workstation is specially developed for the box welding in the cabinet industry, with large production capacity, high welding quality and size requirements.

The box welding robot workstation is composed of an arc welding robot, a welding power supply, a welding torch wire feeding mechanism, a rotary double-station positioner, a tooling fixture and a control system. The workstation is suitable for the welding of all kinds of box workpieces, and the automatic welding of multiple types of boxes can be realized by using non-stop fixtures in the same workstation, and the relative position of the welding is high. Due to the use of double-station positioner, while welding, other stations can disassemble and assemble workpieces, which greatly improves the welding efficiency. Due to the use of MIG pulse transition or CMT cold metal transition welding process for welding, the amount of heat input in the welding process is greatly reduced, to ensure that the product is not deformed after welding, by adjusting the welding specification and robot welding attitude, to ensure that the product weld quality is good, the weld is beautiful, especially for the stainless steel air chamber with high sealing requirements, the gas in the air chamber is not leaked after welding. By setting the variety selection parameters in the control system and replacing the work fixture, the automatic welding of multiple varieties of boxes can be realized.

With arc welding robots with different working ranges and positioners of corresponding sizes, the workstation can meet the welding requirements of various boxes with a weld length of about 2000mm. The welding speed is 3-10mm/s, and according to the basic material of the box, the welding process adopts different types of gas shielded welding. The workstation is also widely used in industries such as electric power, electrical, mechanical, automotive, etc.

1.2 Stainless steel chamber robot flexible laser welding processing equipment is a flexible robot laser welding processing equipment developed for the welding of box workpieces with large stainless steel welding deformation and high sealing requirements.　The processing equipment is composed of robots, laser generator units, water cooling units, laser scanning tracking systems, flexible positioners, tooling fixtures, safety guardrails, dust collection devices and control systems, etc., by setting the variety selection parameters in the control system and replacing the tooling fixtures, the automatic welding of multiple varieties of stainless steel air chamber workpieces can be realized.

1.3 Shaft welding robot workstation is a special equipment specially developed for shaft welding in universal circuit breakers in the low-voltage electrical industry, and a set of special shaft welding robot workstations has been launched.

The shaft welding robot workstation is composed of an arc welding robot, a welding power supply, a welding torch wire feeding mechanism, a rotary double-station positioner, a tooling fixture and a control system. This workstation is used for the welding of various workpieces with a rotating shaft as the base (several cantilever arms on it), and it is possible to automatically weld a variety of rotating shafts by using different fixtures in the same workstation. The accuracy of the welded position is very high. Due to the use of double-station positioner, while welding, other stations can disassemble and assemble workpieces, which greatly improves efficiency.

Technical indicators: shaft diameter: Ф10-50mm, length 300-900mm, welding speed 3-5mm/s, welding process using MAG mixed gas shielded welding, positioner rotation, displacement accuracy of 0.05mm.

It is widely used in high-quality, high-precision welding of various workpieces with rotating shafts, and is suitable for electric power, electrical, mechanical, automotive and other industries. If manual arc welding is used for shaft welding, the labor intensity of workers is extremely high, the consistency of the product is poor, and the production efficiency is low, only 2-3 pieces/hour. After the automatic welding workstation is adopted, the output can reach 15-20 pieces/hour, and the welding quality and product consistency are also greatly improved.

Shaft welding robot workstation Low-voltage electrical shaft

1.4 Robot welding stud workstation

Robot welding stud workstation uses robots to weld studs to workpieces with different specifications on complex parts. The workstation is mainly composed of robots, stud welding power supplies, automatic nail feeding machines, robot automatic stud welding guns, positioners, tooling fixtures, automatic gun changing devices, automatic detection software, control systems and safety guardrails, etc., the studs are sent to the robot automatic welding gun through the automatic nail feeder, and the stud of different specifications is welded to the workpiece through the path of the robot teaching on the workpiece through programming. Energy storage welding or arc welding can be used to firmly weld the stud to the workpiece to ensure welding accuracy and welding strength. The welding efficiency is about 3-10 pcs/min, stud specification: diameter 3-8mm, length: 5-40mm.

production line

The welding robot production line is relatively simple to connect multiple workstations (units) with workpiece conveyor lines to form a production line. This type of production line still maintains the characteristics of a single station, that is, each station can only weld a predetermined workpiece with the program of the selected workpiece fixture and welding robot, and this line cannot weld other workpieces for a period of time before the fixture and program are changed.

The other is the welding flexible production line (FMS-W). The flexible line is also composed of multiple stations, the difference is that the welded workpiece is loaded on a pallet in a uniform form, and the pallet can be matched with the positioner of any station on the line and automatically clamped. The welding robot system first identifies the number of the pallet or the workpiece, and automatically calls up the program for welding the workpiece. In this way, different workpieces can be welded without any adjustment at each station. The welding flexible line generally has a rail sub-mother car, which can automatically take out the fixed workpiece from the storage station and then send it to the positioner of the welding robot workstation with a vacant position. It is also possible to remove the welded workpiece from the workstation and send it to the outflow location of the finished part. The entire flexible welding production line is controlled by a dispatching computer. Therefore, as long as enough workpieces are assembled during the day and placed in the storage station, unmanned or few people can be produced at night.

Which form of automatic welding production is selected by the factory must be determined according to the actual situation and requirements of the factory. The welding machine is suitable for products with large batches and slow modification, and the number of welds of the workpiece is small and long, and the shape is regular (straight line, round); The welding robot system is generally suitable for medium and small batch production, and the weld seam of the welded workpiece can be short and many, and the shape is more complex. Flexible welding line is particularly suitable for product variety, each batch of quantity is very small, at present, foreign companies are vigorously promoting no (less) inventory, according to order production (JIT) management mode, in this case the use of flexible welding line is more appropriate.

Application in automotive production

At present, welding robots have been widely used in the automobile manufacturing industry, such as automobile chassis, seat frame, guide rail, muffler and torque converter welding, especially in the welding production of automobile chassis. Toyota has decided to equip all of its spot welding robots in Japan and overseas as a standard. This technique can improve the quality of welding, and even try to replace some arc welding operations with it. The exercise time over short distances is also greatly reduced. The company recently launched a low-height spot welding robot that can be used to weld lower parts of the car body. This short spot welding robot can also be assembled with a taller robot to work together on the upper part of the car body, thus shortening the overall welding line length. Domestic production of Santana, Passat, Buick, Sail, Polo and other rear axles, subframes, rocker arms, suspensions, shock absorbers and other car chassis parts are mostly MIG welding process-based stress safety parts, the main components of the use of stamping welding, the average thickness of the plate is 1.5-4mm, welding is mainly in the form of lap joints, corner joints, welding quality requirements are quite high, the quality of the car directly affects the safety performance of the car. After the application of robot welding, the appearance and internal quality of the weldment are greatly improved, and the stability of the quality and the reduction of labor intensity are guaranteed, and the labor environment is improved.

Applications under water

As an important part of marine engineering equipment technology, marine welding has now become an indispensable foundation and supporting technology for the development of marine resources and the construction of marine engineering. After a large number of process tests and formula adjustments, the welding materials and special equipment for underwater welding developed have been successfully applied to marine projects such as the offshore oil production platform of Shengli Oilfield and the Hong Kong-Zhuhai-Macao Bridge.

Korea Hyundai Heavy Industries Robot - Welding application of welding robot

Korea Hyundai Heavy Industries Robot - Welding application of welding robot

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