introduction
The traction beam and bolster of the electric vehicle locomotive chassis are the key components of the locomotive. The quality of the welding directly affects the safety of the locomotive operation.
In order to improve the stability of the welding quality. To improve production efficiency, improve workers' working conditions and reduce labor intensity, Zhuzhou Electric Locomotive Co., Ltd. introduced the Austrian IGM welding robot for the welding production of bolster and traction beams.
1IGM welding robot system introduction
The IGM welding robot system consists of a robot body, a control system, a positioner, a teach pendant, a remote control box, a tracking system, a welding system, and application software.
The control system uses Pentium CPU and all-digital signal communication, which can control the robot 6-axis, 3D gantry frame x, y, z axis and positioner axis, and can expand 2 external axes. The robot body adopts a 6-axis toggle structure. A teach pendant and a remote control box as a human-machine interface are used for robot control. The tracking system adopts three kinds of tracking methods: contact nozzle sensor, arc sensor and ELS laser sensor, which can track various forms of welds such as V-shaped, single-V, fillet weld and plug weld. The welding system uses the Fronius TPS5000 fully digitally controlled inverter welding power supply. In addition, the system is also equipped with an efficient welding fume absorption and purification device and automatic cleaning gun, wire cutting, spray anti-splash oil device.
2 Application in the manufacture of locomotive bodies.
2.1 Single-axis positioner robot system applied to bolster welding
The bolster beam welding uses a single-shaft head and tail frame type positioner. The bolster beam is welded into a box-shaped structure by upper and lower cover plates, vertical plates and partitions. After assembly, the four welds on both sides and the straight welds on the upper and lower surfaces are welded in a boat shape.
2.2 Two-axis positioner robot system applied to traction beam welding
The traction beam welding uses two double-axis frame type positioner systems. The traction beam is a complex multi-box structure. After assembly, the robot is welded. Due to the small space, the robot has a small degree of freedom of placement, long programming time, and high programming skills.
3 Problems and solutions in the application of welding robots
3.1 Analysis and treatment of welding defects
The robot welding uses argon-rich mixed gas protective welding. The welding defects that occur during the welding process generally include welding offset, undercut, and venting. The specific analysis is as follows:
(1) A weld offset may occur if the position of the weld is incorrect or the weld gun is looking for problems. At this time, consider whether TCP (the position of the torch center point) is accurate and adjust it. If this happens frequently, check the zero position of each axis of the robot and recalibrate it to correct it.
(2) The undercut may be improperly selected for welding parameters, the angle of the welding torch or the position of the welding torch is incorrect. The power can be appropriately adjusted to change the welding parameters, adjust the posture of the welding torch and the relative position of the welding torch and the workpiece.
(3) The occurrence of pores may be poor gas protection, the primer of the workpiece is too thick or the shielding gas is not dry enough, and the corresponding adjustment can be processed.
(4) Excessive splashing may result in improper selection of welding parameters, gas component reasons or excessive elongation of the welding wire. The power can be appropriately adjusted to change the welding parameters, adjust the gas proportioning instrument to adjust the proportion of the mixed gas, adjust the welding torch and The relative position of the workpiece.
(5) An crater is formed after the end of the weld is cooled, and the buried crater function is added to the work step during programming to fill it.
3.2 Robot Fault Analysis and Processing
The robot system encountered some faults during the welding process. The common ones are as follows:
(1) A rifle occurred. The assembly may be checked or the torch TCP may be corrected due to deviations in the assembly of the workpiece or inaccurate TCP of the torch.
(2) An arc fault occurs and the arc cannot be induced. It may be because the welding wire is not in contact with the workpiece or the process parameters are too small, the wire can be manually fed, the distance between the welding torch and the weld be adjusted, or the process parameters can be adjusted appropriately.
(3) Protective gas monitoring alarm. If there is a problem with the cooling water or the shielding gas supply, check the cooling water or the shielding gas line.
The traction beam and bolster of the electric vehicle locomotive chassis are the key components of the locomotive. The quality of the welding directly affects the safety of the locomotive operation.
In order to improve the stability of the welding quality. To improve production efficiency, improve workers' working conditions and reduce labor intensity, Zhuzhou Electric Locomotive Co., Ltd. introduced the Austrian IGM welding robot for the welding production of bolster and traction beams.
1IGM welding robot system introduction
The IGM welding robot system consists of a robot body, a control system, a positioner, a teach pendant, a remote control box, a tracking system, a welding system, and application software.
The control system uses Pentium CPU and all-digital signal communication, which can control the robot 6-axis, 3D gantry frame x, y, z axis and positioner axis, and can expand 2 external axes. The robot body adopts a 6-axis toggle structure. A teach pendant and a remote control box as a human-machine interface are used for robot control. The tracking system adopts three kinds of tracking methods: contact nozzle sensor, arc sensor and ELS laser sensor, which can track various forms of welds such as V-shaped, single-V, fillet weld and plug weld. The welding system uses the Fronius TPS5000 fully digitally controlled inverter welding power supply. In addition, the system is also equipped with an efficient welding fume absorption and purification device and automatic cleaning gun, wire cutting, spray anti-splash oil device.
2 Application in the manufacture of locomotive bodies.
2.1 Single-axis positioner robot system applied to bolster welding
The bolster beam welding uses a single-shaft head and tail frame type positioner. The bolster beam is welded into a box-shaped structure by upper and lower cover plates, vertical plates and partitions. After assembly, the four welds on both sides and the straight welds on the upper and lower surfaces are welded in a boat shape.
2.2 Two-axis positioner robot system applied to traction beam welding
The traction beam welding uses two double-axis frame type positioner systems. The traction beam is a complex multi-box structure. After assembly, the robot is welded. Due to the small space, the robot has a small degree of freedom of placement, long programming time, and high programming skills.
3 Problems and solutions in the application of welding robots
3.1 Analysis and treatment of welding defects
The robot welding uses argon-rich mixed gas protective welding. The welding defects that occur during the welding process generally include welding offset, undercut, and venting. The specific analysis is as follows:
(1) A weld offset may occur if the position of the weld is incorrect or the weld gun is looking for problems. At this time, consider whether TCP (the position of the torch center point) is accurate and adjust it. If this happens frequently, check the zero position of each axis of the robot and recalibrate it to correct it.
(2) The undercut may be improperly selected for welding parameters, the angle of the welding torch or the position of the welding torch is incorrect. The power can be appropriately adjusted to change the welding parameters, adjust the posture of the welding torch and the relative position of the welding torch and the workpiece.
(3) The occurrence of pores may be poor gas protection, the primer of the workpiece is too thick or the shielding gas is not dry enough, and the corresponding adjustment can be processed.
(4) Excessive splashing may result in improper selection of welding parameters, gas component reasons or excessive elongation of the welding wire. The power can be appropriately adjusted to change the welding parameters, adjust the gas proportioning instrument to adjust the proportion of the mixed gas, adjust the welding torch and The relative position of the workpiece.
(5) An crater is formed after the end of the weld is cooled, and the buried crater function is added to the work step during programming to fill it.
3.2 Robot Fault Analysis and Processing
The robot system encountered some faults during the welding process. The common ones are as follows:
(1) A rifle occurred. The assembly may be checked or the torch TCP may be corrected due to deviations in the assembly of the workpiece or inaccurate TCP of the torch.
(2) An arc fault occurs and the arc cannot be induced. It may be because the welding wire is not in contact with the workpiece or the process parameters are too small, the wire can be manually fed, the distance between the welding torch and the weld be adjusted, or the process parameters can be adjusted appropriately.
(3) Protective gas monitoring alarm. If there is a problem with the cooling water or the shielding gas supply, check the cooling water or the shielding gas line.
Welcome to visit us, we are the factory of Non Slip Floor Mats producer from China, this series made of pvc and widely used for the runners of wet area, like swim pools and vegetable supermarket, also contain chemcial lab or workshop. General of four size mm and Max 8.0mm for customized orders.
| 3.5mm | Disposable |
| 4.5mm | General type |
| 5.0mm | High quality |
| 6.0mm | Higher quality |
| 8.0mm | Customized |
Welcome to visit us.
Non Slip Mats,Indoor Floor Mat Non Slip,Non Slip Flooring Mats,Stay Put Non Slip Matting,Anti Slip Bath Mats
Jiangyin Yining E-Commerce Co., Ltd , https://www.pvcmatyining.com