Industrial Robotic Arm CNC Welding Robot , White Robotic Welding Equipment

CNC Welding Robot equipment introduction:

With the development of electronic technology, computer technology, numerical control and robotics, automatic arc welding robot workstations have been increasingly mature since the 1960s, and have the following advantages:

1) Stabilize and improve the quality of welding;
2) Improve labor productivity;
3) Improve the labor intensity of workers and work in harmful environments;
4) Reduce the requirements for workers' operating technology;
5) Shorten the preparation period for product modification and reduce the corresponding equipment investment.

Therefore, it has been widely used in various industries.
composition
Welding robots mainly include two parts: robots and welding equipment. The robot consists of a robot body and a control cabinet (hardware and software). For welding equipment, for example, arc welding and spot welding are composed of welding power source (including its control system), wire feeder (arc welding), and welding torch (clamp). For intelligent robots, there should also be sensing systems such as laser or camera sensors and their controls. Figures 1a and b show the basic components of an arc welding robot and a spot welding robot.
Structural form and performance
Welding robots produced in countries all over the world are basically joint robots, and most of them have six axes. Among them, the 1, 2, and 3 axes can send the end tool to different spatial positions, while the 4, 5, and 6 axes solve the different requirements of the tool posture. The mechanical structure of the welding robot body has two main forms: one is a parallelogram structure, and the other is a side-mounted (pendulum) structure, as shown in Figures 2a and b. The main advantage of the side-mounted (pendulum) structure is that the upper and lower arms have a large range of motion, making the robot work.

The space can reach almost a sphere. Therefore, the robot can work upside down on the rack to save floor space and facilitate the flow of ground objects. However, the side-mounted robot, the 2, and 3 axes are cantilever structures, which reduce the rigidity of the robot and are generally suitable for robots with small loads for arc welding, cutting or spraying. The parallelogram robot has its upper arm driven by a lever. The drawbar and the lower arm form two sides of a parallelogram. It is named after it. The parallelogram robot developed in the early stage has a small working space (limited to the front of the robot) and is difficult to work upside down. However, the new parallelogram robot (parallel robot) developed since the late 1980s has been able to expand the work space to the top, back and bottom of the robot, and there is no stiffness problem of the robot, which has received widespread attention. This structure is not only suitable for light weight but also for heavy robots. In recent years, robots for spot welding (loads of 100 to 150 kg) have mostly used robots in the form of parallelogram structures.

Each of the above two types of robots is used for rotary motion, so the servo motor is driven by a cycloidal pin (RV) reducer (1 to 3 axes) and a harmonic reducer (1 to 6 axes). Before the mid-1980s, DC servo motors were used for electrically driven robots. Since the late 1980s, countries have switched to AC servo motors. Since the AC motor has no carbon brush and good dynamic characteristics, the new robot not only has a low accident rate, but also has a large maintenance-free time and a fast (subtractive) speed. Some new lightweight robots with a load of less than 16kg have a tool center point (TCP) with a maximum movement speed of more than 3 m/s, accurate positioning and low vibration. At the same time, the robot's control cabinet also uses a 32-bit microcomputer and a new algorithm to make it have the function of self-optimizing the path, and the running track is closer to the teaching track.
Basic functions of spot welding robot
The requirements for spot welding on the robot used are not very high. Because spot welding requires only point control, there is no strict requirement for the movement path of the welding tongs between points. This is also the reason why robots can only be used for spot welding. The spot welding robot must not only have sufficient load capacity, but also speed when moving between points, the movement should be smooth, the positioning should be accurate, and the shift time should be reduced.

High work efficiency. How much load capacity a spot welding robot needs depends on the type of welding tongs used. For welding tongs separated from the transformer, a robot with a load of 30 to 45 kg is sufficient. However, on the one hand, the welding tongs have large electrical energy loss due to the length of the secondary cable, and are not conducive to the robot to extend the welding tongs into the workpiece. On the other hand, the cable runs without the robot moving, and the cable is damaged quickly. . Therefore, the use of integrated welding tongs is gradually increasing. This welding tongs together with the transformer quality is around 70kg. Considering that the robot has sufficient load capacity, the welding tongs can be sent to a space position for welding with a large acceleration, and a heavy-duty robot with a load of 100 to 150 kg is generally selected. In order to meet the requirements of short-distance rapid displacement of welding tongs during continuous spot welding. The new heavy-duty robot adds the ability to perform 50mm displacement in 0.3s. This puts higher requirements on the performance of the motor, the operation speed of the microcomputer and the algorithm.

Welding equipment for spot welding robot
The welding equipment of the spot welding robot, because the integrated welding tongs are used, the welding transformer is installed behind the welding tongs, so the transformer must be miniaturized as much as possible. For small-capacity transformers, 50Hz power frequency AC can be used. For transformers with larger capacity, inverter technology has been used to change 50Hz power frequency AC to 600-700Hz AC, which reduces and reduces the size of the transformer. After the pressure change, it can be directly welded with 600-700 Hz AC, or it can be re-rectified twice and welded by DC. The welding parameters are adjusted by the timer, see Figure 1b. The new timer has been micro-machined, so the robot control cabinet can directly control the timer without the need for an additional interface. The welding tongs of spot welding robots usually use pneumatic welding tongs. The opening degree between the two electrodes of the pneumatic welding tongs is generally only two strokes. Moreover, once the electrode pressure is set, it cannot be changed at will. A new electric servo spot welding tong has appeared in recent years, as shown in Figure 4. The opening and closing of the welding tongs is driven by the servo motor, and the code wheel is fed back, so that the opening degree of the welding tongs can be arbitrarily selected and preset according to actual needs. Moreover, the pressing force between the electrodes can also be adjusted steplessly.

This new electric servo spot welding tong has the following advantages:
1) The welding cycle of each solder joint can be greatly reduced, because the opening degree of the welding tongs is precisely controlled by the robot, the movement of the robot between points and points, the welding tongs can start to close; After the welding tongs are opened, the robot can be displaced at one side, and the welding tongs are not closed after the robot is in place or the robot is moved after the welding tongs are fully opened;
2) The opening degree of the welding tongs can be arbitrarily adjusted according to the condition of the workpiece, as long as no collision or interference occurs to reduce the opening degree as much as possible, so as to save the opening degree of the welding tongs, thereby saving the time taken for the welding tongs to open and close.
3) When the welding tongs are closed and pressurized, not only the pressure can be adjusted, but also the two electrodes are gently closed when closed, reducing impact deformation and noise.

Welding robot maintenance
I. Inspection and maintenance
1. Wire feeding mechanism. Including whether the wire feed force is normal, whether the wire feed pipe is damaged, and whether there is an abnormal alarm. 2. Is the gas flow normal? 3. Is the torch safety protection system normal? (It is forbidden to turn off the welding gun safety protection work) 4. Whether the water circulation system works normally. 5. Test TCP (recommended to prepare a test program, run after each shift)
2. Week inspection and maintenance
1. Scrub the axes of the robot. 2. Check the accuracy of TCP. 3. Check the oil level of the residue. 4. Check if the zero position of each axis of the robot is accurate. 5. Clean the filter behind the welder tank. 6. Clean the filter at the compressed air inlet. 7. Clean the impurities at the nozzle of the torch to avoid blocking the water circulation. 8. Clean the wire feeding mechanism, including the wire feeding wheel, the pressure wire wheel, and the wire guide tube. 9. Check the hose bundle and guide wire hose for damage and breakage. (It is recommended to remove the entire hose bundle and clean it with compressed air.) 10. Check that the torch safety protection system is normal and that the external emergency stop button is normal.
3. Monthly inspection and maintenance
1. Lubricate the axes of the robot. Among them, 1 to 6 axes are white with lubricating oil. Oil No. 86E006. 2. RP positioner and red grease nipple on the RTS rail with butter. Oil number: 86K007
3. The blue grease fitting on the RP positioner is added with gray conductive grease. Oil number: 86K004
4. The wire feed needle roller shaft is multiplied by lubricating oil. (A small amount of butter can be used) 5. Clean the gun device and fill the air motor lubricant. (Ordinary oil can be) 6. Clean the control cabinet and welder with compressed air. 7. Check the cooling water level of the welder tank, and replenish the coolant in time (pure water plus a little industrial alcohol) 8. Complete all the items of the weekly inspection in addition to the work of 1-8.
4. The maintenance work of the welding robot is the responsibility of the operator, and the personnel are assigned as follows:
Maintenance records must be added for each maintenance. If the equipment fails, it should be reported to the maintenance in time. Detailed description of the equipment and operation before the failure occurs, and actively cooperate with the maintenance personnel to repair, in order to smoothly resume production! The company will conduct random inspections on equipment maintenance. It is recommended that the operator carefully check the condition of the equipment during each shift and record the operation of each equipment.

Welding robot application:
Welding robot workstation (unit)
If the workpiece does not need to be displaced during the entire welding process, the workpiece can be positioned on the work surface with a clamp. This system is the easiest. However, in actual production, more workpieces need to be displaced during welding, so that the weld is welded at a good position (attitude). In this case, the positioner and the robot can be separately moved, that is, the robot can be welded after the displacement of the positioner; or it can be simultaneous movement, that is, the position of the positioner is displaced, and the side of the robot is welded, that is, the displacement is often said. The machine coordinates with the robot. At this time, the movement of the positioner and the motion of the robot are combined, so that the movement of the welding gun relative to the workpiece can satisfy the requirements of the weld trajectory and the welding speed and the posture of the welding gun. In fact, the axis of the positioner has now become a part of the robot. This welding robot system can be as many as 7-20 axes, or more. The latest robot control cabinet can be a group of two robots that cooperate with 12 axes to coordinate motion. One of them is a welding robot, and the other is a handling robot for a positioner.
Further subdivision of the welding robot workstation can be obtained in the following four types:

1.1 The box welding robot workstation is specially designed for the robot workstations developed in the cabinet industry with large production volume, high welding quality and high dimensional requirements.
The box welding robot workstation consists of an arc welding robot, a welding power source, a welding gun wire feeding mechanism, a rotary double station positioner, a fixture and a control system. The workstation is suitable for the welding of various types of box-like workpieces. It can realize automatic welding of various types of cabinets by using non-stop fixtures in the same workstation, and the relative position of welding is high. Due to the use of the double-position positioner, the other parts can be disassembled and assembled while welding, which greatly improves the welding efficiency. Due to the MIG pulse transition or CMT cold metal transition welding process, the heat input is greatly reduced during the welding process, and the product is not deformed after welding. By adjusting the welding specifications and the robot welding posture, the weld quality of the product is ensured. The weld seam is beautiful, especially for stainless steel air chambers with high sealing requirements, and the gas in the air chamber is not leaked after welding. Automatic welding of multiple types of cabinets can be achieved by setting the variety selection parameters in the control system and replacing the work fixtures.

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

1.2 The flexible laser welding processing equipment for stainless steel air chamber robot is a flexible robot laser welding processing equipment developed for the welding of box-shaped workpieces with large welding deformation and high sealing requirements. The processing equipment is composed of a robot, a laser generator unit, a water cooling unit, a laser scanning and tracking system, a flexible positioner, a fixture, a safety guardrail, a dust suction device and a control system, and the selection parameters are selected by setting the control system. And the fixtures are replaced, and automatic welding of multiple types of stainless steel gas chamber workpieces can be realized.

1.3 Shaft-based welding robot workstation is a special equipment specially developed for shaft welding in the low-voltage electrical industry. A special rotary-axis welding robot workstation has been introduced.

The shaft welding robot workstation consists of an arc welding robot, a welding power source, a welding gun wire feeding mechanism, a rotary double station positioner, a fixture and a control system. The workstation is used for the welding of various types of workpieces with the rotating shaft as the base body (with several cantilever arms on the top), and various types of shaft automatic welding can be realized by using different clamps in the same workstation. The welding is now highly accurate in position. Due to the use of the double-position positioner, the other parts can be disassembled and assembled while welding, which greatly improves the efficiency.

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

It is widely used in high-quality, high-precision welding of various types of workpieces for 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 the workers is extremely high, the consistency of the products is poor, and the production efficiency is low, only 2-3 pieces/hour. With the automatic welding station, the output can reach 15-20 pieces / hour, and the welding quality and product consistency are also greatly improved.
Shaft welding robot workstation

1.4 Robot Welding Stud Workstation
The Robot Welded Stud Workstation uses a robot to weld studs to the workpiece for studs of different sizes on complex parts. The workstation is mainly composed of robot, stud welding power supply, automatic nail feeder, robot automatic stud welding gun, positioner, fixture, automatic gun changing device, automatic detection software, control system and safety guardrail. The machine sends the studs into the robotic automatic welding torch, and the robots are programmed on the workpiece to weld the studs of different specifications to the workpiece. The stud can be firmly welded to the workpiece by energy storage welding or arc welding to ensure welding precision and welding strength. Welding efficiency is about 3-10/min, stud size: diameter 3-8mm, length: 5-40mm

Changzhou Libon Machinery Co., Ltd. is a professional manufacturer of four-roll bending machine, shrinking machine, gas storage tank production line, aluminum fuel tank production line, motor shell production line, welding robot, welding equipment automation, welding special machine, straight seam welding equipment. The hydraulic shaping machine and ultrasonic laser and products are designed and produced with strong practicability, which makes it have advanced design, reasonable structure, light weight, convenient installation and high efficiency.
The company is mainly engaged in the production and sales of automatic coiling, straight seam welding, imitation welding, single ring seam or double loop seam, testing airtight, automatic forming, automatic painting series automation equipment.

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