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自動(dòng)焊接設(shè)備介紹-昆山榮仕杰
作者: 編輯: 來源: 發(fā)布日期: 2019.12.11
信息摘要:
自適應(yīng)控制的焊接設(shè)備是一種自動(dòng)化程度較高的焊接設(shè)備,它配用傳感器和電子檢測線路,對焊縫軌跡自動(dòng)導(dǎo)向和跟蹤,并對主要的焊接參數(shù)進(jìn)行實(shí)行閉環(huán)的反…
近20年來,隨著數(shù)字化,自動(dòng)化,計(jì)算機(jī),機(jī)械設(shè)計(jì)技術(shù)的發(fā)展,以及對焊接質(zhì)量的高度重視,自動(dòng)焊接已發(fā)展成為一種先進(jìn)的制造技術(shù),自動(dòng)焊接設(shè)備在各工業(yè)的應(yīng)用中所發(fā)揮的作用越來越大,應(yīng)用范圍正在迅速擴(kuò)大。在現(xiàn)代工業(yè)生產(chǎn)中,焊接生產(chǎn)過程的機(jī)械化和自動(dòng)化是焊接機(jī)構(gòu)制造工業(yè)現(xiàn)代化發(fā)展的必然趨勢。
中文名
自動(dòng)焊接設(shè)備
外文名
Automatic welding equipment 
比    較
數(shù)字化,自動(dòng)化,計(jì)算機(jī)發(fā)展
構(gòu)    成
焊接電源等
備    注
自動(dòng)焊接發(fā)展成為先進(jìn)的制造技術(shù)
注意事項(xiàng)
靈活多樣的焊錫方式

種類

編輯
根據(jù)自動(dòng)化程度自動(dòng)化焊接設(shè)備可分為以下三類:
1、剛性自動(dòng)化焊接設(shè)備剛性自動(dòng)化焊接設(shè)備亦可稱為初級自動(dòng)化焊接設(shè)備,其大多數(shù)是按照開環(huán)控制的原理設(shè)計(jì)的。雖然整個(gè)焊接過程由焊接設(shè)備自動(dòng)完成,但對焊接過程中焊接參數(shù)的波動(dòng)不能進(jìn)行 閉環(huán)反饋系統(tǒng),不能隨機(jī)糾正可能出現(xiàn)的偏差。
2、自適應(yīng)控制自動(dòng)化焊接設(shè)備
自適應(yīng)控制的焊接設(shè)備是一種自動(dòng)化程度較高的焊接設(shè)備,它配用傳感器和電子檢測線路,對焊縫軌跡自動(dòng)導(dǎo)向和跟蹤,并對主要的焊接參數(shù)進(jìn)行實(shí)行閉環(huán)的反饋控制。整個(gè)焊接過程將按預(yù)先設(shè)定的程序和工藝參數(shù)自動(dòng)完成
3、智能化自動(dòng)焊接設(shè)備
它利用各種高級的傳感元件,如視覺傳感器觸覺傳感器,聽覺傳感器和激光掃描器等,并借助計(jì)算機(jī)軟件系統(tǒng),數(shù)據(jù)庫和 專家系統(tǒng)具有識別、判斷、實(shí)時(shí)檢測,運(yùn)算、自動(dòng)編程、焊接參數(shù)存儲和自動(dòng)生成焊接記錄文件的功能。 [1]  

構(gòu)成

編輯
1、焊接電源,其輸出功率和焊接特性應(yīng)與擬用的焊接工藝方法相匹配,并裝有與主控制器相連接的接口.
2、送絲機(jī)及其控制與調(diào)速系統(tǒng),對于送絲速度控制精度要求較高送絲機(jī),其控制電路應(yīng)加測速反饋
3、焊接機(jī)頭用其移動(dòng)機(jī)構(gòu),其由焊接機(jī)頭,焊接機(jī)頭支承架,懸掛式拖板等組成,地于精密型焊頭機(jī)構(gòu),其驅(qū)動(dòng)系統(tǒng)應(yīng)采用裝有編碼器的伺服電動(dòng)機(jī)
4、焊件移動(dòng)或變位機(jī)構(gòu),如焊接滾輪架,頭尾架翻轉(zhuǎn)機(jī),回轉(zhuǎn)平臺和 變位機(jī)等,精密型的移動(dòng)變位機(jī)構(gòu)應(yīng)配伺服電動(dòng)機(jī)驅(qū)動(dòng)
5、焊件夾緊機(jī)構(gòu)
6、主控制器,亦稱系統(tǒng)控制器,主要用于各組成部分的聯(lián)動(dòng)控制,焊接程序的控制,主要焊接參數(shù)的設(shè)定,調(diào)整和顯示。必要時(shí)可擴(kuò)展故障診斷人機(jī)對話等控制功能。
7、計(jì)算機(jī)軟件,焊接設(shè)備中常用的計(jì)算機(jī)軟件有:編程軟件,功能軟件,工藝方法軟件和專家系統(tǒng)等
8、焊頭導(dǎo)向或跟蹤機(jī)構(gòu),弧壓自動(dòng)控制器,焊槍橫擺器和監(jiān)控系統(tǒng)
9、輔助裝置,如送絲系統(tǒng),循環(huán)水冷系統(tǒng)、焊劑回收輸送裝置、焊絲支架、電纜軟管及拖鏈機(jī)構(gòu)結(jié)構(gòu)設(shè)計(jì)電氣控制設(shè)計(jì)三大部分。
10、焊接機(jī)器人,又稱機(jī)械手臂,是自動(dòng)化焊接設(shè)備的重要組成部分。其主要工作包括:焊接、切割、 熱噴涂、搬運(yùn)等。

自動(dòng)焊接設(shè)備在全位置焊中的應(yīng)用以及價(jià)值

編輯
第一,在全位置焊中應(yīng)用自動(dòng)焊接設(shè)備,焊接執(zhí)行部件采取旋轉(zhuǎn)副驅(qū)動(dòng)的方式,對焊槍姿態(tài)進(jìn)行靈活且合理地改變,有利于全位置焊接工作的進(jìn)行。同時(shí)在驅(qū)動(dòng)相同焊接執(zhí)行部件的時(shí)候,還可減小電機(jī)功率。在應(yīng)用中,最好將焊接位置上傳感器安裝于末級減速軸,以此對焊槍位置進(jìn)行檢測,采取這種安裝方式,所獲控制精度相對較高。此外,借助于全自動(dòng)焊接設(shè)備上這一存儲器,對部分焊接工藝的參數(shù)以及焊縫跟蹤控制程序等進(jìn)行存儲,將焊接工藝參數(shù)儲存于弧焊電源中,以此使弧焊電源所具優(yōu)勢更好地發(fā)揮,通過兩者配合,有效地解決在全位置自動(dòng)焊接作業(yè)中可能出現(xiàn)的各種質(zhì)量問題。
第二,在焊槍驅(qū)動(dòng)上借助于步進(jìn)電機(jī)(步進(jìn)電機(jī)是指把電脈沖信號轉(zhuǎn)變成為角位移或者線位移的一種開環(huán)控制元步進(jìn)電機(jī)件)來實(shí)施驅(qū)動(dòng),這種電機(jī)可把數(shù)字輸入脈沖型號進(jìn)行有效地轉(zhuǎn)換,將其轉(zhuǎn)換成為一種旋轉(zhuǎn)運(yùn)動(dòng),該元件自身的精度較高,不僅不會出現(xiàn)漂移問題,同時(shí)也不會出現(xiàn)累計(jì)誤差等問題。在全位置焊接中應(yīng)用這一元件,不僅不會使轉(zhuǎn)速發(fā)生改變,同時(shí)控制頻率信號也比較穩(wěn)定,焊槍位移也更為準(zhǔn)確。
第三,在全位置焊接作業(yè)中,將焊接機(jī)頭與弧焊電源有機(jī)結(jié)合,不僅能夠達(dá)到全位置自動(dòng)焊接的目的,同時(shí)在一定程度上還可使自動(dòng)焊接設(shè)備價(jià)格得到降低。通過這種方式,不僅能夠?qū)崿F(xiàn)自動(dòng)焊接,同時(shí)還可借助于弧焊電源以及半自動(dòng)焊槍的利用來實(shí)施半自動(dòng)焊接。 [2]  

自動(dòng)焊接設(shè)備常見的焊接缺陷以及防止策略

編輯
第一,氣孔。在全位置焊中應(yīng)用自動(dòng)焊接設(shè)備時(shí),氣孔是一種比較常見的問題,導(dǎo)致該問題產(chǎn)生的原因有很多,比如焊材自身的原因、操作不當(dāng)、環(huán)境原因等。鑒于此,為有效地防止這一問題,在實(shí)施焊接時(shí),應(yīng)加強(qiáng)氣體的保護(hù),焊接溫度不可過高,嚴(yán)格按照比例以及相關(guān)要求來充裝氣體,確保充裝純度達(dá)到要求。同時(shí)還要注意施焊場地周圍的環(huán)境,若施工場地的風(fēng)速每秒超過8米,應(yīng)用防風(fēng)棚來實(shí)施防護(hù),且環(huán)境濕度不可過大。此外,為確保施焊位置保持干燥,可利用環(huán)形火焰加熱器或中頻感應(yīng) 加熱器來實(shí)施加熱。
第二,未熔合。在焊接中,未熔合這一問題一般常出現(xiàn)于立焊位置,導(dǎo)致該問題的原因有焊道打磨形狀不正確、在焊接時(shí)偏離焊縫或者焊槍擺動(dòng)的寬度不夠合理等。鑒于此,在焊接過程中,在實(shí)施焊道打磨作業(yè)時(shí),應(yīng)盡量打磨平整。同時(shí)在焊接之前,還應(yīng)對焊絲進(jìn)行仔細(xì)地觀察,察看其擺動(dòng)寬度是否正確。此外,在焊接過程中,如發(fā)現(xiàn)焊接熔池和焊道中心出現(xiàn)偏離,應(yīng)及時(shí)實(shí)施調(diào)整,以免出現(xiàn)未熔合問題。  [2]  

注意事項(xiàng)

編輯
1、靈活多樣的焊錫方式,同時(shí)支持點(diǎn)焊和拖焊(拉焊),自動(dòng)化焊錫設(shè)備全部工藝參數(shù)可由客戶自行設(shè)置,以適應(yīng)各種高難度焊錫作業(yè)和微焊錫工藝,全部焊錫參數(shù)可以伴隨焊點(diǎn)坐標(biāo)程序讀取和保存,實(shí)現(xiàn)焊錫作業(yè)的柔性化
2、烙鐵組件可以任意角度、任意方位調(diào)節(jié),控制烙鐵組的R軸,可以360度自由旋轉(zhuǎn),可以根據(jù)不同的焊盤和元器件任意設(shè)置送錫次數(shù)、預(yù)熱時(shí)間和焊錫時(shí)間,實(shí)現(xiàn)一板多種焊點(diǎn)的復(fù)雜焊接工藝,實(shí)現(xiàn)焊錫作業(yè)的多樣化。

3、四軸/五軸聯(lián)動(dòng)機(jī)械手,自動(dòng)化焊錫設(shè)備全部采用伺服驅(qū)動(dòng)及先進(jìn) 運(yùn)動(dòng)控制算法,有效提升運(yùn)動(dòng)末端-烙鐵頭的定位精度和重復(fù)精度,實(shí)現(xiàn)3D空間任意焊點(diǎn)準(zhǔn)確定位。

In the past 20 years, with the development of digitization, automation, computer, and mechanical design technology, and the great emphasis on welding quality, automatic welding has developed into an advanced manufacturing technology. Automatic welding equipment has played a role in the application of various industries. The role is increasing, and the scope of application is rapidly expanding. In modern industrial production, the mechanization and automation of the welding production process is an inevitable trend of the modernization and development of the welding mechanism manufacturing industry.
Chinese name Automatic welding equipment Foreign name Automatic welding equipment Compared with digitalization, automation, computer development constitutes welding power supply, etc.
table of Contents
1 Variety
2 Composition
3 Application and value of automatic welding equipment in all-position welding
4 Common welding defects and prevention strategies of automatic welding equipment
5 Notes
    
Category edit
According to the degree of automation, automatic welding equipment can be divided into the following three categories:
1. Rigid automated welding equipment Rigid automated welding equipment can also be called primary automated welding equipment, most of which are designed according to the principle of open loop control. Although the entire welding process is automatically completed by the welding equipment, the closed-loop feedback system cannot be used for the fluctuation of welding parameters during the welding process, and random deviations cannot be corrected.
2. Adaptive control of automatic welding equipment
Adaptively controlled welding equipment is a highly automated welding equipment. It is equipped with sensors and electronic detection circuits to automatically guide and track the weld trajectory and implement closed-loop feedback control of the main welding parameters. The entire welding process will be completed automatically according to preset procedures and process parameters
3.Intelligent automatic welding equipment
It uses various advanced sensing elements, such as vision sensors, tactile sensors, hearing sensors and laser scanners, etc., and with the help of computer software systems, databases and expert systems have identification, judgment, real-time detection, calculation, automatic programming, welding parameters Ability to store and automatically generate welding log files. [1]     
    
Composition edit
The composition of automatic welding equipment:
1. The welding power source, its output power and welding characteristics should match the intended welding process method, and is equipped with an interface connected to the main controller.
2. Wire feeder and its control and speed regulation system. For wire feeder with high requirements for wire feed speed control accuracy, its control circuit should be added with speed feedback.
3. The welding head uses its moving mechanism, which is composed of a welding head, a welding head support frame, a hanging carriage, etc. It is a precision welding head mechanism, and its drive system should use a servo motor with an encoder
4. Welding parts movement or displacement mechanism, such as welding roller frame, head and tail frame turning machine, rotary platform and positioner, etc., precision mobile displacement mechanism should be equipped with servo motor drive
5. Weldment clamping mechanism
6. The main controller, also known as the system controller, is mainly used for the linkage control of each component, the control of the welding program, the setting, adjustment and display of the main welding parameters. If necessary, control functions such as fault diagnosis and human-machine dialogue can be extended.
7, computer software, computer software commonly used in welding equipment are: programming software, functional software, process software and expert systems, etc.
8. Welding head guidance or tracking mechanism, automatic arc voltage controller, welding gun pendulum and monitoring system
9. Auxiliary devices, such as wire feeding system, circulating water cooling system, flux recovery and conveying device, wire support, cable hose and towline mechanism structure design, electrical control design three major parts.
10. Welding robot, also called mechanical arm, is an important part of automatic welding equipment. Its main tasks include: welding, cutting, thermal spraying, and handling.
    
Application and value editing of automatic welding equipment in all-position welding
First, the automatic welding equipment is used in all-position welding. The welding execution part is driven by a rotary pair to flexibly and reasonably change the attitude of the welding gun, which is beneficial to the all-position welding work. At the same time, the motor power can be reduced when driving the same welding execution components. In application, it is better to install the sensor at the welding position on the final reduction shaft to detect the position of the welding gun. With this installation method, the control accuracy is relatively high. In addition, by means of this memory on fully automatic welding equipment, parameters of some welding processes and welding seam tracking control programs are stored, and the welding process parameters are stored in the arc welding power source, thereby making the advantages of the arc welding power source even more Make good use of it, and through the cooperation of the two, effectively solve various quality problems that may occur in all-position automatic welding operations.
Second, the welding gun is driven by a stepper motor (stepper motor is an open-loop control element stepper motor that converts electrical pulse signals into angular displacement or linear displacement). This motor can The digital input pulse model is effectively converted and converted into a rotary motion. The component itself has a high accuracy, which not only does not cause drift problems, but also does not have problems such as cumulative errors. The application of this component in all-position welding not only does not change the speed, but also controls the frequency signal more stable, and the welding gun displacement is more accurate.
Third, in the all-position welding operation, the organic combination of the welding head and the arc welding power source can not only achieve the purpose of all-position automatic welding, but also reduce the price of automatic welding equipment to a certain extent. In this way, not only automatic welding can be achieved, but also semi-automatic welding can be implemented with the help of an arc welding power source and the use of a semi-automatic welding gun. [2]    
    
Common welding defects of automatic welding equipment and prevention strategy editing
First, the stomata. When applying automatic welding equipment in all-position welding, air holes are a relatively common problem. There are many reasons for this problem, such as the cause of the welding material itself, improper operation, and environmental reasons. In view of this, in order to effectively prevent this problem, the gas protection should be strengthened when welding is carried out. The welding temperature must not be too high. The gas should be filled in strict accordance with the proportion and related requirements to ensure that the filling purity meets the requirements. At the same time, we must also pay attention to the environment around the welding site. If the wind speed of the construction site exceeds 8 meters per second, a windproof shed should be used for protection, and the environmental humidity should not be excessive. In addition, to ensure that the welding position is kept dry, a ring flame heater or an intermediate frequency induction heater can be used for heating.
Second, it is not fused. In welding, the problem of non-fusion often occurs in the vertical welding position. The reasons for this problem include the incorrect shape of the bead grinding, the deviation from the weld seam during welding, or the width of the welding gun swing is not reasonable. In view of this, during the welding process, when welding bead grinding is performed, it should be polished as smooth as possible. At the same time, before welding, the wire should be carefully observed to see if the swing width is correct. In addition, during the welding process, if it is found that the welding pool and the center of the bead deviate, adjustments should be implemented in time to avoid non-fusion problems. [2]   
    
Notes edit
1. Flexible and diverse soldering methods, supporting spot welding and drag welding (pulling welding) at the same time. All process parameters of automated soldering equipment can be set by the customer to adapt to various difficult soldering operations and micro soldering processes. All soldering parameters can be accompanied Point coordinate programs are read and saved to realize the flexibility of soldering operations.
2. The soldering iron components can be adjusted at any angle and orientation. The R axis of the soldering iron group can be controlled to rotate 360 degrees freely. The number of soldering times, preheating time and soldering time can be set arbitrarily according to different pads and components to achieve a board A variety of complex soldering processes for solder joints to diversify solder operations.
3. Four-axis / five-axis linkage manipulators and automatic soldering equipment all use servo drive and advanced motion control algorithms to effectively improve the positioning accuracy and repeatability of the end-of-movement tip and achieve accurate positioning of any solder joint in 3D space.

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一套完整的焊接機(jī)器人工作站包括哪些設(shè)備?

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焊接機(jī)器人與焊接機(jī)器人工作站到底有什么區(qū)別,榮仕杰小編告訴您一般焊接機(jī)器人指的就是一套機(jī)器,主要由機(jī)械手總成、控制系統(tǒng)、示教育系統(tǒng)、焊機(jī)、送絲機(jī)構(gòu)、焊槍等組成。而焊接機(jī)器人工作站除了包括焊接機(jī)器人外,還包括了很多輔助設(shè)備如地軌、變位機(jī)、翻轉(zhuǎn)臺、焊縫跟蹤系統(tǒng)、安全圍欄、清槍器、安全系統(tǒng)、外圍設(shè)備......
庫卡ABB發(fā)那科點(diǎn)焊機(jī)器人機(jī)器人點(diǎn)焊焊接工藝介紹!

庫卡ABB發(fā)那科點(diǎn)焊機(jī)器人機(jī)器人點(diǎn)焊焊接工藝介紹!

榮仕杰為您介紹什么是點(diǎn)焊機(jī)器人,中間的環(huán)節(jié)和要注意的事項(xiàng),以及使用細(xì)節(jié)在下文中我們做了詳細(xì)的介紹。

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