Automatic welding machine is a welding automation equipment specially designed for specific workpieces and welding joints with certain shape. It can realize the rotation or movement of the motor, pneumatic actuator and hydraulic actuator through electrical control, pneumatic control and hydraulic control technology, and realize the relative movement of the welding seam of the workpiece and the welding gun, so as to automatically complete the welding work of the welding joint. So, what are the advantages of automatic welding machine? The price in the market is expensive. Below I will briefly introduce the automatic welding machine and its advantages.
Advantages of automatic welding machine
Automatic welding machine is a kind of equipment for automatic welding. Its advantages are more stable and continuous operation, higher working efficiency, better welding quality, better accuracy, easy adjustment and wide range, and no spatter during welding, which will not damage the health of the machine and workers.
Classification of automatic welding machine
Open-loop control type
The control system of this special welding machine generally adopts open-loop control, that is, the control system is used to set parameters in advance, and the execution components are executed in sequence by the control program. This type of equipment has a simple structure, relatively low technical requirements and relatively low cost, so it has been widely used. During the welding process, the fluctuation of the welding parameters cannot be closed-loop feedback control. The movement of the welding head or welding workpiece can only be carried out according to the predetermined path or trajectory, and cannot be changed with the change of the welding seam of the workpiece. Therefore, In the process of use, the consistency of the workpiece and the precision of the welding seam should be guaranteed to achieve the reliability of improving the welding efficiency and product welding quality. The picture on the right is the robot automatic flip welding machine. The welding machine is pre-set by the CNC control system software to set the movement path of the robot (holding the welding torch part) and the platform turning angle. For multiple points and lines, surfaces, etc. of the weldment, press the advance The set program performs automatic welding in the whole process. Due to the open-loop control, the welding program is set in advance, and the welding gun action does not automatically adjust to the weldment error due to the error of the workpiece. Therefore, the workpiece needs to be closely coordinated and consistent, and the parts to be welded must be consistent or within the error range, otherwise it will Complete all welding work automatically.
Adaptive Control
This special plane is a welding equipment with a high degree of automation. It is equipped with sensors and electronic detection lines, which can automatically guide and track the weld trajectory. Some equipment can also achieve closed-loop control of welding parameters such as welding current, welding voltage, welding speed, etc. The entire welding process is in accordance with the preset procedures and processes The parameters are completed automatically. For example, for larger cylinders or pipe parts, as shown in the figure on the right, it is very difficult to ensure the consistency of the workpiece and achieve a high matching accuracy, which requires greater costs. The special welding machine uses an arc length tracker and a welding gun oscillator. Due to the uneven surface of the workpiece, the welding gun needs to move up and down with the unevenness of the surface of the workpiece to keep the distance between the welding gun and the surface of the workpiece consistent, so as to ensure the stability of the arc. At the same time, multi-layer welding can be realized automatically. If two layers are welded, after one week of welding, the tracker detects that the height of the surface increases, and the welding gun can be automatically raised.
Intelligent
It uses all kinds of advanced sensing elements, such as visual sensors, tentacle sensors, light-sensitive sensors, etc., and with the help of computer software systems, databases, expert systems, has identification, judgment, real-time detection, calculation, automatic programming, welding parameter call, etc. The personnel only need to input the material grade, plate thickness, bevel form, welding wire grade and diameter, flux or shielding gas type, etc. on the man-machine interface, welding process parameters are automatically generated or corresponding parameters are called. You can complete automatic welding. Due to the high cost of such equipment, there are many factors that actually affect the welding quality, such as gas purity, flow rate, welding current, voltage, fluctuations in power input, water vapor or corrosion of the workpiece, the width of the weld, the height of the weld, etc. , So it is difficult to truly complete intelligent welding, which is rarely used in actual production.
Composition and description of automatic welding machine
The automatic welding machine is used for automatic production. It requires manual or mechanical hand loading and unloading of the workpiece. The welding fixture automatically fixes and positions the workpiece, automatically starts the arc of the welding power supply, automatic wire feed and automatic movement of the welding gun or workpiece. , Manual or mechanical hand to remove the workpiece, its composition is mainly composed of welding system, mechanical system, electrical control system.
Welding system
The welding system includes welding power source and welding gun, mainly including argon arc welding machine, CO2 welding machine, MIG / MAG welding machine, plasma welding machine, submerged arc welding machine and so on. Of course, there are also resistance welding, flame welding, laser welding, electron beam welding and other welding forms. Due to the limited space, we will only describe the most commonly used welding power sources here.
The aforementioned welding power sources, argon arc welding machine and plasma welding machine can use the welding seam metal to fuse together to weld the two workpieces together, or an automatic wire filler can be added to complete the welding of thicker workpieces. The CO2 / MIG / MAG welding machine and submerged arc welding machine have their own wire feeding system, and the welding wire is sent out through the center end of the welding gun. The welding parameters are adjusted by the control knob on the welding machine.
computer system
The mechanical system is mainly composed of a bed mechanism, tooling fixture and workpiece auxiliary support mechanism, welding gun fine adjustment mechanism, welding workpiece or welding gun moving mechanism, etc. For example, the picture on the right is the automatic welding machine for tube sheet.
Due to the different shapes, sizes, welding seam positions, etc. of various welding workpieces, each designer has different design ideas, so the style of the welding machine is also strange.
2.1 Bed body mechanism: The bed body mainly supports the equipment and can be made of castings or welding parts. Due to the long production cycle and high cost of castings, they are basically welded with profiles and steel plates, and are made by annealing and finishing. They can be manufactured quickly and at low cost, and are widely used.
2.2 Tooling fixture and auxiliary support mechanism: as shown in the figure, the relative position of the workpiece can be fixed according to the processing surface or positioning hole of the workpiece. The movement of the clamp can be controlled manually, pneumatically, electrically, or hydraulically to achieve clamping and positioning of the workpiece.
2.3 Welding gun fine-tuning mechanism: To align the welding torch with the weld, the X \ Y \ Z direction of the welding torch needs to be adjusted three-dimensionally, which is the direction of the welding torch to the welding seam. At the same time, according to the welding process requirements, it also needs to realize the rotation function in all directions.
2.4 Moving mechanism of welding workpiece or welding gun: To complete the welding of straight, circumferential or curved welding seams, the relative movement of the welding gun and the welding seam trajectory is required to complete the welding requirements. Welding gun movement can be selected, and workpiece movement can also be selected. This needs to decide the design idea according to the shape and size of the workpiece. The design principle is that the mechanism is the simplest, the control is the simplest, and the workers are most convenient to load and unload the workpieces. As shown in the figure, the girth welding machine moves the workpiece and the welding gun does not move. Straight seam welding machine does not move the workpiece, the welding gun moves linearly.
Electrical System
The electrical control system mainly controls the clamping and positioning of the fixture, the start and stop of the welding machine, the movement of the welding gun or the workpiece, the entry and exit of the conveying device, etc. As shown on the right, including automatic / manual conversion, whether or not to control the arc, adjustment and display of welding speed, welding power switch and emergency stop switch, etc.
The electrical control system is generally controlled by relays, PLC programmable controllers, microcontrollers, numerical control systems, and computers. At the welding production site, due to many welding spatters, complicated water and electrical circuits, and large electromagnetic interference, the most commonly used relays, PLCs, and numerical control systems are used. And because PLC takes into account the function of the relay, it can realize programming control. With the development of technology and the emergence of new products, the current PLC can also achieve more complex functions, such as some CNC functions, such as circular interpolation. Therefore, PLC control technology has been most widely used in automatic welding machine.
Editor's summary: Through the above introduction, everyone should have some understanding of the automatic welding machine. It should be understood that there are more than one control and drive forms for the automatic welding machine, that is, different models of products have different performances. The editor recommends that you study more when you buy, especially its instruction manual. It is best to install and debug after purchase.
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