A cutting and welding robot system for stainless steel tanks

Abstract

The application discloses a cutting and welding robot system for a stainless steel tank body, which comprises an industrial robot arranged on a rotating platform and controlled by a control system, a quick-change joint arranged at the end of the mechanical arm of the industrial robot, a plasma cutting head, an electric polishing head and a welding gun arranged on the rotating platform, a lifting platform arranged at the central position of the rotating platform, a clamping device arranged on the lifting platform and used for clamping the lower end cover of the stainless steel tank body and a laser ranging sensor, the plasma cutting head, the electric polishing head and the welding gun are respectively connected with the control system circuit and work step by step after being clamped by the quick-change joint, the rotating platform and the lifting platform are respectively connected with the control system circuit and are respectively controlled to move, rotate, lift and clamp by the control system, and the industrial robot is driven by the rotating platform controlled by the control system to rotate around the stainless steel tank body, so that the cutting and welding robot system has high automation degree and reliable performance.

Description

Technical Field

[0001] This invention relates to an automatically controlled cutting and welding device, and in particular discloses a cutting and welding robot system for stainless steel tanks, which is especially suitable for cutting and welding sponge titanium reaction tanks in the production of sponge titanium. Background Technology

[0002] Currently, in the production of sponge titanium, after the sponge titanium in the stainless steel reaction tank cools, it needs to be lifted and adjusted to the operating position by a crane. The lower end cap of the reaction tank is then manually cut and separated from the upper tank body. A pusher from the ejector then extends into the reaction tank through the cut bottom opening to eject the sponge titanium ingot. After this, the lower end cap and the bottom opening of the tank body must be realigned and manually welded for the next use of the reaction tank. This process is repeated periodically. During the sponge titanium production process, the stainless steel reaction tank requires periodic manual cutting and welding. The manual cutting and welding operations have high technical requirements. It is necessary to avoid sparks igniting the titanium powder and causing an explosion, and to prevent impurities such as iron from being mixed into the titanium ingot due to manual cutting. This not only seriously affects the product quality and equipment safety of the sponge titanium production line, but also results in extremely high labor intensity for on-site workers and low production efficiency. Summary of the Invention

[0003] The purpose of this invention is to overcome the shortcomings of existing technologies and design a robotic system for cutting and welding stainless steel tanks. This system utilizes an industrial robot that uses a quick-change connector to hold a plasma cutting head for cutting, a power grinding head for grinding, and simultaneously works with a negative pressure vacuum cleaner for dust removal. It also holds a welding torch for welding. This system enables automated plasma cutting, grinding, and welding of the stainless steel tank body of the reaction vessel during the production of sponge titanium. It offers high processing precision, reliable performance, and improved efficiency in sponge titanium production.

[0004] This invention is implemented as follows: a robot system for cutting and welding stainless steel tanks, characterized in that it includes an industrial robot mounted on a rotating platform and controlled by a control system; a quick-change clamping connector mounted at the end of the robot's robotic arm; a plasma cutting head, an electric grinding head, and a welding torch mounted on the rotating platform; a lifting platform positioned at the center of the rotating platform; and a clamping device and a laser rangefinder mounted on the lifting platform. The plasma cutting head, electric grinding head, and welding torch are all connected to the control system circuit and are clamped step-by-step by the quick-change connector at the end of the robot's robotic arm. The rotating platform and the lifting platform are connected to the control system circuit and are respectively controlled by the control system to perform movement, positioning, rotation, lifting, and clamping operations. The industrial robot is driven by the rotating platform controlled by the control system to rotate around the stainless steel tank.

[0005] The plasma cutting head, electric grinding head, and welding torch are all placed at designated positions on the quick-change frame mounted on the rotating platform. The robotic arm of the industrial robot is also equipped with a vacuum pipe for a negative pressure vacuum cleaner. The negative pressure vacuum cleaner is mounted on the rotating platform and connected to the control system circuit. The suction port of the vacuum pipe is close to, but not in contact with, the end of the grinding head after the quick-change connector clamps the grinding head, and is used to suck away the dust from the grinding process.

[0006] The industrial robot is mounted on a rotating disk of a rotating platform. A slider is mounted on the bottom surface of a fixed disk below the rotating platform. The slider is mounted on a slide rail and slidably connected to the slide rail. The rotating platform drives the industrial robot to slide along the slide rail to the corresponding work position. The rotating disk is driven by a motor controlled by the control system and rotates within the rotating track of the rotating platform. The rotating platform is also equipped with a traction mechanism that controls the movement of the rotating platform through the control system.

[0007] The lifting platform is a hydraulic lifting platform, and the clamping device on the top surface of the lifting platform for holding the lower end cover of the stainless steel tank adopts an elastic centering clamping mechanism. The stainless steel tank for sponge titanium production is fixed on the tank support. When cutting is required, the control system controls the rotating platform traction mechanism. The slider of the rotating platform moves on the slide rail until it drives the industrial robot to move and position itself at the bottom of the stainless steel tank at the corresponding workstation. Then, the control system continues to control the lifting platform to rise, and the clamping device on the top surface of the lifting platform clamps the lower end cover of the stainless steel tank, preventing the bottom of the tank from moving during automated cutting and affecting the cutting quality. The bottom of the lifting platform is also equipped with a horizontal sliding track layer and a vertical sliding track layer for adjusting the alignment of the upper and lower parts of the stainless steel tank during welding.

[0008] The control system is equipped with an alarm module that automatically alarms when the distance from the clamping device upwards to the lower outer surface of the tank body does not meet the required height range for the safe cutting zone. Based on the current dimensions of stainless steel tanks used in sponge titanium production, the cut width during the cutting process needs to be set to 5mm, and the safe cutting zone height needs to be determined beforehand. l The distance is 250mm. The control system determines the safe cutting distance as L-250mm based on the distance L from the top surface of the clamping device to the bottom outer surface of the tank body measured by the laser range sensor. If L-250≥0, it meets the requirements of the safe cutting area height range. The control system controls the industrial robot to clamp the plasma cutting head for automatic cutting. If the value L-250<0 measured by the laser range sensor, it does not meet the requirements of the safe cutting area height range.

[0009] The industrial robot is an ABB (China) Co., Ltd. IRB 4600 modular industrial robot, the control system is an ABB (China) Co., Ltd. IRC5 controller, the plasma cutting head is a Victor UC200 plasma cutting head from Victor Technology Group of the United States, the electric grinding head is a DL681002B grinding head from Deli Group Co., Ltd., and the welding torch is a Fronius TPS5000 welding torch from Fronius Welding Technology International Ltd. of Austria.

[0010] To facilitate the alignment of the tank body and the lower end cover during welding, positioning blocks are manually marked at corresponding positions on the tank body and the lower end cover before cutting begins. This allows for quick alignment and positioning when the tank body is repositioned for welding after the sponge titanium ingot is removed.

[0011] The beneficial effects of this invention are: This invention is used for the automatic cutting and welding of stainless steel tanks, and is especially suitable for the repeated cutting and welding of reaction tanks in the production of sponge titanium. After each batch production cycle is completed, the industrial robot automatically cuts the lower end cover off the stainless steel tank. After the sponge titanium ingot is ejected from the reaction tank, the lower end cover is automatically welded to the stainless steel tank. The cutting and welding processes are carried out autonomously through visual image recognition, with a high degree of automation. This achieves high efficiency, high precision, and high reliability in the production process of sponge titanium, improves the quality of sponge titanium products, and reduces the labor intensity of workers. Attached Figure Description

[0012] Figure 1 This is a simplified schematic diagram of the overall layout of the main components of the robot system of the present invention.

[0013] Figure 2 This is a simplified schematic diagram illustrating the method for determining the height range of the safe cutting area as described in this invention.

[0014] In the diagram: 1. Industrial robot; 2. Rotary platform; 3. Lifting platform; 4. Clamping device; 5. Tank body; 6. Quick-change connector; 7. Slider; 8. Track; 9. Laser rangefinder sensor; l、 The height of the safe cutting zone; L, the distance from the top surface of the clamping device to the bottom outer surface of the tank body. Detailed Implementation

[0015] The present invention will be further described below with reference to the accompanying drawings and specific embodiments.

[0016] According to the appendix Figure 1This invention relates to a robot system for cutting and welding stainless steel tanks, comprising an industrial robot 1 mounted on a rotating platform 2 and controlled by a control system, a quick-connect clamping connector 6 at the end of the robotic arm of the industrial robot 1, a plasma cutting head, an electric grinding head, and a welding torch mounted on the rotating platform 2, a lifting platform 3 located at the center of the rotating platform 2, a clamping device 4 mounted on the lifting platform 3, and a laser rangefinder 9. The plasma cutting head, electric grinding head, welding torch, and laser rangefinder 9 are all connected to the control system circuit. The rotating platform 2 and the lifting platform 3 are also connected to the control system circuit, and the control system controls their respective movement, positioning, rotation, lifting, and clamping operations.

[0017] To facilitate rapid clamping by the robotic arm of industrial robot 1 via quick-change connector 6, the plasma cutting head, electric grinding head, and welding torch are all placed at designated positions on the quick-change frame, which is mounted on the rotating platform 2. The robotic arm of industrial robot 1 is also equipped with a vacuum cleaner's suction pipe at its end. The vacuum cleaner is mounted on the rotating platform 2 and connected to the control system circuit. For effective vacuuming, the suction port of the suction pipe is positioned as close as possible to the end of the grinding head after it is clamped by the quick-change connector, but not in contact with it.

[0018] The industrial robot in question is an ABB (China) Co., Ltd. IRB 4600 modular industrial robot, and the control system is an ABB (China) Co., Ltd. IRC5 controller.

[0019] The plasma cutting head is the Victor UC200 plasma cutting head from Victor Technology Group of the United States, the electric grinding head is the DL681002B grinding head from Deli Group Co., Ltd., and the welding torch is the Fronius TPS5000 welding torch from Fronius Welding Technology International Ltd. of Austria.

[0020] The industrial robot 1 is mounted on a rotating disk of a rotating platform 2. A slider 7 is mounted on the bottom surface of a fixed disk beneath the rotating platform 2. The slider 7 is mounted on and slidably connected to a slide rail 8. The industrial robot 1 is driven by the rotating platform 2 to slide along the slide rail 8 to the corresponding workstation. The rotating disk is driven by a motor controlled by a control system, rotating within the rotating track of the rotating platform 2. The rotating platform 2 is also equipped with a traction mechanism whose movement is controlled by a control system.

[0021] The stainless steel tank for sponge titanium production is fixed on a tank support. The lifting platform 3, located in the middle of the rotating platform 2, is a hydraulic lifting platform. The clamping device 4 on the top surface of the lifting platform 3 is used to clamp the lower end cover of the stainless steel tank. The clamping device 4 is an elastic centering clamping mechanism. The bottom of the lifting platform is also equipped with a horizontal sliding track layer and a vertical sliding track layer for aligning and adjusting the upper and lower parts of the stainless steel tank during welding.

[0022] The specific working process of this invention is as follows:

[0023] When cutting is required, the control system controls the traction mechanism of the rotating platform 2. The slider 7 of the rotating platform 2 moves on the slide rail 8 until it drives the industrial robot 1 to move and position to the bottom of the stainless steel tank at the corresponding work station. Then the control system continues to control the lifting platform 3 to rise. The clamping device 4 set on the top surface of the lifting platform 3 clamps the lower end cover of the stainless steel tank to prevent the bottom of the reaction tank from moving during the automated cutting process and affecting the cutting quality.

[0024] Before automatic cutting, based on the current size of the stainless steel tanks used in sponge titanium production, it is necessary to first set the kerf width to 5mm and the safe cutting zone height during the cutting process. l The distance is 250mm. The control system determines the safe cutting distance as L-250mm based on the distance L from the top surface of the clamping device to the outer surface of the bottom of the tank body measured by the laser range sensor 9. If L-250≥0, it meets the requirements of the safe cutting area height range. The control system controls the industrial robot to clamp the plasma cutting head for automatic cutting. If the value L-250<0 measured by the laser range sensor 9 does not meet the requirements of the safe cutting area height range, the alarm module of the control system will automatically alarm and stop operation until the stainless steel tank is replaced by manual confirmation. The alarm module of the control system will then deactivate.

[0025] Once the cutting process begins and the height of the safe cutting zone is determined to be within the required range, the control system first controls the quick-connect connector 6 on the robotic arm of industrial robot 1 to clamp the plasma cutting head and align it within the safe cutting zone height range to begin automatic cutting. Simultaneously, the control system controls the rotating platform 2 to rotate industrial robot 1 360° around the stainless steel tank, separating the lower end cover from the upper tank body 5. After cutting, the control system continues to control the rotating platform 2 to rotate industrial robot 1 around the stainless steel tank, automatically creating welding bevels at the two cut points on the upper tank body and the lower end cover using the plasma cutting head.

[0026] To avoid contaminating the titanium sponge ingots in the reaction vessel with metal dust generated during subsequent grinding of the cut edges, the ingots need to be ejected from the vessel first by an ejector before being automatically ground by an industrial robot. Therefore, after the cutting is completed, a crane lifts the main body 5 of the reaction vessel to the ejector station. The ejector's push rod extends into the reaction vessel from the cut at the bottom of the main body 5, pushing the titanium sponge ingot out. The crane then moves the main body 5 back to the cutting and welding station where the industrial robot is located. Next, the control system controls the quick-change connector 6 on the robotic arm of the industrial robot 1 to return the plasma cutting head to its original position, replacing it with a clamping electric grinding head. The electric grinding head is then aligned with the previous cut edge. The control system controls the rotating platform 2 to drive the industrial robot 1 to rotate 360° around the stainless steel vessel, automatically grinding the two cut edges of the upper main body and the lower end cap in stages.

[0027] During the process of grinding the weld bevel surface and surrounding area at the two cuts with an electric grinding head, no manual intervention is allowed. The entire process is controlled by the control system. A special electric grinding head is used to grind until the weld bevel surface and bevel edge (i.e. the perimeter of the weld after welding) have a metallic luster, and all oxides on the bevel surface are completely removed.

[0028] The grinding wheel of the electric grinding head is driven by an electric spindle, rotating at extremely high speeds. It generates very little heat on the workpiece while achieving very high efficiency and reliable grinding results. For grinding the surface and edges of weld bevels, it can achieve milling-like machining effects, laying a solid foundation for subsequent welding processes. Simultaneously with the grinding operation, the control system activates a negative pressure vacuum cleaner. The suction pipe generates suction, drawing away the grinding dust from the suction port.

[0029] Finally, welding is performed. Before welding, the inside and outside of the stainless steel tank must be manually cleaned. Then, the control system controls the lifting platform 3 to rise and fall into place. The clamping device 4 at the top assembles the tank body 5 and the lower end cover together. Based on the values ​​measured and fed back by the laser rangefinder 9, the control system controls the rotating platform 2 to adjust its height and position until the welding height and alignment requirements are met, ensuring a certain gap between the tank body 5 and the lower end cover, and that the misalignment meets the design and process requirements. The quick-change connector 6 on the robotic arm of the industrial robot 1 returns the electric grinding head to its original position, replaces it with a welding torch, and aligns the tip of the welding torch with the safe cutting area. The control system controls the rotating platform 2 to drive the industrial robot 1 to rotate 360° around the stainless steel tank to begin automatic welding. Automatic welding is not allowed to have defects such as cracks, porosity, or slag inclusions. During the welding process, the control system automatically controls the heat input, welding arc length, interpass temperature, and welding sequence.

[0030] To facilitate the alignment of the tank body 5 and the lower end cover during welding, positioning blocks are manually marked at corresponding positions on the tank body 5 and the lower end cover before cutting begins. This allows for quick alignment and positioning of the tank body 5 when it is repositioned for welding after the sponge titanium ingot is removed.

[0031] After welding is completed, the weld seam must undergo 100% penetrant testing and 100% ultrasonic testing, performed according to national standards. Once the weld seam of the reaction vessel passes inspection, the vessel can be put back into the sponge titanium production process.

[0032] This invention employs an industrial robot to automatically cut plasma cutting heads by clamping them with quick-change connectors, automatically grind electric grinding heads while simultaneously removing dust with a negative pressure vacuum cleaner, and automatically weld welding guns. The operation process is highly automated, reducing the labor intensity of workers and achieving high efficiency, high precision, and high reliability, while also improving the quality of sponge titanium products.

Claims

1. A robotic system for cutting and welding stainless steel tanks, characterized in that: The system includes an industrial robot mounted on a rotating platform and controlled by a control system; a quick-change clamping connector at the end of the robot's robotic arm; a plasma cutting head, an electric grinding head, and a welding torch mounted on the rotating platform; a lifting platform at the center of the rotating platform; and a clamping device and a laser rangefinder sensor mounted on the lifting platform. The plasma cutting head, electric grinding head, and welding torch are all connected to the control system circuit and are clamped step-by-step by the quick-change connector at the end of the robot's robotic arm. The rotating platform and lifting platform are also connected to the control system circuit, and the control system controls their respective movement, positioning, rotation, lifting, and clamping operations. The industrial robot rotates around a stainless steel tank, driven by the rotating platform controlled by the control system. The industrial robot is mounted on a rotating disk of a rotating platform. A slider is mounted on the bottom surface of a fixed disk below the rotating platform. The slider is mounted on a slide rail and slidably connected to the slide rail. The rotating platform drives the industrial robot to slide along the slide rail to the corresponding workstation. The rotating disk is driven by a motor controlled by the control system and rotates within the rotating track of the rotating platform. The rotating platform is also equipped with a traction mechanism that controls the movement of the rotating platform through the control system. The lifting platform is a hydraulic lifting platform. The clamping device on the top surface of the lifting platform for holding the lower end cover of the stainless steel tank adopts an elastic centering clamping mechanism. The bottom of the lifting platform is also equipped with a horizontal sliding track layer and a vertical sliding track layer for aligning and adjusting the position of the upper and lower parts of the stainless steel tank during welding.

2. The robotic system for cutting and welding stainless steel tanks according to claim 1, characterized in that: The plasma cutting head, electric grinding head, and welding torch are all placed at designated positions on the quick-change frame mounted on the rotating platform. The robotic arm of the industrial robot is also equipped with a vacuum pipe for a negative pressure vacuum cleaner. The negative pressure vacuum cleaner is mounted on the rotating platform and connected to the control system circuit. The suction port of the vacuum pipe is close to the end of the grinding head after the quick-change connector clamps the grinding head, and is used to suck away the dust from the grinding process.

3. The robotic system for cutting and welding stainless steel tanks according to claim 1, characterized in that: The control system is equipped with an alarm module that automatically alarms when the distance from the clamping device upwards to the outer surface of the bottom of the tank body does not meet the height requirements of the safe cutting zone.

4. The robotic system for cutting and welding stainless steel tanks according to claim 1, characterized in that: The industrial robot is an ABB (China) Co., Ltd. IRB 4600 modular industrial robot, the control system is an ABB (China) Co., Ltd. IRC5 controller, the plasma cutting head is a Victor UC200 plasma cutting head from Victor Technology Group of the United States, the electric grinding head is a DL681002B grinding head from Deli Group Co., Ltd., and the welding torch is a Fronius TPS5000 welding torch from Fronius Welding Technology International Ltd. of Austria.

5. The robotic system for cutting and welding stainless steel tanks according to claim 1, characterized in that: Positioning block marks are provided at corresponding positions on the main body of the stainless steel tank and the lower end cover.

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