Electric locomotive frame manufacturing line

Abstract

This disclosure provides a production line for manufacturing electric locomotive frames, relating to the field of electric locomotive frame manufacturing technology. The production line includes a single-beam manufacturing unit, a frame manufacturing unit, a transfer machine, and a centralized control system. The single-beam manufacturing unit includes adjacent small beam welding workstations and side beam welding workstations, with an automatic welding unit for external beam welds located on one side of each workstation. The frame manufacturing unit includes adjacent frame assembly workstations and frame welding workstations, with a frame small component testing and welding manufacturing unit located on one side of each welding workstation. The centralized control system controls the welding production of electric locomotive frames on the electric locomotive frame manufacturing production line. According to embodiments of this disclosure, automated welding can be achieved through the cooperation of various automated devices, improving the automation rate of the electric locomotive frame welding manufacturing process.

Description

Technical Field

[0001] This disclosure relates to the field of electric locomotive frame manufacturing technology, and in particular to an electric locomotive frame manufacturing production line. Background Technology

[0002] Currently, many domestic and international companies have moved automated welding production lines from the experimental stage to the practical application stage, and there are already mature application examples of automated welding production lines for subway structures in the industry. However, due to the characteristics of locomotive structures—long length, heavy weight, and complex structure—there is currently no automated welding production line for locomotive structures, resulting in a high degree of manual intervention in the manufacturing process of electric locomotive structures.

[0003] It should be noted that the information disclosed in the background section above is only used to enhance the understanding of the background of this disclosure, and therefore may include information that does not constitute prior art known to those skilled in the art. Summary of the Invention

[0004] This disclosure provides a production line and method for manufacturing electric locomotive frames, which at least to some extent improves the automation rate of the welding manufacturing process of electric locomotive frames.

[0005] Other features and advantages of this disclosure will become apparent from the following detailed description, or may be learned in part from practice of this disclosure.

[0006] According to one aspect of this disclosure, an electric locomotive frame manufacturing production line is provided, including a single beam manufacturing unit, a frame manufacturing unit, a transfer machine, and a centralized control system;

[0007] The single beam manufacturing unit includes a small beam welding workstation and a side beam welding workstation arranged adjacent to each other. An automatic welding unit for the external weld seams of the beam is also set on one side of the small beam welding workstation and the side beam welding workstation.

[0008] The frame manufacturing unit includes a frame assembly workstation and a frame welding workstation arranged adjacent to each other. A frame small parts testing and welding manufacturing unit is also set up on one side of the frame welding workstation.

[0009] The centralized control system is used to control the electric locomotive frame manufacturing production line to perform the following steps:

[0010] The control transfer machine transports the small beam plate to the small beam assembly welding station. The small beam assembly welding station and the automatic welding unit for the external weld of the beam workpiece work together to weld the small beam plate to obtain the small beam.

[0011] The control transfer machine transports the side beam plates to the side beam assembly welding station. The side beam assembly welding station and the automatic welding unit for the external welds of the beam workpiece work together to weld the side beam plates to obtain the side beam.

[0012] The small beams and side beams are transported to the frame assembly workstation, where the small beams and side beams are assembled to obtain the initial frame.

[0013] The initial frame is welded sequentially through the frame welding workstation and the frame component assembly and welding manufacturing unit to obtain the electric locomotive frame.

[0014] In one embodiment of this disclosure, the beam welding workstation includes:

[0015] A single-beam raw material plate assembly buffer platform is used to place small beam plates;

[0016] The single-beam internal seam robot assembly welding workstation is adjacent to the single-beam raw material plate assembly buffer station and is used to assemble and weld the small beam plates.

[0017] The single-beam internal seam robotic welding workstation, adjacent to the single-beam internal seam robotic assembly welding workstation, is used to continue welding the small beam plates after the assembly welding.

[0018] A single-beam small-part robot assembly welding workstation is used to weld small parts onto small beams that have already been welded by a single-beam internal seam robot welding workstation.

[0019] Single-beam intelligent automated warehouse;

[0020] Single beam adjustment and inspection station;

[0021] Single beam internal weld seam cleaning, grinding, inspection, and handover station;

[0022] Single beam external weld seam cleaning, grinding, inspection, and handover station;

[0023] Single-beam automated warehouse transfer station;

[0024] Robotic polishing station;

[0025] A transfer machine is used to move welded workpieces between different workstations.

[0026] In one embodiment of this disclosure, the side beam welding workstation includes:

[0027] The side beam robot assembly and welding workstation is used to assemble and weld side beam plates.

[0028] The side beam inner seam robotic welding workstation, adjacent to the side beam assembly welding workstation, is used to weld the inner seam of the side beam plates after assembly welding.

[0029] The side beam external small parts robot assembly welding workstation is used to weld small parts of the side beam after the side beam internal seam robot welding workstation has welded them.

[0030] Side beam automated warehouse transfer station;

[0031] Side beam intelligent automated warehouse;

[0032] The side beam outer seam robotic welding workstation is used to continue welding the outer seam after the previous welding process;

[0033] Manual assembly and spot welding station for the side beam lower cover plate component;

[0034] The side beam internal weld seam cleaning, grinding, inspection, and handover station;

[0035] The manual assembly and spot welding station for the side beam upper cover plate component;

[0036] The side beam external weld seam cleaning, grinding, inspection, and handover station;

[0037] Side beam adjustment and inspection station.

[0038] In one embodiment of this disclosure, the automatic welding unit for the external welds of the beam includes multiple external weld robots; the external weld robots are used to complete the welding of the external welds of each single beam after the AGV assembles the welding workpiece into the C-type positioner.

[0039] In one embodiment of this disclosure, the single-beam manufacturing unit further includes an intelligent automated warehouse stacker crane system and a manual manufacturing unit, which is used to meet production requirements in case of automated production line failure.

[0040] In one embodiment of this disclosure, the intelligent automated warehouse stacker crane system includes a combined steel structure racking system, a rail-guided aisle stacker crane system, and a backpack AGV conveyor system.

[0041] In one embodiment of this disclosure, the hand-manufacturing unit includes a truss structure and a positioner.

[0042] In one embodiment of this disclosure, the frame assembly workstation is a truss structure, including a side beam transfer machine transfer station, a small beam transfer machine transfer station, a frame transfer machine transfer station, a KBK crane, and a frame transfer machine transfer station.

[0043] In one embodiment of this disclosure, the frame welding workstation includes a lifting positioner, a ceiling rail side gantry, and multiple welding robots.

[0044] In one embodiment of this disclosure, the frame component assembly and welding manufacturing unit includes a welding overhead gantry, an assembly welding overhead gantry, a handling robot, and multiple welding robots.

[0045] According to another aspect of this disclosure, a method for manufacturing an electric locomotive frame is provided, applied to the aforementioned electric locomotive frame manufacturing production line, the method comprising:

[0046] The control transfer machine transports the small beam plate to the small beam assembly welding station. The small beam assembly welding station and the automatic welding unit for the external weld of the beam workpiece work together to weld the small beam plate to obtain the small beam.

[0047] The control transfer machine transports the side beam plates to the side beam assembly welding station. The side beam assembly welding station and the automatic welding unit for the external welds of the beam workpiece work together to weld the side beam plates to obtain the side beam.

[0048] The small beams and side beams are transported to the frame assembly workstation, where the small beams and side beams are assembled to obtain the initial frame.

[0049] The initial frame is welded sequentially through the frame welding workstation and the frame component assembly and welding manufacturing unit to obtain the electric locomotive frame.

[0050] The electric locomotive frame manufacturing production line provided in this embodiment includes a centralized control system that controls a transfer machine to transport small beam plates to a small beam welding workstation. The small beam welding workstation and an automatic welding unit for external beam welds cooperate to weld the small beam plates to obtain small beams. The control system also controls a transfer machine to transport side beam plates to a side beam welding workstation, where the side beam welding workstation and an automatic welding unit for external beam welds cooperate to weld the side beam plates to obtain side beams. The small beams and side beams are then transported to a frame assembly workstation, where they are assembled to obtain an initial frame. Finally, the initial frame is sequentially welded through a frame welding workstation and a frame component assembly and welding manufacturing unit to obtain the electric locomotive frame. This disclosure achieves automated welding in the production process by utilizing the cooperation between various automated devices, thereby improving the automation rate of the electric locomotive frame welding manufacturing process.

[0051] It should be understood that the above general description and the following detailed description are exemplary and explanatory only, and are not intended to limit this disclosure. Attached Figure Description

[0052] The accompanying drawings, which are incorporated in and form a part of this specification, illustrate embodiments consistent with this disclosure and, together with the description, serve to explain the principles of this disclosure.

[0053] Obviously, the accompanying drawings described below are merely some embodiments of this disclosure. Those skilled in the art can obtain other drawings based on these drawings without any creative effort.

[0054] Figure 1 This diagram illustrates a single-beam manufacturing unit according to an embodiment of the present disclosure;

[0055] Figure 2 This diagram illustrates a framework manufacturing unit according to an embodiment of the present disclosure;

[0056] Figure 3 This diagram illustrates a small beam welding workstation according to an embodiment of the present disclosure;

[0057] Figure 4This diagram shows a side beam welding workstation according to an embodiment of the present disclosure;

[0058] Figure 5 This diagram illustrates a frame assembly welding production line according to an embodiment of the present disclosure;

[0059] Figure 6 This diagram illustrates a frame docking and connection seam welding station according to an embodiment of the present disclosure;

[0060] Figure 7 This diagram illustrates a small component testing and welding station according to an embodiment of the present disclosure.

[0061] Figure 8 A flowchart illustrating a method for manufacturing an electric locomotive frame according to an embodiment of this disclosure is shown. Detailed Implementation

[0062] The exemplary implementation will now be described more fully with reference to the accompanying drawings.

[0063] It should be noted that the example implementation can be implemented in many forms and should not be construed as being limited to the examples set forth herein.

[0064] In recent years, with the continuous development of the manufacturing industry towards automation and intelligence, and the continuous progress of various welding technologies, the flexibility, automation, and intelligence of welding have become increasingly higher. Welding automation, with robots at its core, has become one of the main production methods in the contemporary welding manufacturing industry. To adapt to market development, improve welding quality, and ultimately achieve intelligent production, this has become an industry trend.

[0065] Currently, many domestic and international companies have moved automated welding production lines from the experimental stage to the practical application stage, and there are already mature application examples of automated welding production lines for subway structures within the industry. However, due to the characteristics of locomotive structures—long length, heavy weight, and complex structure—automated welding production lines for them are still in the research stage. Therefore, the research on fully automated welding production lines for locomotive structures aims to achieve automated welding of locomotive structures, ultimately improving production efficiency, ensuring weld quality, and reducing maintenance costs.

[0066] The manufacturing process of electric locomotive frames involves a high degree of manual intervention. Due to the weight and size of the electric locomotive frames themselves, automated loading and unloading present challenges, placing significant demands on the load-bearing capacity of the supporting process equipment. Currently, material handling using line-side racks and AGVs is commonly employed, but this method has the following drawbacks: 1. It requires a large surface area; 2. It demands a high rate of material delivery. Another method involves manual assembly followed by robotic welding, but this suffers from low automation and potential safety hazards for personnel.

[0067] To address the issues of high manual involvement and low automation in the manufacturing process of electric locomotive frame products, this disclosure provides an electric locomotive frame manufacturing production line. Taking into account the characteristics of the electric locomotive frame itself being heavy and large, this line utilizes advanced automated logistics and transportation tools such as KBK, gantry robots, welding robots, RGV, and AGV to achieve automated welding in the production process through the cooperation between various automated equipment, thus completing the production line layout design for automated production of electric locomotives.

[0068] The following detailed description of this exemplary implementation method is provided in conjunction with the accompanying drawings and embodiments.

[0069] An embodiment of the present disclosure provides an electric locomotive frame manufacturing production line, including a single beam manufacturing unit, a frame manufacturing unit, a transfer machine, and a centralized control system.

[0070] Figure 1 A single-beam manufacturing unit is shown, such as Figure 1 As shown, the single beam manufacturing unit includes a small beam welding workstation 101 and a side beam welding workstation 102 arranged adjacent to each other. An automatic welding unit 103 for the external weld seams of the beam is also provided on one side of the small beam welding workstation and the side beam welding workstation.

[0071] In some embodiments, the beam welding workstation 101 may include Figure 1 The layout, from left to right, includes a small beam component welding station, a small beam inner seam welding station, and a small beam assembly welding station. A manual small beam area can also be located next to the small beam assembly welding workstation 101. Figure 1 Below the small and medium beam welding workstation 101.

[0072] Figure 2 An example of a structural manufacturing unit is shown, such as Figure 2 As shown, the frame manufacturing unit includes a frame assembly workstation 201 and a frame welding workstation 202 arranged adjacent to each other. A frame component testing and welding manufacturing unit 203 is also provided on one side of the frame welding workstation. The frame welding workstation 202 may include a frame three-axis welding positioner, a frame connection seam welding station, and a frame butt joint welding station. The frame component testing and welding manufacturing unit 203 may include a primary testing and welding station and a secondary testing and welding station for frame components.

[0073] The single beam manufacturing unit and the frame manufacturing unit form a lean logistics production line by connecting the upstream and downstream processes.

[0074] The centralized control system is used to control the electric locomotive frame manufacturing production line to perform the following steps: The system controls a transfer machine to transport the small beam plates to the small beam welding workstation, where the small beam welding workstation and the automatic welding unit for external welds of the beam body cooperate to weld the small beam plates to obtain small beams; the system controls a transfer machine to transport the side beam plates to the side beam welding workstation, where the side beam welding workstation and the automatic welding unit for external welds of the beam body cooperate to weld the side beam plates to obtain side beams; the small beams and side beams are transported to the frame assembly workstation, where the frame assembly workstation assembles the small beams and side beams to obtain the initial frame; the initial frame is then sequentially welded through the frame welding workstation and the frame component testing and welding manufacturing unit to obtain the electric locomotive frame.

[0075] This disclosure improves the automation rate of the welding manufacturing process for electric locomotive frames by utilizing the cooperation between various automated devices to achieve automated welding in the production process.

[0076] In this embodiment of the disclosure, taking into account the current production situation, the design principle of the automated production line for electric locomotive frames is as follows: the manufacturing process of each individual beam and frame of the electric locomotive frame follows the principle of lean production. By rationally arranging each production unit and designing an automated logistics method, automated transportation of electric locomotive materials, automated assembly and welding of each beam, and storage of work-in-process are achieved. Advanced logistics and in-line storage methods are fully utilized to construct an intelligent automated warehouse, realizing automated material retrieval and storage.

[0077] This disclosure achieves breakthroughs in six key technologies: layout, cycle time, workstations, process flow simulation optimization design of locomotive frame welding production line; automatic positioning and assembly process and tooling design of locomotive frames and their components; efficient adaptive intelligent welding of locomotive frame robots; design of intelligent IoT-based logistics system for frame components; design of online sensing and control information system for welding process; and integration and application verification of automated welding production line for locomotive frames. A complete automated production line for locomotive frames is developed, including hardware such as "intelligent material conveying for locomotive frames," "intelligent identification, positioning, and robot gripping equipment for locomotive frame component materials," "intelligent assembly unit equipment for locomotive frames," "intelligent robot welding system unit equipment," and "process control system"; and software programs such as "intelligent identification and retrieval of locomotive frame material plates," "production line logistics system control," "robot adaptive welding software system," "online real-time dynamic sensing and intelligent quality evaluation software system for welding process parameters," and "simulation system for locomotive frame arc welding production line and welding process simulator." Develop and verify typical locomotive frame prototypes, establish flexible intelligent welding process specifications and process-quality relationship databases for locomotive frames, and realize the engineering application of technological achievements such as process, equipment, control, digitalization, and intelligence in electric locomotive frame products.

[0078] In some embodiments, the small beam welding workstation includes a single beam raw material plate assembly buffer table, a single beam inner seam robot assembly welding workstation, a single beam inner seam robot welding workstation, a single beam small part robot assembly welding workstation, a single beam intelligent automated warehouse, a single beam adjustment and inspection station, a single beam inner weld cleaning, grinding, inspection and inspection station, a single beam outer weld cleaning, grinding, inspection and inspection station, a single beam automated warehouse transfer station, a robot grinding station, and a transfer machine.

[0079] A single-beam raw material plate assembly buffer platform is used to place small beam plates.

[0080] The single-beam internal seam robotic assembly and welding workstation, adjacent to the single-beam raw material plate assembly and buffer station, is used to assemble and weld small beam plates.

[0081] The single-beam internal seam robotic welding workstation, adjacent to the single-beam internal seam robotic assembly welding workstation, is used to continue welding the small beam plates after the assembly welding.

[0082] The single-beam small-part robot assembly welding workstation is used to weld small parts onto small beams that have already been welded by the single-beam internal seam robot welding workstation.

[0083] A transfer machine is used to move welded workpieces between different workstations.

[0084] In some embodiments, such as Figure 3 As shown, the main components of one small beam welding workstation include: one single beam raw material plate assembly buffer table; one single beam internal seam robot assembly welding workstation; two single beam internal seam robot welding workstations; one intelligent automated warehouse; one single beam small part robot assembly welding workstation; one single beam adjustment and inspection station; one single beam adjustment and inspection station; two single beam internal weld seam cleaning, grinding, inspection, and inspection stations; two single beam external weld seam cleaning, grinding, inspection, and inspection stations; one single beam automated warehouse transfer station; one robot grinding station; and one transfer machine.

[0085] In some embodiments, the side beam assembly welding workstation includes a side beam robot assembly welding workstation, a side beam inner seam robot welding workstation, a side beam external small parts robot assembly welding workstation, a side beam automated warehouse transfer station, a side beam intelligent automated warehouse, a side beam outer seam robot welding workstation, a side beam lower cover plate component manual assembly spot welding station, a side beam inner weld cleaning, grinding, inspection and handover station, a side beam upper cover plate component manual assembly spot welding station, a side beam outer weld cleaning, grinding, inspection and handover station, and a side beam adjustment and handover station.

[0086] The side beam robot assembly and welding workstation is used to assemble and weld side beam plates.

[0087] The side beam inner seam robotic welding workstation, adjacent to the side beam assembly welding workstation, is used to weld the inner seam of the side beam plates after assembly welding.

[0088] The side beam external small parts robot assembly welding workstation is used to weld small parts of the side beam after the side beam internal seam robot welding workstation has welded them.

[0089] The side beam outer seam robotic welding workstation is used to continue welding the outer seam after the previous welding process.

[0090] In some embodiments, such as Figure 4 As shown, one set of side beam assembly welding workstation includes: 1 set of side beam robot assembly welding workstation; 2 sets of side beam inner seam robot welding workstation; 1 set of side beam external small parts robot assembly welding workstation; 1 set of side beam automated warehouse transfer station; 1 set of side beam intelligent automated warehouse; 3 sets of side beam outer seam robot welding workstation; 2 sets of side beam lower cover plate component manual assembly spot welding station; 2 sets of side beam inner weld cleaning, grinding, inspection and handover station; 2 sets of side beam upper cover plate component manual assembly spot welding station; 2 sets of side beam outer weld cleaning, grinding, inspection and handover station; and 2 sets of side beam adjustment and handover station.

[0091] In some embodiments, the automatic welding unit for external welds of the beam includes multiple external weld robots; the external weld robots are used to complete the welding of external welds of each single beam after the AGV assembles the workpiece to the C-type positioner.

[0092] In some embodiments, an automatic welding unit for external weld seams of a beam body mainly consists of 5 external weld robotic arms.

[0093] In some embodiments, the single-beam manufacturing unit further includes an intelligent automated storage and retrieval system stacker crane system and a manual manufacturing unit, which is used to meet production requirements in the event of a failure in the automated production line.

[0094] In some embodiments, the intelligent automated storage and retrieval system (AS / RS) stacker crane system includes a modular steel structure racking system, a rail-guided aisle stacker crane system, and a backpack AGV conveyor system.

[0095] In some embodiments, a stacker crane system includes a modular steel structure racking system, a rail-guided stacker crane system, a backpack AGV conveyor system, and a computer management and monitoring system. The computer management and monitoring system enables real-time monitoring of warehouse operations, displaying equipment operating status, location, and completion status, providing fault alarms, and transmitting arrival and departure documents via network. The computer monitoring and management system can be a subsystem of a centralized control system, with interfaces for information sharing to accommodate future expansion and development.

[0096] The management of goods entering and leaving the warehouse and the storage location are managed by computer, which can realize functions such as automated management of goods entering and leaving the warehouse, data maintenance, query, inventory analysis, and report printing.

[0097] In some embodiments, the manual manufacturing unit mainly consists of a truss structure, positioners, etc., to meet the production requirements when the automated production line fails.

[0098] In some embodiments, the frame assembly workstation is a truss structure, including a side beam transfer machine transfer station, a small beam transfer machine transfer station, a frame transfer machine transfer station, a KBK crane, and a frame transfer machine transfer station.

[0099] In some embodiments, the frame assembly workstation mainly consists of a truss structure to facilitate manual assembly. It includes a 10-ton KBK (Automatic Guided Vehicle); one side beam AGV transfer bay; one small beam AGV transfer bay; and one frame AGV transfer bay.

[0100] In some embodiments, the frame welding workstation includes a lifting positioner, a ceiling-mounted side gantry, and multiple welding robots.

[0101] In some embodiments, the frame welding workstation includes one lifting positioner with a tilting load capacity of 20T and a slewing load capacity of 10T. It also includes one overhead gantry with a maximum X-axis speed of 10m / min, a maximum Y-axis speed of 10m / min, and a maximum Z-axis speed of 5m / min; and a repeatability accuracy of ±0.2mm. Two welding robots are also included, each with a payload of 16kg and a reach of 1610mm.

[0102] In some embodiments, the frame component assembly and welding manufacturing unit includes a welding overhead gantry, an assembly welding overhead gantry, a handling robot, and multiple welding robots.

[0103] In some embodiments, the frame component assembly and welding manufacturing unit includes: one welding overhead gantry with a maximum X-axis speed of 10 m / min and a maximum Y-axis speed of 10 m / min; repeatability of ±0.2 mm; two welding robots with a payload of 16 kg and an arm span of 1610 mm; one assembly welding overhead gantry with a maximum X-axis speed of 10 m / min and a maximum Y-axis speed of 10 m / min; repeatability of ±0.2 mm; and one handling robot with a payload of 240 kg and an arm span of 2900 mm.

[0104] This production line is used for laser scanning measurement, virtual simulation and intelligent assembly, physical assembly, and automatic spot welding of structural components. Through the digital, automated, flexible, and intelligent design of the production line, the entire process from automatic frame measurement and intelligent assembly to automatic spot welding can be completed on a single production line, adaptable to the production of different product models. Simultaneously, through effective data accumulation and management, the design of the frame is improved and optimized, enhancing the enterprise's digital and intelligent product design and manufacturing capabilities. Main functions: laser scanning measurement of parts; data analysis and processing of part scanning data; virtual simulation and intelligent assembly calculation of the frame; flexible assembly of structural components; data-driven automatic spot welding of the frame; weld seam scanning and data output after spot welding of the frame.

[0105] This disclosure, based on a simulation model system, optimizes and reorganizes an intelligent welding production line for locomotive frames, proposing a solution to address production bottlenecks. The discrete nature of the intelligent welding production line for locomotive frames is analyzed, and simulation and optimization methods for discrete systems are studied. For the intelligent welding production line for locomotive frames, its production line elements are modeled, simulation optimization evaluation indicators for the intelligent welding production line are proposed, a mathematical model for the reorganization and optimization of the intelligent welding production line for locomotive frames is established, and the business process of the production line simulation is analyzed, with a specific implementation algorithm proposed. Based on the main characteristics of the intelligent welding production line for locomotive frames, models of processing equipment, workers, product transportation channels, and lifting equipment are established, and control methods connecting individual elements of the production line are studied.

[0106] The robot intelligent welding system of this embodiment is designed to consist of an arc welding robot, a fully digital CMT arc welding equipment, intelligent flexible tooling, a seam tracking system, a molten pool vision sensing system, and tooling fixtures. After automatic adjustment by the machine vision servo intelligent flexible tooling, the weld position is automatically aligned with the robot welding torch. Before welding, the robot welding torch trajectory, posture, and welding process specification parameters for each point of the weld are formed according to the intelligent welding process planning system. After the arc length adjuster and the molten pool vision sensing system are automatically activated, the robot automatically starts the welding program to realize automatic robot welding.

[0107] This disclosure discloses an intelligent welding production line for locomotive frames, which mainly includes an intelligent assembly system and an intelligent welding system. The machine vision-based automated assembly and fixing device design includes a machine vision system, a visual servo posture control system, a dedicated pneumatic fixture, a conveying and assembly robot, and a control system, each designed and integrated separately. The robotic intelligent welding system design consists of an arc welding robot, a fully digital compressed arc welding equipment, intelligent flexible tooling, a joint tracking system, a molten pool vision sensing system, and tooling fixtures. The integrated machine vision-based automated assembly robot and robotic intelligent welding system are coupled to form an intelligent assembly and welding production line.

[0108] Automating the welding of locomotive frames can reduce the investment of human capital, improve production efficiency and increase workshop production capacity; robotic welding can better ensure weld quality, reduce the rate of defective products being reworked, and lower maintenance costs.

[0109] In embodiments of this disclosure, the terms "first," "second," and "third" are used for descriptive purposes only and should not be construed as indicating or implying relative importance.

[0110] In this disclosure, the term "and / or" is merely a description of the relationship between related objects, indicating that three relationships can exist. For example, A and / or B can represent: A existing alone, A and B existing simultaneously, or B existing alone. Additionally, the character " / " in this document generally indicates that the preceding and following related objects have an "or" relationship.

[0111] The concepts of "first" and "second" mentioned in this disclosure are used only to distinguish different devices, modules or units, and are not used to define the order of functions performed by these devices, modules or units or their interdependencies.

[0112] It should be noted that although several modules or units of the device used for action execution are mentioned in the detailed description above, this division is not mandatory.

[0113] In fact, according to embodiments of this disclosure, the features and functions of two or more modules or units described above can be embodied in one module or unit. Conversely, the features and functions of one module or unit described above can be further divided and embodied by multiple modules or units.

[0114] Some of the block diagrams shown in the accompanying drawings are functional entities and do not necessarily correspond to physically or logically independent entities. These functional entities can be implemented in software, in one or more hardware modules or integrated circuits, or in different network and / or processor devices and / or microcontroller devices.

[0115] Based on the same inventive concept, this disclosure also provides a method for manufacturing an electric locomotive frame, applied to the aforementioned electric locomotive frame manufacturing production line, such as... Figure 8 As shown, the electric locomotive frame manufacturing method includes steps S802-S808.

[0116] In S802, the control transfer machine transports the small beam plate to the small beam assembly welding workstation. The small beam assembly welding workstation and the automatic welding unit for the external weld of the beam workstation work together to weld the small beam plate to obtain the small beam.

[0117] In S804, the control transfer machine transports the side beam plates to the side beam assembly welding station. The side beam assembly welding station and the automatic welding unit for the external welds of the beam work together to weld the side beam plates to obtain the side beam.

[0118] In S806, the small beams and side beams are transported to the frame assembly workstation, where the small beams and side beams are assembled to obtain the initial frame.

[0119] In S808, the initial frame is welded sequentially through the frame welding workstation and the frame component assembly and welding manufacturing unit to obtain the electric locomotive frame.

[0120] This disclosure presents an embodiment that optimizes and reorganizes a locomotive frame intelligent welding production line based on a simulation model system, proposing a solution to the bottleneck problem of automated production.

[0121] The embodiments disclosed herein solve the problem that the long length, heavy weight, and complex structure of locomotive frames make automated production difficult.

[0122] This disclosure completes the research on key technologies such as the simulation optimization design of locomotive frame welding production line layout, cycle time, work station, and process flow; automatic positioning and assembly process and tooling design of locomotive frame and its components; efficient adaptive intelligent welding of locomotive frame robots; design of a logistics system for frame components based on the Internet of Things; and integration and application verification of automated welding production line for locomotive frames.

[0123] This disclosed embodiment enables automated manufacturing of electric locomotive frames through the scientific design of various manufacturing units and intelligent logistics. Each intelligent manufacturing unit, based on automated assembly robots and automated logistics design, achieves automated production from raw material input to finished product output. Automated transportation throughout the production line is designed, utilizing RGVs and AGVs to automate the transport of materials required at each workstation. The entire production line minimizes manual intervention; for work-in-process with high output at each workstation, storage is achieved through an intelligent automated warehouse. The automated warehouse monitoring system (WCS) consists of a monitoring computer, a PROFIBUS network communication system, a network interface with a network switch, a communication interface with the stacker crane control equipment PLC, and a communication interface with the conveyor system PLC. It enables automatic data acquisition and monitoring control of the automated equipment in the warehouse, allowing the control equipment to operate efficiently and accurately according to system requirements, achieving automated storage and dispatch of goods.

[0124] In some embodiments, certain steps may be omitted, multiple steps may be combined into one step for execution, and / or one step may be broken down into multiple steps for execution.

[0125] Those skilled in the art will understand that all or part of the steps of the above embodiments can be specifically implemented in the following forms: a completely hardware implementation, a completely software implementation (including firmware, microcode, etc.), or a combination of hardware and software implementations, which can be collectively referred to as "circuit", "module" or "system".

[0126] Other embodiments of this disclosure will readily occur to those skilled in the art upon consideration of the specification and practice of the invention disclosed herein.

[0127] This disclosure is intended to cover any variations, uses, or adaptations of this disclosure that follow the general principles of this disclosure and include common knowledge or customary techniques in the art not disclosed herein. The description and examples are to be considered exemplary only, and the true scope and spirit of this disclosure are indicated by the appended claims.

Claims

1. A production line for manufacturing electric locomotive frames, characterized in that, This includes a single-beam manufacturing unit, a frame manufacturing unit, a transfer machine, and a centralized control system; The single beam manufacturing unit includes a small beam welding workstation and a side beam welding workstation arranged adjacent to each other. An automatic welding unit for the external weld seam of the beam is also provided on one side of the small beam welding workstation and the side beam welding workstation. The frame manufacturing unit includes a frame assembly workstation and a frame welding workstation arranged adjacent to each other. A frame small component testing and welding manufacturing unit is also provided on one side of the frame welding workstation. The centralized control system is used to control the electric locomotive frame manufacturing production line to perform the following steps: The control transfer machine transports the small beam plate to the small beam assembly welding station. The small beam assembly welding station and the automatic welding unit for the external weld of the beam workpiece work together to weld the small beam plate to obtain the small beam. The control transfer machine transports the side beam plates to the side beam assembly welding station. The side beam assembly welding station and the automatic welding unit for the external welds of the beam workpiece work together to weld the side beam plates to obtain the side beam. The small beams and the side beams are transported to the frame assembly workstation, where the frame assembly workstation assembles the small beams and the side beams to obtain the initial frame; The initial frame is sequentially welded through the frame welding workstation and the frame component testing and welding manufacturing unit to obtain the electric locomotive frame. The small beam welding workstation includes: A single-beam raw material plate assembly buffer platform is used to place small beam plates; The single-beam internal seam robot assembly welding workstation is adjacent to the single-beam raw material plate assembly buffer station and is used to assemble and weld the small beam plates. The single-beam internal seam robotic welding workstation, adjacent to the single-beam internal seam robotic assembly welding workstation, is used to continue welding the small beam plates after the assembly welding. A single-beam small-part robot assembly welding workstation is used to weld small parts onto small beams that have already been welded by a single-beam internal seam robot welding workstation. Single-beam intelligent automated warehouse; Single beam adjustment and inspection station; Single beam internal weld seam cleaning, grinding, inspection, and handover station; Single beam external weld seam cleaning, grinding, inspection, and handover station; Single-beam automated warehouse transfer station; Robotic polishing station; A transfer machine is used to move welded workpieces between different workstations.

2. The production line according to claim 1, characterized in that, The side beam welding workstation includes: The side beam robot assembly and welding workstation is used to assemble and weld side beam plates. The side beam inner seam robotic welding workstation, adjacent to the side beam assembly welding workstation, is used to weld the inner seam of the side beam plates after assembly welding. The side beam external small parts robot assembly welding workstation is used to weld small parts of the side beam after the side beam internal seam robot welding workstation has welded them. Side beam automated warehouse transfer station; Side beam intelligent automated warehouse; The side beam outer seam robotic welding workstation is used to continue welding the outer seam after the previous welding process; Manual assembly and spot welding station for the side beam lower cover plate component; The side beam internal weld seam cleaning, grinding, inspection, and handover station; The manual assembly and spot welding station for the side beam upper cover plate component; The side beam external weld seam cleaning, grinding, inspection, and handover station; Side beam adjustment and inspection station.

3. The production line according to claim 1, characterized in that, The automatic welding unit for the external welds of the beam includes multiple external weld robots; the external weld robots are used to complete the welding of the external welds of each single beam after the AGV assembles the workpiece into the C-type positioner.

4. The production line according to claim 1, characterized in that, The single-beam manufacturing unit also includes an intelligent automated warehouse stacker crane system and a manual manufacturing unit, which is used to meet production requirements when the automated production line fails.

5. The production line according to claim 4, characterized in that, The intelligent automated warehouse stacker crane system includes a combined steel structure racking system, a rail-guided stacker crane system, and a backpack AGV conveyor system.

6. The production line according to claim 4, characterized in that, The hand-manufacturing unit includes a truss structure and a positioner.

7. The production line according to claim 1, characterized in that, The frame assembly workstation is a truss structure, including a side beam transfer machine transfer station, a small beam transfer machine transfer station, a KBK crane, and a frame transfer machine transfer station.

8. The production line according to claim 1, characterized in that, The frame welding workstation includes a lifting and positioning machine, a side gantry rail, and multiple welding robots.

9. The production line according to claim 1, characterized in that, The frame component assembly and welding manufacturing unit includes a welding overhead gantry, an assembly welding overhead gantry, a handling robot, and multiple welding robots.

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