Automatic welding process and equipment for metro brake hanging seat

Abstract

The invention discloses an automatic welding process and equipment for a metro brake hanging seat, the process adopts a first welding device for full-automatic welding, and comprises the following steps: assembling and welding a sealing plate of the brake hanging seat and a brake pipe; rib plates and vertical plates of the brake hanging seat are manually assembled, brake hanging seat rib plates of various width specifications are prepared, the width of the upper portion of each rib plate is 200-206 mm, the width of the lower portion of each rib plate is 186-192 mm, and the gap between each rib plate and the corresponding vertical plate is controlled to be 0-1 mm; a vertical plate of the brake hanging seat is welded with a circumferential weld of the brake pipe, and a rib plate is welded with the brake pipe and the vertical plate. A solution is found for the inevitable contour deviation problem of the brake hanging seat vertical plate; welding personnel are reduced, and the working intensity is reduced; the product welding efficiency is improved; and grinding consumables are saved, and the working environment is improved.

Description

Technical Field

[0001] The present invention belongs to the technical field of assembly welding of the braking part of a railway vehicle bogie. The welded brake hanger is a core component of a high-stress, high-load bogie product; specifically, it relates to an automatic welding process and equipment for a subway brake hanger. Background Technique

[0002] The brake hanger is applied to the PW120E subway bogie and is a key component of the braking assembly in the bogie. Through this component, the braking assembly is connected to the bogie. The structure of the brake hanger is as Figure 1 shown.

[0003] For the welding of the brake hanger, the existing technologies are divided into: ① manual assembly plus welding mode; ② automatic assembly welding mode (Chinese Patent ZL2019113064771).

[0004] ① Manual assembly plus welding mode: Under the existing manual technical conditions, it is very difficult to ensure the relative positions of the vertical plates of the brake hanger. Due to the errors in manual assembly, products are often unqualified and a large amount of rework is required; moreover, the assembly position of the rib plates of the brake hanger belongs to spatial dimensions, and it is difficult to meet the assembly accuracy by manual template scribing and assembly. Therefore, the inaccurate position of the rib plates will affect the stress condition of the component and the service life of the product, and there are certain potential safety hazards; the brake hanger has left and right parts, and sometimes the left and right parts are assembled in reverse during manual assembly, resulting in product scrapping, wasting product materials and increasing production costs.

[0005] ② Automatic assembly welding mode (Chinese Patent ZL2019113064771): All components and all welds can be assembled and welded fully automatically. However, after several years of batch welding use, it is found that due to the aging of the forging die and the uncertainty of the material forging springback amount of the vertical plate component of the brake hanger, the contour inconsistency of the vertical plate component of the brake hanger is very common and there is no rule to follow. As a result, when processing holes subsequently, the holes cannot be completely at 79.73° with the machining surface ( Figure 2), resulting in inconsistent angles after the assembly of the brake hanger vertical plate and the brake pipe, and an uneven and irregular distribution of angle changes. However, the position and angle of the welding torch in fully automated welding are determined by teaching and cannot be automatically adjusted with the changes in the product. At the same time, the welding speed is very fast, and even with the addition of relevant sensors (such as vision sensors, laser angle sensors, etc.), it is impossible to achieve timely adjustment of the welding torch angle. Therefore, after the product is welded, problems such as bead undercut (smaller angle) of the brake hanger vertical plate and asymmetric weld leg (larger angle) of the overall weld seam will occur. The appearance of welding defects in the weld seam increases the workload of post-weld repair. Although the welding efficiency of automated welding products has been improved, the increase in the repair volume makes the production efficiency of the product equal to or lower than that of manual welding (in the case where each product needs to be repaired). At the same time, the deviation of the vertical plate profile will also cause too large a gap between the brake hanger rib plate and the brake hanger vertical plate (see Figure 3 ), which in turn affects the automated welding of the fillet weld between the brake hanger rib plate and the brake hanger vertical plate.

[0006] Therefore, in order to improve the above problems, it is necessary to optimize the process and welding form of the fully automated welding of the brake hanger according to the problems found. Summary of the Invention

[0007] In view of the above-mentioned prior art, the technical problems to be solved by the present invention are as follows: ① The problem of batch welding defects in the weld seam caused by inconsistent angles after the assembly of the brake hanger vertical plate and the brake pipe due to the deviation of the vertical plate profile of the brake hanger, which requires optimizing the welding position of the circumferential weld of the brake hanger vertical plate; ② The problem that the gap between the brake hanger rib plate and the brake hanger vertical plate is too large due to the deviation of the vertical plate profile of the brake hanger, making it impossible to achieve automated welding of the fillet weld between the brake hanger rib plate and the brake hanger vertical plate, which requires preparing materials in multiple specifications for the width of the brake hanger rib plate.

[0008] To achieve the above object, the technical solution provided by the present invention is as follows: An automated welding device for a subway brake hanger, including a first welding device for welding the circumferential weld of the brake hanger vertical plate and the brake pipe, and the fillet weld between the rib plate, the vertical plate and the brake pipe; the first welding device includes a two-axis positioner, a welding robot and a brake hanger welding fixture. The brake hanger welding fixture is arranged on the two-axis positioner, and the brake hanger welding fixture includes a left part movable limit, a right part movable limit, a three-jaw chuck, a left part chute, a right part chute, a chute stopper and a movable positioning block; A cavity is provided at the center of the three-jaw chuck for pre-clamping or fastening the brake pipe of the brake suspension seat; on one side of the three-jaw chuck, there are provided opposite left and right part chutes. At the inner ends of the left and right part chutes, chute stoppers are fixedly provided for sliding limit; on the left and right part chutes, there are respectively slidably erected left and right part movable limits. At the upper ends of the left and right part movable limits, there are provided movable positioning blocks, and the movable positioning blocks are in contact positioning with the vertical plate of the brake suspension seat.

[0009] Furthermore, the sliding directions of the left and right part movable limits are exactly opposite, and the left and right part movable limits can be withdrawn from the outer ends of the left and right part chutes respectively.

[0010] Furthermore, the welding equipment further includes a second welding device for the assembly welding of the sealing plate and the brake pipe of the brake suspension seat; the second welding device includes the following welding areas: at both ends of the brake pipe, there are provided brake pipe assembly limits, and outside both ends of the brake pipe, there are provided sealing plate clamping members. The sealing plate clamping members can fix the sealing plate through the material of their own electromagnetic members, and send the sealing plate into the brake pipe for tack welding and then withdraw through the movement of the cylinder, referring to Chinese Patent ZL2019113064771.

[0011] The automatic welding method of the brake suspension seat using the automatic welding equipment of the subway brake suspension seat described in any one of the above, and using the first welding device for full-automatic welding, the method includes: (1) The assembly welding of the sealing plate and the brake pipe of the brake suspension seat; (2) The manual assembly of the rib plate and the vertical plate of the brake suspension seat. The upper width of the rib plate is 200 - 206 mm, and the lower width is 186 - 192 mm, ensuring that the gap between the rib plate and the vertical plate is controlled within 0 - 1 mm; (3) The circumferential weld welding of the vertical plate of the brake suspension seat and the brake pipe, and the welding of the rib plate with the brake pipe and the vertical plate.

[0012] Furthermore, for the step (3): (3.1) The positioning assembly of the brake suspension seat product to be assembled and welded and the brake suspension seat welding fixture; (3.2) The welding of 4 circumferential welds on the inner and outer sides of the vertical plate of the brake suspension seat and the brake pipe; (3.3) The welding of the welds between the rib plate of the brake suspension seat and the vertical plate and the brake pipe.

[0013] Further, in the step (3.1): Hoist the brake hanger product assembled manually in the step (2) onto the brake hanger welding fixture. Place the brake pipe into the three-jaw chuck and manually rotate the jaw driving mechanism with a wrench to pre-clamp it, ensuring that the brake hanger product is perpendicular to the fixture and can rotate freely in the three-jaw chuck. The movable limit moves in the chute and abuts against the chute stop block, and then the movable positioning block is installed in place. Rotate the brake hanger to make the vertical plate contact the movable positioning block to achieve product positioning. Rotate the jaw driving mechanism with a wrench again to fasten the brake hanger product on the three-jaw chuck, and then the movable limit slides out of the chute to avoid interference between the welding torch and the movable limit and affect the circumferential weld welding.

[0014] Further, in the step (3.2): The rotating shaft 1 of the double-axis positioner rotates counterclockwise by 45°, making the brake hanger product form an angle of 45° obliquely upward with the horizontal plane. The rotating shaft 2 of the double-axis positioner rotates to start welding the first welds on the inner and outer sides of the vertical plate and the brake pipe ring: The robot carries the welding torch and moves to the welding starting point, and the welding torch makes an angle of 80 - 100° with the horizontal plane for welding. The rotating shaft 1 of the double-axis positioner continues to rotate counterclockwise by 90°, making the brake hanger product form an angle of 45° obliquely downward with the horizontal plane. The rotating shaft 2 of the double-axis positioner rotates to start welding the second welds on the inner and outer sides of the vertical plate and the brake pipe ring: The robot carries the welding torch and moves to the welding starting point, and the welding torch makes an angle of 80 - 100° with the horizontal plane for welding.

[0015] Furthermore, for the welding of the first welds on the inner and outer sides: When welding the first weld on the outer side, the rotating shaft 2 of the double-axis positioner rotates counterclockwise; when welding the first weld on the inner side, the rotating shaft 2 of the double-axis positioner rotates clockwise. For the welding of the second welds on the inner and outer sides: When welding the second weld on the outer side, the rotating shaft 2 of the double-axis positioner rotates counterclockwise; when welding the second weld on the inner side, the rotating shaft 2 of the double-axis positioner rotates clockwise.

[0016] Further, in the step (3.3): The rotating shaft 1 of the double-axis positioner rotates clockwise by 45° based on the posture of the second welds on the inner and outer sides, making the workpiece in a horizontal state; the rotating shaft 2 of the double-axis positioner rotates clockwise by 50° again, making the rib plate in a horizontal state. After welding the upper side of the fillet weld between the rib plate, the vertical plate and the brake pipe, the rotating shaft 2 of the double-axis positioner rotates counterclockwise by 180°, and then welds the lower side.

[0017] Further, weld the sealing plate and the brake pipe using the second welding device.

[0018] The advantages of the present invention are mainly manifested in: (1) A solution is found for the inevitable contour deviation problem of the brake hanger vertical plate Through verification, this set of automated welding processes can effectively solve the welding defect problems caused by the profile deviation of the vertical plate of the brake hanger seat, making the automated welding production more stable. The welding defect generation rate of each train (48 pieces) of products has decreased from 83.3% to 3%.

[0019] Table 1 Comparison table of welding defect generation rates before and after the optimization of the automatic welding process for the brake hanger seat (2)The number of personnel involved in welding is reduced, and the work intensity is lowered Before optimization, 1 equipment operator and 2 welding repair personnel were required to ensure the output of finished products. After the process optimization, the number of welding repair personnel has decreased by 1, and the work intensity of the repair personnel has been reduced by 82%.

[0020] Table 2 Comparison list of the number of personnel involved in the welding process before and after the optimization of the automatic welding process for the brake hanger seat Table 3 Comparison table of the work intensity of repair personnel before and after the optimization of the automatic welding process for the brake hanger seat (3)The welding efficiency of the product is improved After the process optimization, compared with the existing patented automated welding process, the welding efficiency of this automated welding process has increased by 10%.

[0021] Table 4 Comparison list of the welding duration of each weld before and after the optimization of the automatic welding process for the brake hanger seat (4)The grinding consumables are saved, and the working environment is improved After optimization, the welds have good consistency and few welding defects. The subsequent grinding amount of the welds is reduced, and the savings in grinding consumables are 70%. The reduction in the grinding amount not only saves grinding consumables but also reduces the generation of grinding dust, improving the working environment of the workstation.

[0022] Table 6 Comparison list of the consumption of grinding consumables before and after the optimization of the automatic welding process for the brake hanger seat 。 Description of the drawings

[0023] Figure 1 is a schematic diagram of the brake hanger seat; Figure 2 is the angular relationship of the machining holes on the vertical plate; Figure 3 is a schematic diagram of the distance between the rib plate and the vertical plate, which is the gap; Figure 4 is a schematic diagram of the fillet weld welding position; Figure 5It is a schematic diagram of the flat welding position; Figure 6 It is a schematic diagram of the width of the reinforcing plate of the brake suspension seat; Figure 7 It is a schematic diagram of the existing patented welding equipment Figure 1 ; Figure 8 It is a schematic diagram of the existing patented welding equipment Figure 2 ; Figure 9 It is the existing patented head and tail frame positioner; Figure 10 It is a top view of the welding equipment of the present invention; Figure 11 It is a side view of the welding equipment of the present invention; Figure 12 It is a side view of the double-axis positioner; Figure 13 It is to complete the welding between the brake pipe and the sealing plate on the existing patented tooling; Figure 14 It is an enlarged view of the sealing plate clamping part of the existing patented tooling; Figure 15 It is a schematic diagram of the rotation axis and rotation direction of the double-axis positioner; Figure 16 It is a schematic diagram of the brake suspension seat welding tooling; Figure 17 It is an enlarged view of the brake suspension seat welding tooling (the positional relationship between the movable positioning block and the brake suspension seat product); Figure 18 It is a schematic diagram of the angle relationship between the workpiece and the horizontal plane and the posture adjustment Figure 1 ; Figure 19 It is the weld number Figure 1 ; Figure 20 It is a schematic diagram of the rotation direction when the rotation axis 2 of the double-axis positioner welds the inner and outer 1-1 welds; Figure 21 It is a schematic diagram of the angle relationship between the workpiece and the horizontal plane and the posture adjustment Figure 2 ; Figure 22 It is the weld number Figure 2 ; Figure 23 It is a schematic diagram of the rotation direction when the rotation axis 2 of the double-axis positioner welds the inner and outer 1-2 welds; Figure 24 It is a schematic diagram of the angle relationship between the workpiece and the horizontal plane and the posture adjustment Figure 3 ; Figure 25 It is a schematic diagram of the posture adjustment of the reinforcing plate of the brake suspension seat; Figure 26 It is a schematic diagram of the welding sequence of the reinforcing plate of the brake suspension seat; Figure 27 It is the automated welding flow chart of the brake suspension seat; Among them, A - stiffening plate, B - vertical plate, C - brake pipe, D - sealing plate; 11 - control cabinet, 12 - positioner, 13 - intermediate screen, 14 - start detection system, 15 - gun cleaning mechanism, 16 - safety fence, 17 - manipulator, 18 - wire support, 19 - torch cooling system; 411 - sealing plate clamp, 411A - direction of cylinder pushing to tighten the assembled material, 411B - direction of cylinder retracting to withdraw the sealing plate clamp; 412 - brake pipe assembly limit; E - brake suspension seat product, E1 - right part of the brake suspension seat; F - two - axis positioner; G - welding robot; H - brake suspension seat welding fixture, H1 - left part movable limit, H2 - right part movable limit, H3 - three - jaw chuck, H4 - left part sliding groove, H5 - right part sliding groove, H6 - sliding groove stop block, H7 - movable positioning block. Detailed implementation mode

[0024] In order to make the technical means, creative features, achieved purposes and effects of the present invention easy to understand, the technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the attached drawings of the specification.

[0025] Embodiment 1 The automated welding equipment for the subway brake suspension seat in this embodiment includes two sets of equipment: One set of equipment is set according to the existing patent (as Figures 7 to 9 shown, which will not be elaborated here. For details, please refer to paragraphs 78 - 79 of Chinese Patent ZL201911306477.1), and the assembly welding work of the sealing plate D and the brake pipe C of the brake suspension seat is carried out.

[0026] According to the optimization of the process flow, only the part of the assembly and welding of the sealing plate D and the brake pipe C of the brake suspension seat in Figure 13 will be used with the above - mentioned existing patent. The assembly parts of the vertical plate B of the brake suspension seat and the stiffening plate A of the brake suspension seat with the brake pipe C are cancelled due to the influence of the profile of the vertical plate B of the brake suspension seat and another set of equipment is adopted.

[0027] Another set of equipment is as Figures 10 to 12 shown, and the circumferential weld of the vertical plate B of the brake suspension seat and the brake pipe C and the fillet weld between the stiffening plate A of the brake suspension seat, the vertical plate B of the brake suspension seat and the brake pipe C are welded. It includes a two - axis positioner F, a welding robot G and a brake suspension seat welding fixture H. The L - shaped two - axis positioner F can realize the all - round welding of the product through two mutually perpendicular rotating shafts, as Figure 15As shown in the figure; a brake hanger welding tooling H is arranged on the double-axis positioner F.

[0028] As Figure 16 and Figure 17 shown, the brake hanger welding tooling H includes a left part movable limit H1, a right part movable limit H2, a three-jaw chuck H3, a left part chute H4, a right part chute H5, a chute stop block H6, and a movable positioning block H7. Among them, a cavity is arranged at the center of the three-jaw chuck H3 for pre-clamping or fastening the brake hanger product E (specifically, pre-clamping or fastening the brake pipe C); on one side of the three-jaw chuck H3, opposite left part chute H4 and right part chute H5 are arranged (in order to adapt to the relative position placement for left and right part welding. As Figure 17 is for more intuitive distinction of the installation of left and right parts. And the workpieces are assembled on the same side, and the production personnel do not need to work around the equipment positioner.). The left part movable limit H1 and the right part movable limit H2 are respectively erected and slid on the left part chute H4 and the right part chute H5. Chute stop blocks H6 are fixedly arranged at the inner ends of the left part chute H4 and the right part chute H5 for sliding limit; the sliding directions of the left part movable limit H1 and the right part movable limit H2 are exactly opposite, and the left part movable limit H1 and the right part movable limit H2 can be respectively withdrawn from the left part chute H4 and the right part chute H5. Movable positioning blocks H7 are arranged at the upper ends of the left part movable limit H1 and the right part movable limit H2. The end of the vertical plate B of the brake hanger contacts the movable positioning block H7 to realize the positioning of the brake hanger product E.

[0029] Embodiment 2 As Figure 27 shown, the automatic welding of the brake hanger is carried out by using the subway brake hanger automatic welding equipment of Embodiment 1, and the process is as follows: (1) The sealing plate D of the brake hanger is assembled and welded with the brake pipe C, as Figure 13 and Figure 14 shown. This step will not be elaborated here. For details, please refer to paragraphs 80-81 of Chinese Patent ZL201911306477.1. After the brake hanger materials are assembled at the corresponding positions of the tooling, the operator leaves the operation area, clamps the workpiece by operating the equipment buttons, and starts the welding program by operating the teach pendant after clamping the workpiece. After the welding program is started, it will first carry out tack welding on the assembled parts (tack welding parameters: current 230A, voltage 24V, pause time 1s). After the tack welding is completed, the robot will automatically weld the assembled parts. Complete the weld between the sealing plate D and the brake pipe C (welding parameters: current 245-255A, voltage 26-27V, welding speed 32-45 cm / min). The clamping actions of the tooling on each part are shown in Figure 14 , and the fixing of the sealing plate D is carried out by electromagnetic adsorption, and the pushing and contracting movements of the clamping mechanism are completed by the telescopic movement of the cylinder.

[0030] (2)Manually assemble the brake hanger rib plate A and the vertical plate B.

[0031] In addition, prepare materials for the brake hanger rib plate A with various width specifications and adapt them during product assembly to ensure that the gap between the brake hanger rib plate A and the brake hanger vertical plate B is controlled within 0 - 1 mm. The width of the brake hanger rib plate A is increased by 2 mm, 4 mm, and 6 mm to meet product assembly under different welding gaps. The width information is shown in the following table.

[0032] Table 5 Statistical table of width increase for brake hanger rib plates (3)Weld the circumferential weld of the vertical plate B of the brake hanger and the brake pipe C, and weld the rib plate A with the brake pipe C and the vertical plate B.

[0033] (3.1)Positioning and assembly of the brake hanger product E to be assembled and welded and the brake hanger welding fixture H: Lift the brake hanger product E manually assembled in the above step (2) to the brake hanger welding fixture H using a crane. The brake pipe C needs to be placed into the three - jaw chuck H3. Manually rotate the jaw drive mechanism with a wrench to pre - clamp the brake hanger product E (ensure that the brake hanger product E is perpendicular to the fixture and can rotate freely between the movable jaws of the three - jaw chuck H3).

[0034] According to the type of the brake hanger product E (the brake hanger product E has left and right parts, and in this embodiment, the right - hand brake hanger E1 is taken as an example), select the corresponding movable limit block. The movable limit block moves in the chute on the fixture and abuts against the chute stop block H6, and then the movable positioning block H7 is installed in place. Rotate the brake hanger to make the brake hanger vertical plate B contact the movable positioning block H7 to achieve product positioning.

[0035] After product positioning, rotate the jaw drive mechanism with a wrench again to fasten the brake hanger product E on the three - jaw chuck H3, and then the movable limit slides out of the chute to avoid interference between the welding torch and the movable limit and affect the circumferential weld welding.

[0036] (3.2)Weld the 4 circumferential welds on the inner and outer sides of the vertical plate B of the brake hanger and the brake pipe C: After the product positioning and assembly are completed, the operator evacuates from the equipment assembly area. Start the welding program on the teaching pendant. After the welding program is started, the rotating shaft 1 of the L - type double - axis positioner F rotates counterclockwise by 45°, making the brake hanger product E form an angle of 45° obliquely upward with the horizontal plane, as Figure 18 shown.

[0037] After flipping in place, the welding robot G carries the welding torch to move to the welding starting point. While the welding torch arcs, the rotating shaft 2 of the L - type double - axis positioner F rotates to start the circumferential weld welding between the brake hanger vertical plate B and the brake pipe C. The welds welded in this posture are asFigure 19 。

[0038] When welding the outer 1-1 weld (the first outer weld), the rotating shaft 2 of the L-shaped biaxial positioner F rotates counterclockwise. When welding the inner 1-1 (the first inner weld) weld, the rotating shaft 2 of the L-shaped biaxial positioner F rotates clockwise. The rotation direction of the rotating shaft is as Figure 20 shown (since the servo motor cannot rotate infinitely clockwise or counterclockwise, the servo motor of this equipment can only rotate 540° clockwise or counterclockwise. Therefore, after rotating 360° clockwise, it needs to rotate back counterclockwise. The rotation scheme of this patent is that the servo motor of the equipment starts to rotate from the original position, which can save the positioning time and improve the welding efficiency).

[0039] After the welding of the inner and outer 1-1 numbered welds is completed, the rotating shaft 1 of the L-shaped biaxial positioner F continues to rotate counterclockwise by 90° on the basis of the previous posture (the posture of the inner and outer 1-1 welds, that is Figure 18 ), so that the brake hanger product E forms an angle of 45° obliquely downward with the horizontal plane. See Figure 21 。

[0040] After flipping in place, the welding robot G moves the welding torch to the welding starting point. While the welding torch arcs, the rotating shaft 2 of the L-shaped biaxial positioner F rotates, and the remaining 2 circumferential welds between the brake hanger vertical plate B and the brake pipe C start to be welded. The welds welded in this posture are as Figure 22 。

[0041] When welding the outer 1-2 weld (the second outer weld), the rotating shaft 2 of the L-shaped biaxial positioner F rotates counterclockwise. When welding the inner 1-2 weld (the second inner weld), the rotating shaft 2 of the L-shaped biaxial positioner F rotates clockwise. The rotation direction of the rotating shaft is as Figure 23 。

[0042] The welding parameters for the 4 circumferential welds between the brake hanger vertical plate B and the brake pipe C inside and outside are as follows: current 280 - 300A, voltage 30 - 32V, welding speed 18 - 30 cm / min, welding torch oscillation amplitude 2 - 2.5 mm, welding torch oscillation frequency 1 - 1.5 HZ.

[0043] Optimize the welding position of the circumferential weld between the brake hanger vertical plate B and the brake pipe C, thereby compensating for the welding defects caused by the angular deviation between the brake hanger vertical plate B and the brake pipe C. The prior art uses the flat fillet weld position (see Figure 4 ), that is, welding with the angle between the welding torch and the horizontal plane being 40 - 50°. And this invention will use the flat weld position (see Figure 5 ), that is, welding with the angle between the welding torch and the horizontal plane being 80 - 100°.

[0044] Although there are dimensional deviations between the vertical plate B and the brake pipe C of each product, the deviation of the product material is different from the assembly deviation of the product on the tooling (the deviation of the product material affects the size of the product, but the assembly deviation between the product and the tooling affects the start and end positions of the product welding procedure). Therefore, it is necessary to give priority to ensuring the assembly position of the product on the tooling to achieve fully automated welding, and then compensate for the adverse effects of the dimensional deviation between the workpiece components on the weld appearance by changing the welding position of the workpiece. At the same time, in order to weld the product weld completely and with few weld defects, it is necessary to flip the workpiece in the form of Figure 18 and Figure 21 .

[0045] Among them, the brake hanger welding tooling H is designed to meet fully automated welding. To achieve fully automated welding, it is necessary to use a tooling with positioning function, so as to make the positions of different workpieces assembled on the tooling exactly the same (the deviation of the start and end positions of the welding procedure is not large), and then ensure the smooth progress of fully automated welding.

[0046] (3.3) Welding of the weld between the rib plate A, vertical plate B and brake pipe C of the brake hanger: After the circumferential welds on the inner and outer sides of the vertical plate B and the brake pipe C of the brake hanger are welded, the rotating shaft 1 of the L-shaped double-axis positioner F rotates clockwise by 45° on the basis of the previous posture (the posture of the inner and outer side 1-2 welds, Figure 21 ), so that the workpiece is in a horizontal state.

[0047] The rotating shaft 2 of the L-shaped double-axis positioner F then rotates clockwise by 50°, so that the rib plate A of the brake hanger is in a horizontal state, as shown in Figure 24 and Figure 25 .

[0048] After one side of the fillet weld between the rib plate A of the brake hanger, the vertical plate B of the brake hanger and the brake pipe C is welded, the rotating shaft 2 of the L-shaped double-axis positioner F rotates counterclockwise by 180°, and then the other side is welded. The specific welding sequence is shown in Figure 26 .

[0049] The welding parameters of the fillet weld between the rib plate A of the brake hanger, the vertical plate B of the brake hanger and the brake pipe C are: current 230-250A, voltage 26-28V, welding speed 24-36cm / min.

[0050] The above processes are all the automated welding processes of the right part E1 of the brake hanger. The welding sequence and process of the left part and the right part are the same.

[0051] The above description is only the preferred embodiment of the present invention and does not constitute a limitation on the protection scope of the present invention. Any modification, equivalent replacement and improvement made within the spirit and principle of the present invention shall be included within the protection scope of the claims of the present invention.

Claims

1. A subway brake hanger automatic welding equipment, characterized in that: The welding equipment includes a first welding device, which is used for welding the circumferential weld between the brake hanger vertical plate and the brake pipe, and the fillet weld between the rib plate and the vertical plate and the brake pipe; the first welding device includes a biaxial positioner, a welding robot and a brake hanger welding tool, the biaxial positioner is provided with a brake hanger welding tool, and the brake hanger welding tool includes a left part movable limit, a right part movable limit, a three-jaw chuck, a left part slide, a right part slide, a slide block and a movable positioning block; A cavity is set in the center of the three-jaw chuck for pre-clamping or tightening the brake pipe of the brake hanger; a left-piece slide groove and a right-piece slide groove are set opposite to each other on one side of the three-jaw chuck, and slide groove blocks are fixedly set at the inner ends of the left-piece slide groove and the right-piece slide groove for sliding limiting; left-piece movable limit and right-piece movable limit are respectively slidably erected on the left-piece slide groove and the right-piece slide groove, and movable positioning blocks are provided at the upper ends of the left-piece movable limit and the right-piece movable limit, and the movable positioning blocks are contacted with the vertical plate of the brake hanger for positioning.

2. The subway brake hanger automatic welding equipment according to claim 1, characterized in that: The sliding directions of the left part movable limiter and the right part movable limiter are just opposite, and the left part movable limiter and the right part movable limiter can be withdrawn from the outer ends of the left part sliding groove and the right part sliding groove respectively.

3. The subway brake hanger automatic welding equipment according to claim 1 or 2, characterized in that: The welding equipment also includes a second welding device, which is used for assembly welding of the sealing plate of the brake hanger and the brake pipe; the second welding device includes the following welding areas: brake pipe assembly limiters are provided at both ends of the brake pipe, and sealing plate clamps are provided on the outer sides of both ends of the brake pipe. The sealing plate clamps can fix the sealing plate through the material of their own electromagnetic parts, and send the sealing plate into the brake pipe through the movement of the cylinder to fix it and then withdraw it, refer to Chinese patent ZL2019113064771.

4. A brake hanger automated welding method using the subway brake hanger automated welding equipment according to any one of claims 1 to 3, characterized in that: The first welding device is used for full-automatic welding, and the method comprises: (1) Assembly and welding of the cover plate of the brake hanger and the brake pipe; (2) The rib plate and the vertical plate of the brake hanger are manually assembled, the upper width of the rib plate is 200-206 mm, and the lower width is 186-192 mm, so that the gap between the rib plate and the vertical plate is controlled within 0-1 mm; (3) The vertical plate of the brake hanger is welded to the brake pipe by a circumferential weld, and the rib plate is welded to the brake pipe and the vertical plate.

5. The brake hanger automatic welding method of the subway brake hanger automatic welding equipment according to claim 4, characterized in that: The step (3): (3.1) Positioning and assembly of the brake hanger product to be assembled and welded and the brake hanger welding tooling: (3.2) The four inner and outer circumferential welds of the brake hanger plate and the brake pipe are welded; (3.3) Welding of the ribs and vertical plates of the brake hanger and the brake pipe.

6. The brake hanger automatic welding method of the subway brake hanger automatic welding equipment according to claim 5, characterized in that: The step (3.1) is as follows: hoisting the brake hanger product manually assembled in step (2) onto the brake hanger welding tooling, placing the brake pipe into the three-jaw chuck and manually rotating the jaw drive mechanism by a wrench to pre-clamp it, ensuring that the brake hanger product is perpendicular to the tooling and can rotate freely on the three-jaw chuck; after the movable limit moves in the slide groove and abuts against the slide groove block, the movable positioning block is installed in place, and the brake hanger is rotated to make the vertical plate contact with the movable positioning block to achieve product positioning; the brake hanger product is tightened on the three-jaw chuck by rotating the jaw drive mechanism again with a wrench, and then the movable limit slides out of the slide groove to avoid interference between the welding gun and the movable limit and affect the circumferential weld welding.

7. The brake hanger automatic welding method of the subway brake hanger automatic welding equipment according to claim 5 or 6, characterized in that: The steps (3.2): The rotating axis 1 of the double-axis positioner rotates 45° counterclockwise, so that the brake hanger product is inclined upward at an angle of 45° with the horizontal plane. The rotating axis 2 of the double-axis positioner rotates to start welding the first weld between the vertical plate and the inner and outer sides of the brake pipe ring: the robot carries the welding gun and moves to the welding starting point, and the welding gun is welded at an angle of 80-100° with the horizontal plane; The rotating axis 1 of the double-axis positioner continues to rotate counterclockwise by 90°, so that the brake hanger product is at a 45° downward angle with the horizontal plane; the rotating axis 2 of the double-axis positioner rotates to start welding the second weld between the vertical plate and the inner and outer sides of the brake pipe ring: the robot carries the welding gun and moves to the welding starting point, and the welding gun is welded at an angle of 80-100° with the horizontal plane.

8. The brake hanger automatic welding method of the subway brake hanger automatic welding equipment according to claim 7, characterized in that: Welding of the first inner and outer weld seams: when welding the first outer weld seam, the rotating shaft 2 of the double-axis positioner rotates counterclockwise, and when welding the first inner weld seam, the rotating shaft 2 of the double-axis positioner rotates clockwise; The welding of the inner and outer second weld seams: when the outer second weld seam is welded, the rotating shaft 2 of the double-axis positioner rotates counterclockwise, and when the inner second weld seam is welded, the rotating shaft 2 of the double-axis positioner rotates clockwise.

9. The brake hanger automatic welding method of the subway brake hanger automatic welding equipment according to claim 7 or 8, characterized in that: The steps (3.3): The rotating axis 1 of the double-axis positioner is rotated 45° clockwise on the basis of the second inner and outer weld postures to make the workpiece horizontal; the rotating axis 2 of the double-axis positioner is further rotated 50° clockwise to make the rib plate horizontal; after the upper side of the fillet weld between the rib plate, the vertical plate and the brake pipe is completed, the rotating axis 2 of the double-axis positioner is rotated 180° counterclockwise to weld the lower side.

10. The brake hanger automatic welding method of the subway brake hanger automatic welding equipment according to claim 5, characterized in that: The sealing plate and the brake pipe are welded by using the second welding device.

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