Design method and system for light weight of cross beam of cantilever support of wire feeder

Abstract

The embodiment of the invention discloses a lightweight design method for a cantilever support cross beam of a wire feeder. The lightweight design method comprises the following steps: selecting related structure parameters according to an actual structure of the cantilever support cross beam and establishing a cantilever support cross beam parameterized three-dimensional model; a CAE finite element model is established according to the three-dimensional model, and boundary conditions are applied to the finite element model; selecting key design variables from the structure parameters in the step 1, and constructing a target design optimization model according to the key design variables; sampling points of the structural parameters in the finite element model in the step 2 by adopting a central group method to obtain a plurality of groups of sample point groups containing the structural parameters, and fitting the plurality of groups of sample points to obtain a response curved surface; and an optimization algorithm is adopted to solve the target design optimization model, and the final optimization size of each structure parameter is obtained in combination with the relationship of each structure parameter in the response curved surface. According to the method, the problem of high time cost of optimization calculation of the cantilever support beam model is effectively solved, and the lightweight optimization efficiency of the cantilever support model is greatly improved.

Description

Technical Field

[0001] The present invention belongs to the technical field of the structural design of wire feeders, and particularly relates to a design method and system for lightening the cross beam of the cantilever frame of a wire feeder. Background Art

[0002] The cross beam of the cantilever frame is a key component of the cantilever frame of the wire feeder. The strength of its product has a great impact on the reliability and safety of the entire cantilever frame. Therefore, carrying out strength analysis and optimal design on the cross beam of the cantilever frame is of great significance for reducing costs, reducing weight, and improving economic benefits.

[0003] The cross beam of the cantilever frame is generally composed of rectangular tubes, profiles and hinge point seats welded together for the hanging placement of the welding wire feeder. The cantilever frame can rotate up and down freely, enabling the operator to quickly transfer the working position when operating the welding torch, shortening the wire feeding stroke of the wire feeder, avoiding blocking the wire feeding hose, and at the same time providing guarantee for the 6S management of the production site and improving the utilization rate of the factory building.

[0004] In daily use, welding workers often change the working position. The structural performance of the cantilever frame is excessive, resulting in inconvenient operation. Long-term use causes deformation of the whole machine and inconvenient rotation, affecting work efficiency. The traditional cantilever frame of the wire feeder only considers strength and overall performance. Therefore, it is necessary to carry out a lightening design on the cantilever beam to meet the needs of production and operation. Summary of the Invention

[0005] An object of the present invention is to provide a design method for lightening the cross beam of the cantilever frame of a wire feeder in view of the deficiencies of the prior art. This method effectively solves the problem of high time cost for optimizing the calculation of the cantilever frame cross beam model, and greatly improves the lightening optimization efficiency of the cantilever frame model.

[0006] To solve the above technical problems, the present invention adopts the following technical solutions:

[0007] A design method for lightening the cross beam of the cantilever frame of a wire feeder includes the following steps:

[0008] Step 1: Select relevant structural parameters according to the actual structure of the cross beam of the cantilever frame and establish a parametric three-dimensional model of the cross beam of the cantilever frame;

[0009] Step 2: Establish a CAE finite element model according to the three-dimensional model and apply boundary conditions to the finite element model;

[0010] Step 3: Select key design variables from the structural parameters in Step 1 and construct a target design optimization model based on this;

[0011] Step 4: Use the central composite method to take sample points for each structural parameter in the finite element model in Step 2 to obtain multiple groups of sample point groups containing each structural parameter, and then fit the multiple groups of sample points to obtain a response surface;

[0012] Step 5: Solve the target design optimization model using an optimization algorithm, and combine the relationships of various structural parameters in the response surface to obtain the optimized dimensions of each structural parameter finally.

[0013] Further, in Step 1, select the thickness t1 of the crossbeam top plate, the thickness t2 of the side plate, the height P1 of the side plate, the distance P2 between the hinge point O2 of the side plate and the cusp point A, and the transition fillet radius P3 between the hinge point and the crossbeam as structural parameters.

[0014] Further, Step 2 specifically includes:

[0015] Import the established parametric 3D model into the software to construct a finite element model of the cantilever beam of the cantilever rack, discretize the model using solid elements, and perform mesh division using the adaptive grid method;

[0016] Determine the constraint loads of the finite element model, and set the column connection point and the oil cylinder connection point as hinge supports; determine the maximum load at the factory, the load application position is the connection between the cantilever beam of the cantilever rack and the wire feeder base, and apply the gravity load to the whole.

[0017] Further, in Step 3, first perform a sensitivity analysis on each structural parameter, and select the k structural parameters with the highest sensitivity as the key design variables.

[0018] Further, constrain the total mass, maximum deformation, maximum equivalent stress, and safety factor of the cantilever beam of the cantilever rack, and construct a target design optimization model according to the key design variables:

[0019]

[0020] Among them, X is the key design variable; m(X) is the mass of the cantilever beam of the cantilever rack; f1(X) is the maximum deformation of the cantilever beam of the cantilever rack; f2(X) is the maximum equivalent stress of the cantilever beam of the cantilever rack; R is the maximum working radius of the cantilever beam of the cantilever rack; σ1 is the material yield limit; σ is the allowable stress; s is the safety factor.

[0021] Further, use the multi-objective genetic algorithm for the target design optimization model. When calculating, pre-determine the population size, crossover probability, and mutation probability, obtain multiple groups of key design variables through iterative calculation, and combine the response surface in Step 4 to obtain the design values of each structural parameter;

[0022] After obtaining multiple groups of results, compare and verify the multiple groups of results through the mass and maximum deformation of the cantilever beam of the cantilever rack and finite element calculation. After verification, it is the final optimized value, and the optimization ends here.

[0023] Another object of the present invention is to provide a system for implementing the above-mentioned design method for lightweighting the cantilever beam of the wire feeder, including:

[0024] A three-dimensional model construction module, configured to select relevant structure parameters according to the actual structure of the cross beam of the cantilever frame and establish a parametric three-dimensional model of the cross beam of the cantilever frame;

[0025] A finite element model construction module, configured to establish a CAE finite element model according to the three-dimensional model and apply boundary conditions to the finite element model;

[0026] A target optimization model establishment module, configured to select key design variables from the structure parameters and construct a target design optimization model accordingly;

[0027] A parameter response surface establishment module, configured to use the central composite method to take sample points for each structure parameter in the finite element model, obtain multiple groups of sample point sets including each structure parameter, and then fit the multiple groups of sample points to obtain a response surface;

[0028] A solution module, configured to use an optimization algorithm to solve the target design optimization model, and combine the relationship between each structure parameter in the response surface to obtain the optimized dimensions of each structure parameter finally.

[0029] An electronic device, including a memory and a processor, where the memory stores a computer program, and when the processor executes the computer program, the steps of the above method are implemented.

[0030] A computer-readable storage medium, on which a computer program is stored, and when the computer program is executed by a processor, the steps of the above method are implemented.

[0031] Compared with the prior art, the beneficial effects of the present invention are as follows: The present invention first selects the structure parameters of the cross beam of the cantilever frame, selects the structure parameters with high sensitivity to establish a target optimization model, then constructs a response surface of the relationship between each structure parameter, and finally sets the maximum deformation and the maximum equivalent stress for the target design optimization model, and sets the optimization goal as the minimum mass for optimization and solution. The obtained structure parameters are combined with the response surface to obtain the values of each structure parameter, and finally verification is carried out to obtain the optimized values of each structure parameter. The present invention changes the traditional single-objective lightweight design, realizes the improvement of the strength level of the cross beam of the cantilever frame; effectively solves the problem of high time cost of optimizing the calculation of the cantilever frame beam model, greatly improves the lightweight optimization efficiency of the cantilever frame model, and can reduce the mass of the cross beam of the wire feeder cantilever frame without changing the effective load, and the weight reduction ratio reaches more than 50%. BRIEF DESCRIPTION OF THE DRAWINGS

[0032] Figure 1 It is a flowchart of the design method for lightweighting the wire feeder cantilever frame according to an embodiment of the present invention;

[0033] Figure 2 It is a schematic structural diagram of the cross beam of the wire feeder cantilever frame according to an embodiment of the present invention;

[0034] Figure 3 This is the dimension parameter diagram of the crossbeam of the wire feeder cantilever frame in the embodiment of the present invention;

[0035] Figure 4 This is the constraint load diagram of the finite element model of the crossbeam structure of the wire feeder cantilever frame in the embodiment of the present invention. Detailed implementation manners

[0036] Next, the technical solutions in the embodiments of the present invention will be clearly and completely described in conjunction with the embodiments of the present invention. Obviously, the described embodiments are only a part of the embodiments of the present invention, rather than all of the embodiments. All other embodiments obtained by those of ordinary skill in the art based on the embodiments of the present invention without creative efforts shall fall within the protection scope of the present invention.

[0037] It should be noted that, without conflict, the embodiments in the present invention and the features in the embodiments may be combined with each other.

[0038] Next, the present invention will be further described in conjunction with specific embodiments, but it is not a limitation of the present invention.

[0039] The embodiment of the present invention discloses a design method for lightweight of the wire feeder cantilever frame, including the following steps:

[0040] Step 1: Select relevant structure parameters according to the actual structure of the crossbeam of the cantilever frame and establish a parametric three-dimensional model of the crossbeam of the cantilever frame;

[0041] As Figure 2 shown, it is the structure schematic diagram of the crossbeam of the wire feeder cantilever frame; as Figure 3 shown, it is the dimension parameter diagram of the crossbeam of the wire feeder cantilever frame; in this embodiment, the crossbeam side plate and the top plate are the main load-bearing components, and the wall thickness, length, and height dimensions will all affect the stiffness, strength, and stress of the crossbeam. Therefore, the thickness t1 of the crossbeam top plate, the thickness t2 of the side plate, the height P1 of the side plate, the distance P2 between the side plate hinge point O2 and the tip point A, and the transition fillet radius P3 between the hinge point and the crossbeam are selected, a total of 5 parameters as structure parameters.

[0042] According to Figure 2 the crossbeam of the wire feeder cantilever frame and the above structure parameters, a three-dimensional model is established in SolidWorks software, and the dimensions corresponding to the 5 structure parameters are modified to dimension names with the prefix "DS_" in the name, and imported into DesignModler. Check the above 5 structure parameters in the modeling column to obtain a parametric three-dimensional model of the crossbeam of the wire feeder cantilever frame.

[0043] Step 2: Establish a CAE finite element model according to the three-dimensional model and apply boundary conditions to the finite element model;

[0044] In this step, the established parametric 3D model is imported into the finite element software ANSYS Workbench to construct the finite element model of the cantilever beam. The parametric 3D model is discretized using solid elements and divided using the adaptive mesh method with the rest of the values being default. A total of 34,067 nodes and 5,900 solid elements are divided. The finite element model obtained through mesh division facilitates the calculation of mass, deformation, stress, etc. under different combinations of design variables. Through this step, complex continuum problems can be transformed into discrete mathematical problems, which are convenient for computer solution.

[0045] Boundary loads are applied to the finite element model, and the constraint loads of the finite element model are determined. In this embodiment, the column connection point and the oil cylinder connection point are set as hinge constraints; and the maximum load at the factory is set to 80 kg, the load application position is at the connection between the cantilever beam and the wire feeder base, and the gravity load is applied to the whole. As Figure 4 shown, it is the constraint load diagram of the finite element model of the wire feeder cantilever beam structure.

[0046] In this embodiment, the final results show that the maximum deformation of the cantilever beam occurs at the rightmost end of the cantilever, with a maximum deformation of 5.11 mm. Under the rated load condition of the cantilever beam, the maximum stress appears at the P3 arc part, with a maximum stress of 126.93 MPa.

[0047] Step 3: Select the key design variables from the structural parameters in Step 1 and construct the target design optimization model accordingly;

[0048] When using numerical optimization to optimize the design of the cantilever beam, it is necessary to determine which structural parameters have the greatest impact on the lightweight design of the cantilever beam. Therefore, in this embodiment, the value ranges of each structural parameter are first set, and a sensitivity analysis is performed on each structural parameter. When performing the parameter sensitivity analysis, 4 of the structural parameters are fixed, and multiple values are taken for the remaining one structural parameter. The maximum deformation and the maximum stress at different values are calculated, and the influence degree of different values on the strength and stiffness performance is judged by the magnitudes of the maximum deformation and the maximum stress. Then, the influence degrees of the 5 structural parameters on the strength and stiffness performance are ranked from heavy to light, and the top 2 ranked plate thickness t2 and beam height P1 are selected as the key design variables.

[0049] After determining the key design variables, the overall mass, maximum deformation, maximum stress, and safety factor of the cantilever beam are constrained, and the target design optimization model with specific constraint relationships is established, described as follows:

[0050]

[0051] Where X is the design variable, and its value range is 2 ≤ t1 ≤ 6, 2 ≤ t2 ≤ 6, 60 ≤ P1 ≤ 100, 300 ≤ P2 ≤ 400, 10 ≤ P3 ≤ 15; m(X) is the mass of the crossbeam of the cantilever rack; f1(X) is the maximum deformation of the crossbeam of the cantilever rack (in this embodiment, it is set to 5.11 mm); f2(X) is the maximum equivalent stress of the crossbeam of the cantilever rack (in this embodiment, it is set to 126.93 MPa); R is the maximum working radius of the crossbeam of the cantilever rack (in this embodiment, 2000 mm), and R / 250 is the maximum allowable deformation of 8 mm; σ1 is the yield limit of the material, which is taken as 235 MPa in this embodiment; σ is the allowable stress of 195.8 MPa; s is the safety factor, which is taken as 1.2 in this embodiment.

[0052] Step 4: Use the central composite method to take sample points for each structural parameter in the finite element model in Step 2 to obtain multiple groups of sample point sets containing each structural parameter, and then fit the multiple groups of sample points to obtain the response surface.

[0053] In this embodiment, in the Mechanical module of the finite element software, define the total mass, maximum deformation, and maximum stress design variables. Call the response surface analysis module (Response Sruface Optimization) in ANSYS and associate it with the created structural parameters. In the ANSYS call to the response surface analysis module, set the upper and lower limit value ranges of 5 structural parameters, namely t1, t2, P1, P2, and P3, and then use the central composite method (Central Composite Design, CCD) to obtain 27 groups of sample point sets on the finite element model. Each group of sample point sets includes the values of the above 5 structural parameters. Fit the above 27 groups of sample point sets to obtain the response surface characterizing the relationship between the 5 structural parameters.

[0054] Step 5: Use the optimization algorithm to solve the target design optimization model, and combine the relationship of each structural parameter in the response surface to obtain the optimized dimensions of each final structural parameter.

[0055] In this embodiment, set the maximum deformation and maximum equivalent stress for the target design optimization model, and set the optimization goal to minimize the mass. Use the multi-objective genetic algorithm, set the population size to 100, the crossover probability to 0.9, and the mutation probability to 0.02. After 36 iterations, solve to obtain 3 groups of Pareto optimal solutions for the lightweight of the crossbeam of the cantilever rack. Obtain the optimized dimensions of the 5 parameters according to the Pareto optimal solutions combined with the response surface.

[0056] After obtaining multiple groups of results, compare and verify the multiple groups of optimization results through the mass, maximum deformation and finite element calculation of the crossbeam of the cantilever frame. After reliable verification, it is the final optimized value, and the optimization ends here. When t1 is 2.7 mm, t2 is 2 mm, P1 is 98.9 mm, P2 is 303.6 mm, and P3 is 11.9 mm, the total mass of the crossbeam is 9.63 kg, the maximum deformation is 8 mm, and the maximum equivalent stress is 181.2 MPa.

[0057] After optimization, the optimized values of the selected 5 structural parameters are finally determined, and the final optimization results and their performance of the crossbeam of the cantilever frame are obtained. Finally, without changing the payload, the above method is used to achieve multi-objective optimization of the crossbeam of the wire feeder cantilever frame, and the weight reduction ratio reaches more than 50%.

[0058] The embodiment of the present invention also provides a system for implementing the design method for lightweighting the crossbeam of the wire feeder cantilever frame as described above, including:

[0059] A three-dimensional model construction module, configured to select relevant structural parameters according to the actual structure of the crossbeam of the cantilever frame and establish a parametric three-dimensional model of the crossbeam of the cantilever frame;

[0060] A finite element model construction module, configured to establish a CAE finite element model according to the three-dimensional model and apply boundary conditions to the finite element model;

[0061] A target optimization model establishment module, which selects key design variables from the structural parameters and constructs a target design optimization model accordingly;

[0062] A parameter response surface establishment module, configured to use the central composite method to take sample points for each structural parameter in the finite element model, obtain multiple groups of sample point groups including each structural parameter, and then fit the multiple groups of sample points to obtain a response surface;

[0063] A solving module, configured to use an optimization algorithm to solve the target design optimization model, and combine the relationships of each structural parameter in the response surface to obtain the optimized dimensions of each structural parameter finally.

[0064] In another specific embodiment, an electronic device is further provided, including a memory and a processor, where the memory stores a computer program, and it is characterized in that when the processor executes the computer program, the steps of the above method are implemented.

[0065] In another specific embodiment, a computer-readable storage medium is further provided, on which a computer program is stored, and it is characterized in that when the computer program is executed by a processor, the steps of the above method are implemented.

[0066] The above are only the preferred embodiments of the present invention, and thus do not limit the implementation manners and protection scope of the present invention. For those skilled in the art, it should be realized that all the solutions obtained by equivalent substitutions and obvious changes made by using the content of the specification of the present invention should be included within the protection scope of the present invention.

Claims

1. A design method for lightweighting the cross beam of the wire feeder cantilever frame, characterized in that, It includes the following steps: Step 1: Select relevant structural parameters according to the actual structure of the cantilever beam and establish a parametric 3D model of the cantilever beam; Step 2: Establish a CAE finite element model based on the parametric 3D model and apply boundary conditions to the finite element model; Step 3: Select key design variables from the structural parameters in Step 1 and construct a target design optimization model accordingly; Step 4: Use the central composite method to take sample points for each structural parameter in the finite element model in Step 2, obtain multiple groups of sample point groups containing each structural parameter, and then fit the multiple groups of sample points to obtain a response surface; Step 5: Use an optimization algorithm to solve the target design optimization model, and combine the relationships of each structural parameter in the response surface to obtain the optimized dimensions of each final structural parameter.

2. The design method for lightening the cross beam of the wire feeder cantilever frame according to claim 1, characterized in that, In Step 1, select the thickness t1 of the crossbeam top plate, the thickness t2 of the side plate, the height P1 of the side plate, the distance P2 between the side plate hinge point O2 and the tip point A, and the transition fillet radius P3 between the hinge point and the crossbeam as structural parameters.

3. The design method for lightening the cross beam of the wire feeding machine cantilever frame according to claim 1, wherein Step 2 specifically includes: Import the established parametric 3D model into software to construct a finite element model of the cantilever beam, discretize the model using solid elements, and perform mesh division using the adaptive mesh method; Determine the constraint loads of the finite element model, and set the column connection point and the oil cylinder connection point as hinge constraints; determine the maximum load at the factory, the load application position is the connection between the cantilever beam and the wire feeder base, and apply a gravity load to the whole; 4. The design method for the lightweight of the wire feeder cantilever beam according to claim 1, characterized in that In Step 3, first perform a sensitivity analysis on each structural parameter, and select the k structural parameters with the highest sensitivity as key design variables.

5. The design method for lightening the transverse beam of the wire feeder cantilever frame according to claim 4, characterized in that Constrain the total mass, maximum deformation, maximum equivalent stress, and safety factor of the cantilever beam, and construct a target design optimization model based on the key design variables: Among them, X is the key design variable; m(X) is the mass of the cantilever beam; f1(X) is the maximum deformation of the cantilever beam; f2(X) is the maximum equivalent stress of the cantilever beam; R is the maximum working radius of the cantilever beam; σ1 is the material yield limit; σ is the allowable stress; s is the safety factor.

6. The design method for the lightweight of the wire feeder cantilever beam according to claim 1, characterized in that Use the multi-objective genetic algorithm for the target design optimization model. When calculating, pre-determine the population size, crossover probability, and mutation probability, obtain multiple groups of key design variables through iterative calculation, and combine the response surface in Step 4 to obtain the design values of each structural parameter; After obtaining multiple groups of results, compare and verify the multiple groups of results through the mass and maximum deformation of the cantilever beam and finite element calculation. After verification, it is the final optimized value, and the optimization ends here.

7. A system for implementing a design method for lightening the cross beam of the wire feeder cantilever frame described in any one of claims 1-6, characterized in that, It includes: A 3D model construction module for selecting relevant structural parameters according to the actual structure of the cantilever beam and establishing a parametric 3D model of the cantilever beam; A finite element model construction module for establishing a CAE finite element model based on the parametric 3D model and applying boundary conditions to the finite element model; A target optimization model establishment module for selecting key design variables from the structural parameters and constructing a target design optimization model accordingly; A parameter response surface establishment module for using the central composite method to take sample points for each structural parameter in the finite element model, obtaining multiple groups of sample point groups containing each structural parameter, and then fitting the multiple groups of sample points to obtain a response surface; A solution module, which is used to solve the target design optimization model by using an optimization algorithm and obtain the optimized dimensions of the final structural parameters in combination with the relationships of the various structural parameters in the response surface.

8. An electronic device, comprising a memory and a processor, the memory storing a computer program, characterized in that, When the processor executes the computer program, it implements the steps of the method according to any one of claims 1 to 6.

9. A computer-readable storage medium having a computer program stored thereon, characterized in that, When the computer program is executed by the processor, it implements the steps of the method according to any one of claims 1 to 6.

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