Welding system for manufacturing a workpiece

Abstract

The utility model provides a kind of welding system for production workpiece, it includes: at least one welding chamber (100-i);3D measuring device (300), it is configured to measure the rough version of workpiece (1-i) that is arranged in the welding chamber (100-i), at least one grinding pit (2-i) is formed on it, to generate actual size data;At least one robot (200), it is configured to guide at least one welding tool (201,202);Database (400), it is configured to store the nominal size data of the workpiece (1-i);Computing device (500), it is configured to calculate the trajectory of the robot (200) that guides the welding tool (201,202);And control device (600), it is configured to use the trajectory calculated to control the welding tool (201,202) and the robot (200), to fill at least one grinding pit (2-i) by manufacturing welding.

Description

Technical Field

[0001] This utility model relates to a welding system for manufacturing workpieces (especially large-sized workpieces) that are essentially produced in a casting process such as steel casting. Background Technology

[0002] Large components that must withstand exceptionally high loads are typically manufactured using casting processes, particularly cast steel. The casting process first produces a rough version of the workpiece, which is then subjected to various post-processing steps. Post-processing is complex and presents specific challenges, especially for large components.

[0003] For example, it is known to remove excess material from dimensional deviations in workpieces by carbon arc gouging. This is a heat treatment that uses copper-plated carbon rods as consumable electrodes. The material is melted by an electric arc formed between the consumable electrode and the excess material, which is then typically blown away with compressed air. However, this process has many side effects, such as undesirable changes in the material composition at the treated area (surface “carburization”), as well as considerable smoke and noise emissions and a large amount of heat.

[0004] There are also challenges, particularly those related to electromagnetic fields and interference effects, which occur in all applications employing high currents, but are especially significant over long distances involving large components. Utility Model Content

[0005] The objective of this invention is to provide an improved welding system for manufacturing workpieces, particularly for producing large-sized workpieces using a cast steel process.

[0006] An example method for manufacturing a workpiece includes at least the following steps:

[0007] A rough version of the workpiece is manufactured in the steel casting process;

[0008] At least one grinding pit is formed in the rough version of the workpiece;

[0009] A rough version of the workpiece with at least one grinding pit formed thereon, manufactured by automated three-dimensional measurement, is used to generate actual dimensional data;

[0010] Based on the generated actual size data and the stored nominal size data of the workpiece, the trajectory that the robot guiding the welding tool must follow is automatically calculated; and

[0011] The at least one grinding pit is automatically filled by manufacturing a weld, wherein the robot is controlled according to a calculated movement path.

[0012] The “rough version” of a workpiece should be specifically understood as an intermediate state of the workpiece before its final completion, particularly as an intermediate state as a direct result of casting steel or as a result of subsequent processing steps after casting steel, wherein at least one, but usually multiple, discontinuities temporarily exist in the rough version of the workpiece. At least one discontinuity may be, in particular, a material defect in the structure, such as a crack, inclusion, hole, pore, double section, or another type of discontinuity.

[0013] Such discontinuities that occur during casting are typically removed quickly and efficiently from rough versions using thermal cutting processes (e.g., utilizing a carbon arc). This can sometimes result in significant defects in rough versions compared to the desired final state of the workpiece, which requires refilling. Additionally, thermal cutting processes can cause undesirable changes in the material at the defect edges, such as carburizing (i.e., carbon buildup) in the case of working with a carbon arc.

[0014] To obtain a suitable substrate for filling the defects as necessary after defect removal, grinding pits are advantageously created by further grinding away the defects, particularly grinding pits of defined dimensions. Thus, such grinding pits are recesses in the roughened version of the workpiece, located at the points in the roughened version where defects were previously detected and removed. Therefore, once grinding pits are created, advantageously, there are no discontinuities or material variations in the roughened version of the workpiece, only defects in the form of pure grinding pits.

[0015] As will be explained later, a predetermined set of parameters can then be saved and used for these grinding pits so that a particularly suitable manufacturing weld can fill the weld pits.

[0016] Typically, this description sometimes refers to "multiple versions" of a workpiece. This should be understood as meaning that the same workpiece undergoes different versions (or: intermediate states) during its manufacturing process, and therefore it is not a collection of different workpieces.

[0017] Compared to nominal dimensional data, actual dimensional data of a workpiece can specifically refer to the current shape of the workpiece, while nominal dimensional data can describe the desired final shape of the workpiece to be realized, particularly the finished product. It should be understood that actual dimensional data can be generated multiple times during the workpiece manufacturing process, each corresponding to the shape of the workpiece at that time. Dimensional data (both actual and nominal dimensional data) specifically describe the three-dimensional shell of the workpiece.

[0018] As a result of subsequent manufacturing welding, each grinding pit is advantageously treated, particularly filled, so that the workpiece is thus completed or placed in a state where subsequent processing can be performed at the point where the original defect was not present. In other words, by eliminating at least one defect and subsequently automatically filling at least one grinding pit, the rough version of the workpiece can be placed in a uniform state in which subsequent processing steps can be performed on the workpiece (preferably without further consideration of the previous at least one defect).

[0019] The calculated trajectory used for manufacturing welds and also for automatically filling grinding pits can also be referred to as the manufacturing weld trajectory, especially for more clearly distinguishing them from other possible trajectories.

[0020] According to some preferred embodiments, variations or improvements of the embodiments, the welding tool used to manufacture the welding is a gas metal arc welding tool.

[0021] According to some preferred embodiments, variations or improvements of the embodiments, the example method also includes automated welding of workpieces for coating or contouring, particularly by laser welding (i.e., laser metal deposition) or by plasma-transferred arc (PTA) welding.

[0022] According to some preferred embodiments, variations or improvements of the embodiments, the example method further includes: automatically calculating, based on the generated actual size data and the stored nominal size data, a plasma planing trajectory to be passed through a plasma torch to remove excess dimensions from a rough version of the workpiece by plasma planing.

[0023] In another step, excess dimensions can be removed by plasma planing using a plasma torch, which moves along an automatically calculated plasma planing trajectory.

[0024] In this way, excess dimensions that were originally present in the rough version can be removed, as well as excess dimensions (e.g., protrusions of weld beads) generated in intermediate process steps (e.g., when using manufacturing weld filler grinding pits), so that the dimensions of the workpiece continue to (or are completely) close to the desired nominal dimensional data.

[0025] Using plasma gouging, material removal is advantageously non-contact and virtually abrasive compared to existing processes such as arc gouging. Therefore, the plasma torch can be used continuously, which improves process efficiency and does not cause any changes to the material composition.

[0026] According to some preferred embodiments, variations, or improvements of the embodiments, the plasma torch is attached to the robot via a linear actuator. Distance control between the plasma torch and the workpiece can be achieved to maintain a constant energy input over time, which can improve process stability and reliability.

[0027] Distance control between the plasma torch and the workpiece is preferably achieved using a linear actuator. A linear actuator is preferably more dynamic than a robot, which typically cannot react quickly enough to changing physical conditions at the arc due to its greater mass. Conversely, a linear actuator with a servo-driven linear axis can react much faster to perform the corresponding distance control. Specifically, the linear actuator (in conjunction with the plasma torch itself) can be controlled such that the plasma arc voltage, and therefore the energy input, is maintained at a constant (predetermined and / or adjustable) value.

[0028] According to some preferred embodiments, variations or improvements of the embodiments, this example method further includes the following steps:

[0029] Plasma arcs are generated by plasma torches to perform plasma planing on workpieces.

[0030] The plasma arc voltage of the generated plasma arc is detected; and

[0031] The detected plasma arc voltage is used as a control variable to control the distance between the plasma torch and the workpiece.

[0032] According to some preferred embodiments, variations or improvements of the embodiments, a robot is used to realize the plasma planing trajectory that the plasma torch will traverse. In addition to guiding the manufacturing welding tool (or at least one other metalworking tool, especially a welding tool), the robot can also guide the plasma torch, or alternately guide the manufacturing welding tool (or at least one other metalworking tool, especially a welding tool) and the plasma torch.

[0033] According to some preferred embodiments, variations or improvements of the embodiments, this example method further includes the following steps:

[0034] Automated 3D measurement is used to create a rough version of the manufactured workpiece to generate preliminary actual dimensional data; and

[0035] Based on the generated preliminary actual size data and the stored nominal size data of the workpiece, the grinding trajectory to be traversed by at least one grinding tool is automatically calculated.

[0036] In the rough version of the workpiece, at least one grinding pit is formed by passing through the grinding path that at least one grinding tool must traverse.

[0037] In this way, at least one grinding pit can be automatically generated according to a specific grinding trajectory, which in particular simplifies the subsequent filling of at least one grinding pit by manufacturing welding.

[0038] As already explained, discontinuities are advantageously removed by thermal cutting processes, particularly using carbon arcs (so-called "carbon arc gouging"), which produce defects that are then further ground into grinding pits.

[0039] According to some preferred embodiments, variations or improvements of the embodiments, this example method therefore also includes the following steps:

[0040] Based on the previously generated actual dimensions of the workpiece and the stored nominal dimensions of the workpiece, the cutting trajectory to be traveled by at least one thermal cutting tool is automatically calculated; and

[0041] Discontinuities are automatically eliminated by tracing the cutting path that at least one thermal cutting tool will follow.

[0042] According to some preferred embodiments, variations, or improvements of the embodiments, welding parameters are provided by a database, wherein separate sets of welding parameters are provided for at least two different orientations in space for the grinding pit to be filled. Manufacturing welding by welding tools can then be performed based on the corresponding associated set of parameters for the orientation in space of the respective grinding pit to be filled.

[0043] The parameter set, as a whole, provides welding parameters for all technically feasible locations of the grinding pit in space. For example, three different parameter sets can be provided: one for locations near the horizontal line, one for locations near the vertical line, and one for the transition region in between. Alternatively, only two different parameter sets can be provided, each covering half of the possible locations. According to one aspect of the present invention, a welding system for manufacturing workpieces is provided, comprising:

[0044] At least one welding chamber;

[0045] A 3D measuring device is configured to automatically measure a rough version of a workpiece arranged in a welding chamber, on which at least one grinding pit is formed, in order to generate actual dimensional data.

[0046] At least one robot configured to guide at least one welding tool;

[0047] A database configured to store the nominal dimensions of workpieces;

[0048] A computing device configured to automatically calculate the trajectory of a robot guiding a welding tool based on generated actual dimensional data and stored nominal dimensional data of the workpiece; and

[0049] A control device configured to use a calculated trajectory to control welding tools and a robot to fill at least one grinding pit by creating a weld.

[0050] Computing and control devices can be designed to be integrated or separate from each other. This distinction is made specifically based on function. Such computing and / or control devices can be, or can be implemented as, any device capable of computing and, in particular, executing software, applications, or algorithms. The computing and / or control devices may, for example, include at least one processor unit, such as a central processing unit (CPU) and / or a graphics processing unit (GPU) and / or a field-programmable logic array (FPGA) and / or an application-specific integrated circuit (ASIC) and / or combinations thereof. The computing and / or control devices may also include working memory operatively coupled to at least one processor unit, and non-volatile memory operatively coupled to at least one processor unit and working memory. The computing and / or control devices can be implemented entirely or entirely in a local device (e.g., in a soldering room), and / or entirely or entirely in a remote system (e.g., a remote server and / or a cloud computing platform).

[0051] The welding system may preferably include multiple welding chambers, each specifically configured such that a single workpiece (preferably a large-sized workpiece) is produced or can be produced (completed) therein. The welding system may have multiple robots for its use, wherein at least one of these robots is configured to weld in more than one welding chamber. This allows for more efficient use of existing robots. It is also possible that at least one welding chamber and at least two robots are designed such that at least two robots can weld simultaneously in at least one welding chamber.

[0052] Movable partition walls can also be provided between two (or more) welding chambers, allowing the two (or more) welding chambers to be combined into one large welding chamber when needed. In this case, all robots previously configured to work on a workpiece in one of the welding chambers can now be configured to work on one (or more) workpieces in the combined welding chamber.

[0053] The welding chambers of the welding system can be arranged one after another, with one robot for every two adjacent welding chambers. The robots can overlap, such that, except for the first and last welding chambers, two robots can weld in each welding chamber, and the welding system thus has N-1 robots for N welding chambers, so the robots can handle (e.g., weld) at most N-1 workpieces simultaneously. Alternatively, the robots can be arranged without overlap, such that only one specific robot can work / weld in every two welding chambers (and only there), such that the welding system has N / 2 robots for N welding chambers, and thus can handle (specifically weld) at most N / 2 workpieces simultaneously.

[0054] Welding chambers in welding systems, combined with other forms or arrangements of a number of robots, are also possible.

[0055] According to some preferred embodiments, variations, or improvements of the embodiments, the welding system also includes a plasma torch for removing excess dimensions from a rough version of the workpiece by plasma gouging. Control devices can be arranged to control the plasma torch as described above with reference to the example method. Specifically, the control devices can be arranged to control the plasma torch based on generated actual dimensional data and stored nominal dimensional data. In this way, the dimensions of the actual version of the workpiece after plasma gouging are advantageously closer to (or more similar to) the nominal dimensional data than before plasma gouging.

[0056] According to some preferred embodiments, variations, or improvements of the embodiments, the plasma torch can be attached to or mounted on a robot via a linear actuator. The control device can be configured to use the linear actuator to achieve distance control between the plasma torch and the workpiece. As described above, the plasma arc voltage can be used by the control device as a control variable for distance control. For this purpose, the control device may have a plasma arc voltage determination module configured to determine the current plasma arc voltage.

[0057] When this article refers to "module", it should be understood that this does not necessarily mean that such a module is designed as a separate unit.

[0058] When a module is designed as software, it can be implemented as program code segments or program code components, which can be distinct from each other, but they can also be intertwined. Similarly, when one or more modules are implemented as hardware, the functionality of the one or more modules can be implemented by the same hardware component. Alternatively or additionally, different functions of a single module, or even different functions of different modules, can be implemented on one or more separate hardware components, and therefore such one or more separate hardware components do not necessarily have a one-to-one relationship with a module. In this sense, any device, system, method, etc., having all the attributes and functions belonging to a particular module can be understood as having, representing, or implementing such a module. In particular, it is possible for all modules to be implemented as program code executed by a computing device and / or a control device.

[0059] According to some preferred embodiments, variations, or improvements of the embodiments, the welding system also includes a welding tool attached to or potentially attachable to a robot, particularly a laser welding tool or a plasma powder welding tool. This allows welding to be performed to bring the current version of the workpiece closer to the finished version of the workpiece.

[0060] The term "tool can be attached to a robot" can specifically mean that the robot can grasp the corresponding tool or attach it to itself, or that the tool can be attached to the robot using an automated tool holder.

[0061] According to some preferred embodiments, variations or improvements of the embodiments, the welding system also includes a busbar.

[0062] The robot has a current collector with a sliding contact configured to maintain electrical contact with the busbar during the robot's movement, so as to establish an electrical connection, particularly a grounding connection, between the robot's electrodes and the workpiece via the busbar.

[0063] By using busbars, the total length of the effective current path between the robot's electrodes (more precisely, the robot's welding current source) and the workpiece can be significantly shortened, which can reduce or completely avoid electromagnetic interference (e.g., arc blowing effect), especially electromagnetic interference caused or amplified by the large size of the workpiece to be produced and the geometry of the current conductors.

[0064] Therefore, this advantage is particularly evident in welding chambers designed for large workpieces, especially those with dimensions of 3m. 3m For workpieces 3m or larger (in any size) or of the same or larger volume, a size of 4m is particularly preferred. 4m For example, a workpiece with a size of 4m or larger (in any dimension) or the same or larger volume, such as a workpiece with a size of 4m. 4m Workpieces that are 8m or larger (in any size) or of the same or larger volume.

[0065] Large-sized workpieces can also be workpieces weighing 10 tons or more in rough versions after (especially immediately) casting steel, such as 30 tons or more, 50 tons or more, 100 tons or more, 150 tons or more, or even 200 tons or more.

[0066] By using the busbar according to the present invention, the inductance of the current path can be advantageously kept low, for example, below 30 microhenries (μH), below 29 microhenries (μH), below 25 microhenries (μH), or particularly preferably below 20 microhenries (μH).

[0067] According to some preferred embodiments, variations or improvements of the embodiments, the workpiece in the welding chamber is electrically connected or can be electrically connected to the busbar via a grounding wire.

[0068] The combined current-carrying length of the grounding conductor and busbar is preferably 12 meters or less, particularly 10 meters or less, and especially preferably less than 8 meters. Meanwhile, due to the size of the welding chamber required for large-sized workpieces, the busbar typically has a length of 3 meters or longer, particularly 4 meters or longer.

[0069] In particular, if the welding system has multiple welding chambers arranged one after another (especially in a straight line), the busbar can be formed across multiple welding chambers. Although the busbar itself can become significantly longer, the combined current-carrying length (i.e., the effective current path) of the busbar and the corresponding grounding wire of the respective welding chamber is advantageously kept below 12 meters, especially below 10 meters, and preferably below 8 meters. The busbar can have a bending radius, and therefore the robot's trajectory can also typically have a bending radius.

[0070] According to some preferred embodiments, variations or improvements of the embodiments, the sliding contact comprises, or is composed of, ground carbon, gray cast iron, brass, bronze, aluminum and / or copper. For example, the sliding contact may advantageously comprise, or be composed of, a brass / bronze alloy or an aluminum / copper alloy.

[0071] The electrical conductivity of one or more materials (especially all materials) constituting the sliding contact is advantageously 5 siemens / meter (S / m) or higher, preferably 13 S / m or higher, particularly preferably 28 S / m or higher, especially 33 S / m or higher or 55 S / m or higher.

[0072] The welding system can also advantageously have a database providing operating parameters for at least one process, such as welding parameters for manufacturing welds. Advantageously, a separate set of welding parameters is provided for each of at least two different orientations in space of the grinding pit to be filled. The welding system can be advantageously configured such that the welding tool performs the manufacturing weld using the corresponding associated set of parameters based on the orientation in space of the respective grinding pit to be filled.

[0073] Further advantageous embodiments, variations and improvements of the embodiments are shown in the following detailed description with reference to the accompanying drawings. Attached Figure Description

[0074] The present invention will now be explained in more detail with reference to examples of embodiments shown in the accompanying drawings.

[0075] Figure 1 This describes a welding system according to one embodiment of the present invention;

[0076] Figure 2 express Figure 1 A schematic 3D detailed view of a portion of the busbar of a welding system;

[0077] Figure 3 express Figure 2 A schematic cross-section of the busbar;

[0078] Figure 4 This diagram illustrates the electrical layout in a welding room based on the current technological state.

[0079] Figure 5 A schematic electrical layout of the welding chamber of a welding system according to an embodiment of the present invention;

[0080] Figure 6 express Figure 1 A schematic detailed view of the robot's welding system;

[0081] Figure 7 Various views showing grinding pits;

[0082] Figure 8 The diagram illustrates the possible geometry of the grinding pit;

[0083] Figure 9 This represents a schematic flowchart used to explain the example method.

[0084] In all the accompanying drawings, unless otherwise specified, identical or functionally identical elements and devices are labeled with the same reference numerals. The designation and numbering of method steps do not necessarily imply order, but are used for better distinction; however, in some variations, the order may correspond to the order of the numbers. Detailed Implementation

[0085] Figure 1 A welding system 1000 according to an embodiment of the present invention is shown. The welding system 1000 includes at least one welding chamber, wherein two welding chambers 100-1 and 100-2 are located in... Figure 1 The example shown is provided below. The welding system 1000 may include only one welding chamber 100-1 or more than two welding chambers 100-1, 100-2. Welding chambers of any number are also referred to below as "welding chamber 100-i". The same nomenclature is also used below for other components that may exist in more than one form.

[0086] The welding system 1000 also includes at least one robot 200 configured to guide at least one welding tool. Figure 1 In the illustration, a single robot 200 is shown as an example, which is configured to use welding tools in both the first welding chamber 100-1 and the second welding chamber 100-2. In other words, the robot 200 can handle both the first workpiece 1-1 in the first welding chamber 100-1 and the second workpiece 1-2 in the second welding chamber 100-2 (first and / or later in time).

[0087] Since welding (i.e., handling workpiece 1-i with welding tools) typically constitutes only a portion of the process steps to be performed in welding chamber 100-i and not every process step requires robot 200, robot 200 can be utilized in this way in a particularly comprehensive manner, because if it is not currently needed in a welding chamber 100-i, it can be used in another welding chamber 100-j that it can reach (where “100-j” here represents a welding chamber other than welding chamber “100-i”).

[0088] As previously described, the welding system 1000 may also include one robot 200 for each welding chamber 100-i, one robot for every two welding chambers 100-i (overlapping or non-overlapping), or any other number of robots 200. It may also be specified that more than one robot 200 is provided for each welding chamber 100-i, which may be dedicated (i.e., only for that welding chamber 100-i) or configured in an average manner.

[0089] As will be explained in more detail below, robot 200 can actually be used for a large number of process steps in manufacturing workpiece 1-i, which sometimes require different tools. It can be specified that robot 200 is equipped with multiple tools and / or can switch between multiple tools, and / or different robots 200 are provided, each with (fully or partially) different tools. For this purpose, welding system 1000 may, for example, have a tool holder that can be used by robot 200, which has multiple tools that can be used by robot 200.

[0090] Specifically, the welding tool can be a welding tool used for manufacturing welding, and therefore can also be referred to as a welding tool manufacturing tool 201. Such a welding tool manufacturing tool 201 can be, for example, a gas metal arc welding tool.

[0091] The robot 200 can also be configured to guide a plasma torch, for example, for removing excess material (excess dimensions). The robot 200 can also be configured to guide welding tools, particularly laser welding tools and / or plasma powder welding tools. The robot 200 can also be configured to guide grinding tools. These and other tools and their possible applications will be explained in more detail below in conjunction with the method according to this invention.

[0092] The welding system 1000 also includes a 3D measuring device 300 configured to automatically perform three-dimensional measurements on a rough version of a workpiece 1-i arranged in the welding chamber 100-i, on which at least one grinding pit is formed, in order to generate actual dimensional data. It should be understood that the measuring device 300 can also be configured to generate actual dimensional data (i.e., measure workpiece 1-i) in other versions—for example, before the grinding pit is formed on workpiece 1-i, or after the grinding pit 2-i has been filled.

[0093] As described with reference to one or more robots 200, a measuring device 300 may be provided for each welding chamber 100-i, every two welding chambers 100-i, 100-j (overlapping or non-overlapping), or any other number and / or configuration of welding chambers. For example, it may be an optical measuring device performing an optical measurement process. For example, the measuring device 300 may be configured to perform methods based on strip and / or pattern projection, such as laser cutting methods. Other possible optical measuring devices are, for example, devices for confocal measurement techniques, white light interferometry, time-of-flight measurement, and / or stereoscopic photography. Depending on the specific variant, the measuring device 300 may also be permanently arranged on the welding chamber 100-i.

[0094] In a preferred variant, the measuring device 300 is integrated into each robot 200, or each robot 200 includes the measuring device 300. However, the measuring device 300 can also be designed as an interchangeable tool, i.e., the robot 200 (or each robot) can automatically equip itself with the measuring device 300 (or be equipped with the measuring device 300) at a tool holder in a so-called "tool station" as needed or according to a planned sequence, which can be automatically stored again after the corresponding measurement (e.g., for equipping cutting tools, grinding tools, welding tools, etc.).

[0095] The welding system 1000 also includes a database 400 configured to store at least the nominal dimensional data of workpiece 1-i. The database 400 can be located locally in or on welding chamber 100-i, or it can be remotely located, for example, implemented as a cloud database. The database 400 can also store other data, such as control data from robot 200. The database 400 can be physically implemented as multiple separate data storage devices.

[0096] As will be explained in more detail below, the database 400 can also be designed to store a large number of operating parameters, particularly welding parameters for one or more welding process steps (e.g., fabrication welding, surfacing, etc.). The welding parameters are preferably stored in two or more parameter sets, and particularly preferably in three or more parameter sets. Specifically, a separate set of welding parameters for fabrication welding can be provided for each of at least two different orientations in space for the grinding pit 2-i to be filled, and fabrication welding can be performed by the welding tool 201 using the corresponding associated set of parameters based on the orientation in space of the respective grinding pit 2-i to be filled.

[0097] The welding system 1000 also includes a computing device 500 configured to automatically calculate the trajectory to be traversed by the robot 200 guiding the welding tool 201 based on the generated actual size data and the stored nominal size data of the workpiece 1-i. If the robot 200 is designed to operate in multiple welding chambers 100-i, particularly to weld, the computing device 500 can also be designed to automatically generate the trajectory to be traversed in the multiple welding chambers 100-i.

[0098] The welding system 1000 also includes a control device 600 configured to use a calculated trajectory to control the manufacturing welding tool 201 and the robot 200 to fill at least one grinding pit 2-i by manufacturing a weld.

[0099] As will be explained in more detail below, especially with reference to the possible method steps according to the example method, the welding system 1000 can be configured for various other functions.

[0100] In some embodiments, particularly in conjunction with the welding chamber 100-i designed for large workpieces 1-i, the welding system 1000 may also have a busbar 700.

[0101] The robot 200 may have a current collector 270 with a sliding contact 277, which is configured to remain in electrical contact with the busbar 700 during the movement of the robot 200, so as to establish an electrical connection between the electrodes of the robot 200 (in particular the welding power source 210 of the robot 200) and the workpiece 1-i via the busbar 700.

[0102] Figure 2 A schematic three-dimensional detailed view showing a portion of busbar 700 and a possible design of current collector 270 with sliding contact 277. Robot 200 is specifically designed to move along busbar 700 (at least in one spatial dimension) such that its current collector 270 moves along busbar 700 and is always in electrical contact with it. Busbar 700 can be straight or have a bending radius, for example, 1000mm to 10000mm, particularly 2000mm to 8000mm, and especially preferably 3000mm to 5000mm.

[0103] The sliding contact 277 may include, or be composed of, carbon brushes, gray cast iron, brass, bronze, aluminum (especially pure aluminum) and / or copper. The sliding contact 277 may, for example, advantageously be composed of, a brass / bronze alloy or an aluminum / copper alloy, or have such alloys.

[0104] The electrical conductivity of one or more materials (especially all materials) constituting the sliding contact is advantageously 5 siemens / meter (S / m) or higher, preferably 13 S / m or higher, particularly preferably 28 S / m or higher, especially 33 S / m or higher or 55 S / m or higher.

[0105] Figure 3 A schematic cross-section of busbar 700 is shown to illustrate a possible advantageous cross-sectional profile of busbar 700. Specifically, busbar 700 can be implemented as a generally T-shaped steel rail, to which copper head 720 is attached at the base of the T-shape. This steel rail is designed to contact the sliding contact 277, as... Figure 2 As shown. The copper head 720 can advantageously have a 35mm diameter. 2 Or larger, especially 50mm 2 Or a larger cross-sectional area. The width b of the track base of the busbar 700 (i.e. the width of the T-shaped crossbar 710) can be, for example, 30 mm or more, especially 45 mm or more.

[0106] Figure 4This illustrates the schematic electrical arrangement in welding chamber 10 according to the prior art. Figure 5 This diagram illustrates the schematic electrical arrangement of the welding chamber 100-i of the welding system 1000 according to an embodiment of the present invention. For clarity, the robot itself is not shown in any of the figures.

[0107] exist Figure 4 In the conventional welding chamber 10, the welding power supply 21 of the welding robot is electrically connected to a short copper track 30 via a grounding wire 25, wherein a first portion 27 of the grounding wire 25 is moved by the welding robot, and a second portion 28 of the grounding wire 25 extends statically in a vertical axis. The copper track 30 is electrically connected to a plate 32 via a wire 31, and the rotary table 33 is therefore electrically connected to the ground where the workpiece 1-i is placed via the wire 31. A second electrode is routed to the robotic tool for handling the workpiece via an intermediate cable assembly 41 and a burner hose 42.

[0108] In this design, the grounding wire 25 must be very long, especially in welding chambers used for large workpieces, where the first section 27 of the grounding wire 25 is typically 15 meters or longer, to avoid restricting the mobility of the welding robot. This results in a considerable inductance, such as 40 microhenries or more, which can cause a destructive arcing effect during welding.

[0109] On the other hand, in accordance with the embodiments of this utility model Figure 5 In the welding chamber 100-i of the welding system 1000 shown, at least the first portion of the conventional grounding conductor 25 is replaced by a busbar 700. The grounding conductor 725 of the electrical contact busbar can be electrically guided to a copper rail 730, from which the workpiece 1-i can be electrically contacted via a conductor 731 (and thus connected to ground), allowing an electric arc to be formed to the welding tool (e.g., manufacturing welding tool 201). Here, the workpiece 1-i can also be mounted on a workpiece carrier 733, particularly a rotary table, which can be designed to be controllable by a control device 600, and particularly movable (e.g., rotatable).

[0110] In this arrangement, the grounding connection to workpiece 1-i is therefore external to and independent of the plate 732 on which the workpiece carrier 733 is arranged. This also helps to reduce or eliminate the arcing effect. The workpiece carrier 733 can be designed to electrically insulate workpiece 1-i from the plate 732.

[0111] Advantageously, the busbar 700 is arranged in the upper region of the welding chamber 100-i, particularly above the workpiece carrier 733, thereby the main body of the robot 200 is arranged even higher, i.e., on the side of the busbar 700 opposite to the workpiece carrier 733.

[0112] The grounding wire 725 may be specifically arranged at the center (or around the center within + / -20%, particularly + / -10%) relative to the width of the welding chamber 100-i (or relative to the moving radius of the robot 200).

[0113] As a result, the contribution of busbar 700 to the current-carrying length of the entire grounding conductor from the grounding electrode of welding power source 210 to workpiece carrier 733 reaches a maximum of half the width of welding chamber 100-i. Therefore, even in the maximum case (when robot 200 is completely on one side, e.g., completely on the left / completely on the right), it is less than Figure 4 The conventional grounding conductor 25—typically guided in the drag chain—is half of the first section 27. The combined current-carrying length of the grounding conductor and busbar is preferably 12 meters or less, particularly 10 meters or less, and especially preferably less than 8 meters. This allows for a significant reduction in the inductance of the grounding conductor during operation, for example, below 30 microhenries (μH), below 29 microhenries (μH), below 25 microhenries (μH), or particularly preferably below 20 microhenries (μH).

[0114] If the busbar 700 is designed to extend over multiple welding chambers 100-i, this will not change the above situation, because the current will always take the shortest path, and therefore only a portion of the busbar 700 will be energized. Meanwhile, a busbar 700 extending over two or more welding chambers 100-i can advantageously achieve good mobility for the robot 200, because even when moving between two or more welding chambers 100-i, the sliding contact 277 of the robot 200 will always remain in contact with the busbar 700.

[0115] For example, in Figure 5 In the embodiment shown, the second electrode of the welding power source 210, which typically moves with the robot 200, is also fed to the workpiece carrier 733 via the intermediate cable assembly 741 and the burner hose 742.

[0116] As already explained, robot 200 can also be designed and configured to guide tools other than manufacturing welding tool 201, such as carbon electrodes for carbon arc gouging and / or plasma torches for plasma gouging.

[0117] Figure 6 A schematic diagram showing details of the robot 200 of the welding system 1000 in one embodiment. More specifically, Figure 6 Linear actuator 220 is indicated, and plasma torch 202 can be arranged on robot 200 via linear actuator 220. As already explained, linear actuator 220 can advantageously respond significantly faster (more dynamically) than robot 200 itself, especially in order to enable distance control.

[0118] The combination of linear actuator 220 and plasma torch 202 (which may also be referred to as plasma planing device) can be designed as an interchangeable tool that, like other interchangeable tools, can be automatically assembled by robot 200 into tool holder in tool station and automatically stored there again after use.

[0119] For example, the control device 600 may have an arc voltage determination module configured to determine the plasma arc voltage of the plasma arc formed by the plasma torch 202. The control device 600 may also have a distance control module configured to use a linear actuator 220 to achieve distance control between the plasma torch 202 and the workpiece 1-i, as described previously, where the plasma arc voltage is a controlled variable. However, the robot 200 may also directly guide the plasma torch 202 without arranging the linear actuator 220 therebetween. In this case, the robot 200 may, for example, clamp the plasma torch 202 when needed and then reinsert it into the tool holder of the tool station.

[0120] Therefore, robot 200 can be specifically configured to remove excess dimensions from a rough version of workpiece 1-i by means of plasma torch 202, particularly by means of so-called plasma planing, based on actual dimension data previously generated by 3D measuring device 300 (especially specifically for this purpose) and nominal dimension data stored in database 400. Computing device 500 can be configured to automatically calculate the plasma planing trajectory of plasma torch 202 for removing excess dimensions from the rough version of workpiece 1-i by plasma planing, based on the generated actual dimension data and the stored nominal dimension data. As part of the manufacturing process of workpiece 1-i, control device can be configured to control robot 200 to perform plasma planing according to the calculated plasma planing trajectory.

[0121] It should be understood that robot 200 can also be configured to perform conventional planing techniques, such as carbon arc planing, where copper-plated carbon rods are used as electrodes. However, the use of the plasma torch 202 taught herein has several advantages in comparison:

[0122] - Material removal is non-contact and virtually abrasive, and it is a continuous operation.

[0123] - No consumable materials (such as carbon rods).

[0124] - The material composition of workpiece 1-i remains unchanged, and in particular, there is no "carburization" on the surface.

[0125] - Reduced smoke and noise emissions.

[0126] In addition, robot 200 can also be arranged to guide welding tools, particularly laser welding tools or plasma powder welding tools, to perform welding, particularly laser metal deposition or plasma-transferred arc welding, on workpiece 1-i (or a version of workpiece 1-i).

[0127] Robot 200 can also be designed to guide all possible other tools that can be used for or to handle workpiece 1-i, particularly rough versions after cast steel. Welding system 1000 may have a tool holder from which robot 200 can remove the required welding tools 201, 202, and robot 200 can store currently unused (or no longer in use) welding tools 201, 202 in the tool holder. Each robot 200 may be provided with a separate tool holder, or multiple (e.g., two) robots 200 may use a common tool holder.

[0128] In another advantageous option, robot 200 can also be configured to guide the grinding tool. 3D measuring device 300 can be configured to automatically perform three-dimensional measurements of a rough version of workpiece 1-i to generate preliminary actual dimensional data. Computing device 500 can be set to automatically calculate the grinding trajectory to be traversed by the grinding tool based on the generated preliminary actual dimensional data and the stored nominal dimensional data of workpiece 1-i. Control device 600 can be configured to control robot 200 to form at least one grinding pit 2-i in the rough version of workpiece 1-i by traversing the grinding trajectory to be traversed by the grinding tool.

[0129] As previously mentioned, robot 200 can also be configured to eliminate at least one discontinuity on a rougher version of workpiece 1-i, for example by automatically equipping it with a thermal cutting tool (e.g., a carbon arc welding torch) as a replacement tool and automatically moving it according to an automatically calculated cutting trajectory. Undesired shapes and / or undesired material variations can be removed by creating grinding pits 2-i.

[0130] Figure 7 Examples of grinding pit 2-i are shown in a) to c), where Figure 7 a) shows a top view. Figure 7 b) shows a longitudinal section through the two grinding pits 2-i. Figure 7Figure c) shows a cross-section through the six grinding pits 2-i. It should be understood that the grinding pits 2-i are not typically arranged in such a regular manner, but rather generated based on any possible discontinuities. The geometry (or multiple geometries) of the grinding pits 2-i can be pre-stored, so that only the corresponding dimensions of the discontinuities need to be recorded, and the grinding pits 2-i are scaled accordingly. This also allows the set of welding parameters stored in the database 400 to be specifically adapted to the shape of the stored grinding pits 2-i. It should be understood here that the database 400 can also be arranged in a distributed manner, such that, for example, actual dimensional data and parameter sets can be stored at different physical or virtual storage locations that can be assigned to the database 400.

[0131] Especially in Figure 7 As seen in b), the grinding pits 2-i typically have relatively steep sidewalls 3, a relatively (or completely) flat bottom surface 5, and a transition region 4 between them. The welding conditions for manufacturing the welding tool 201 can vary considerably depending on how the grinding pits 2-i to be filled are oriented in space (particularly relative to the horizontal line H). The orientation (or: tilt angle α) of the grinding pits 2-i is advantageously determined below relative to their flat bottom surface 5 (i.e., relative to the plane E in which the respective bottom surface 5 is arranged). Figure 7 b) shows that the tilt angle α is determined as the angle between the plane E and the horizontal line H.

[0132] Alternatively, it can be specified that the inclination angle α between the horizontal line H and the imaginary surface V of the corresponding grinding pit 2-i is determined, and the parameter set is determined and stored accordingly. The imaginary surface V is an imaginary surface spanned by the outer edge of the grinding pit 2-i (within the outer surface of the workpiece 1-i). Typically, the plane E of the bottom surface 5 and the imaginary surface V of the grinding pit 2-i are parallel to each other, such as... Figure 7 As shown in b).

[0133] When the imaginary surface V is not flat, an imaginary substitute plane can be determined as the reference plane that is closest to or as close as possible to the imaginary surface V at an angle α of inclination relative to the horizontal line H, such as a leveling plane using the least squares method.

[0134] Therefore, the three parameter sets can be advantageously stored in database 400, particularly for manufacturing welds on grinding pit 2-i (but optionally also for other welding processes):

[0135] - Vertical parameters set for the "vertical range" of grinding pit 2-i in a position relative to the horizontal line in a range of approximately α=60° to 90° (especially α=70° to 90°) (i.e., relative to the vertical line in a range of 0° to 30°, especially 0° to 20°);

[0136] - The horizontal parameter set for the "horizontal range," that is, the grinding pit 2-i located approximately within the range of α = 0° to 10° relative to the horizontal line (i.e., 80° to 90° relative to the vertical line); and

[0137] - Transition parameters set for the range in between, such as the grinding pit 2-i in the position relative to the horizontal line in the range of α=10° to 70°.

[0138] As another example, database 400 may store only two parameter sets, for example, a horizontal parameter set for grinding pit 2-i in a position relative to the horizontal line in the range of 0°≤α≤45° (i.e., α=0° to 45°), and a vertical parameter set for grinding pit 2-i in a position relative to the horizontal line in a range of 45°<α≤90° (i.e., α>45° to 90°).

[0139] Figure 8 The possible dimensions of the grinding pit 2-i, corresponding to the possible geometry of the grinding pit 2-i, are shown, which can be automatically calculated by the computing device 500 of the welding system 1000.

[0140] The base width b is advantageously 20 mm or greater, particularly 23 mm or greater. The pit width B is advantageously 25 mm or greater, preferably 30 mm or greater, and particularly preferably 34 mm or greater. The side angle W is advantageously 20° or greater, preferably 25° or greater, and particularly preferably 29° or greater. The height H of the flat section of the sidewall 3 is freely selectable and is generally caused by the defect depth t of the discontinuity in workpiece 1-i.

[0141] It should be understood that each of these parameter sets can be used for different welding situations, such as welding different materials and welding with different welding tools. For example, they can be distinguished based on the material, material quality, or material alloy grade of workpiece 1-i.

[0142] The table below shows the advantageous parameters and parameter ranges for manufacturing welds, respectively for non-alloy materials (i.e., materials containing at most carbon but 0% of other alloying elements as additives), low-alloy materials (i.e., materials containing less than 5% by mass of alloying elements in total), and high-alloy materials (i.e., materials in which at least one alloying element accounts for more than 5% by mass), wherein the position of the grinding pit 2-i to be filled relative to the horizontal line is 20°.

[0143]

[0144] Here, v D The feed rate of the consumable electrode, v HThe horizontal trajectory speed of the welding torch (or the electric arc generated at the welding torch) used to manufacture the welding tool 201 is represented by v. V This indicates the vertical trajectory speed of the welding torch. The track spacing is located between two adjacent tracks or track centers, and the welding tool 201 moves along said track or track center to completely fill the grinding pit 2-i. Layer thickness t L This indicates the height at which material is applied by the manufacturing welding tool 201 along each trajectory.

[0145] Figure 9 This is a schematic flowchart illustrating an example method for manufacturing workpiece 1-i. As explained multiple times, this method can be used specifically in or with the welding system 1000 according to the present invention, but can also be used independently. Therefore, the method can be adapted according to all described choices, variations, implementations, and modifications of the welding system 1000 according to the present invention, and vice versa. In particular, some method steps are described or explained in more detail below by way of example using components or elements of the welding system 1000 according to the present invention. This is intended to provide a clearer explanation and does not necessarily mean that method steps must always be performed using that component or element, although this is always a possibility.

[0146] The following describes, by way of example, a series of method steps that can facilitate the manufacture of part 1-i of workpiece in welding chamber 100-i. The list of method steps does not imply that they are all necessary, and in particular, does not imply that all method steps shown are essential. Rather, it should be understood that, depending on the desired product, one or more method steps may be omitted, performed more frequently, or supplemented. Therefore, the example method may include one, more, or all of the listed method steps.

[0147] Typically, a concept of a workpiece is first generated or received in step S10, particularly in the form of 3D data, which may optionally be rich in additional workpiece specifications (or: information), such as the desired material, tolerances to be met, etc. This 3D data may be defined as nominal dimensional data and stored for this purpose, for example, in database 400, as described above.

[0148] In step S20, the mold is produced, for example, by additive or subtractive manufacturing.

[0149] In step S30, a rough version of workpiece 1-i (i.e., a rough casting version) is produced in the steel casting.

[0150] In step S40, the rough version of the mold is removed, any gates are removed, and heat treatment can be performed.

[0151] In step S50, the rough version is introduced into the welding chamber 100-i, which is advantageously introduced into the welding chamber 100-i of the welding system 1000 according to the present invention.

[0152] In step S60, the workpiece 1-i is automatically planed by the robot 200, preferably by plasma planing using the plasma torch 202, as explained in detail above.

[0153] Therefore, planing S60 may specifically include one, more, or all of the following steps:

[0154] - Based on the generated actual size data and the stored nominal size data, the plasma gouging trajectory that the plasma torch 202 of S61 should pass through for removing excess dimensions on the rough version of workpiece 1-i by plasma gouging is automatically calculated.

[0155] - An S62 plasma arc is generated by plasma torch 202;

[0156] - Use plasma arc melting to melt the S63 material from workpiece 1-i;

[0157] - The molten material in S64 is usually blown away by the gas nozzle of the plasma torch 202;

[0158] - Detect the plasma arc voltage of the plasma arc generated by S65 (or a quantity based on or derived from the plasma arc voltage).

[0159] - The distance between the plasma torch 202 and the workpiece 1-i is adjusted by using the detected plasma arc voltage as a control variable, in particular by controlling the linear actuator 220 of the plasma torch 202 on the robot 200 based on the detected plasma arc voltage (possibly in addition to or simultaneously with the control robot 200).

[0160] The automatic calculation of the plasma planing trajectory to be traversed by the plasma torch 202 (S61) can be performed, for example, by the computing device 500, as explained above. The adjustment of the distance (S66) can be performed, for example, by the control device 600, also as described above. Therefore, the plasma planing trajectory to be traversed by the plasma torch 202 can be achieved by combining the control of the robot 200 (e.g., via the control device 600) and the control of the linear actuator 220 (if present on the robot 200) (S67).

[0161] In step S70, a rough version of workpiece 1-i is automatically measured in three dimensions to generate preliminary actual dimensional data. This can be performed, for example, by a 3D measuring device 300, which can be guided by or integrated into robot 200, for example.

[0162] It should be understood that, in principle, automated 3D measurement of workpiece 1-i can be performed before and / or after each step in which workpiece 1-i is processed in any way, in order to generate current actual dimensional data. Subsequent methodological steps can then be advantageously performed based on this corresponding current actual dimensional data (among other things, or even uniquely). The only drawback of this continuous (re)measurement is the time required, which is generally weighed against the efficiency and / or accuracy gains from more accurate / up-to-date actual dimensional data. This consideration may vary depending on the specific workpiece 1-i and the tolerances specified for various process steps, as well as the associated possible errors.

[0163] Automated 3D measurement can also be used for inspection and quality control.

[0164] In step S80, at least one discontinuity is removed, preferably all discontinuities. Discontinuities can be identified automatically, particularly based on a comparison of preliminary actual size data with nominal size data (e.g., via computing device 500).

[0165] The method may include removing the S81 discontinuities by a thermal cutting process (e.g., by carbon arc gouging).

[0166] In another optional step (particularly after removing any discontinuities in S81, for example, by carbon arc gouging), an automatic calculation of the grinding trajectory to be traversed by at least one grinding tool in S82 can preferably be performed based on the generated preliminary actual dimensional data and the stored nominal dimensional data of workpiece 1-i. Specifically, the grinding trajectory can be calculated such that the material changes (e.g., carburizing) that occur during the removal of discontinuities in S81 are eliminated. The calculation of S82 can be performed, for example, by a computing device 500, as explained above.

[0167] In another step S83, at least one grinding pit 2-i is formed in the rough version of workpiece 1-i by automatically passing through the grinding path to be traversed by at least one grinding tool.

[0168] Alternatively or partially supplementally, grinding pit 2-i can also be produced by manual grinding.

[0169] In step S90, manufacturing welding is performed, wherein at least one grinding pit 2-i (preferably all grinding pits 2-i) is filled. For this purpose, as explained in detail above, the robot 200 of the welding system 1000 can advantageously access welding parameters that are precisely adapted to the situation and are available, for example, in the database 400.

[0170] The manufacturing welding tool used for manufacturing welding can be, in particular, a gas metal arc welding tool (MIG / MAG welding tool), that is, the manufacturing welding can be performed as gas metal arc welding. Advantageously, the trajectory to be followed by the robot 200 guiding the manufacturing welding tool 201 is automatically calculated based on the recently generated actual size data and the stored nominal size data of the workpiece 1-i.

[0171] The material used to fill the grinding pit 2-i (and any additional material) can be adapted to the material of workpiece 1-i.

[0172] At least one grinding pit 2-i can then be automatically filled by manufacturing welding S92, wherein the robot 200 is controlled according to the calculated trajectory, for example as described above in the reference control device 600.

[0173] In another step S100, at least one automated welding process, particularly laser metal deposition (LMD) and / or plasma-transferred arc (PTA) welding, can be performed. For this purpose, new automated 3D measurements can be advantageously performed in advance (e.g., by 3D measuring device 300) to generate current actual size data, and the automated welding process S100 can be performed based on the most recent actual size data, nominal size data, and / or workpiece specifications.

[0174] In the foregoing detailed description, various features have been outlined in one or more examples to improve the rigor of the description. It should be understood that the above description is merely illustrative and in no way limiting in nature. It is intended to cover all alternatives, modifications, and equivalents of various features and implementations. Given the above description, many other examples will be immediately and directly apparent to those skilled in the art.

[0175] List of reference numerals

[0176] 1-i workpiece

[0177] 2-i grinding pit

[0178] 3 sidewalls

[0179] 4 Transition Zone

[0180] 5 Bottom surface

[0181] 10 Welding Room

[0182] 20 welding power supply

[0183] 25 grounding wire

[0184] 27. The first part of the grounding conductor

[0185] 28. The second part of the grounding conductor

[0186] 30 copper rails

[0187] 31 conductor

[0188] 32-inch tablet

[0189] 33 Rotary Table

[0190] 41 Intermediate Cable Assembly

[0191] 42 Burner Hose

[0192] 100-i Welding Room

[0193] 200 robots

[0194] 201 Manufacturing Welding Tools

[0195] 202 plasma flame moment

[0196] 210 welding power supply

[0197] 220 linear actuator

[0198] 270 collector

[0199] 277 sliding contact

[0200] 3003D measuring device

[0201] 400 Database

[0202] 500 computing device

[0203] 600 control device

[0204] 700 busbars

[0205] 710 crossbar

[0206] 720 copper head

[0207] 725 grounding wire

[0208] 730 copper rail

[0209] 731 conductor

[0210] 732 tablet

[0211] 733 workpiece carrier

[0212] 741 intermediate cable assembly

[0213] 742 burner hose

[0214] 1000 Welding System

[0215] The position of the α grinding pit relative to the horizontal line

[0216] The horizontality of the bottom surface of the E-grind pit

[0217] H horizontal line

[0218] S10……S100 Method Steps

[0219] The hypothetical surface of V-shaped grinding pits

Claims

1. A welding system (1000) for manufacturing workpieces (1-i), characterized in that, The welding system (1000) includes: At least one welding chamber (100-i); A 3D measuring device (300) is configured to automatically perform three-dimensional measurements on a rough version of a workpiece (1-i) arranged in the welding chamber (100-i) and having at least one grinding pit (2-i) formed thereon, in order to generate actual dimensional data. At least one robot (200) is configured to guide at least one welding tool (201); A database (400) is configured to store the nominal dimension data of the workpiece (1-i); A computing device (500) configured to automatically calculate the trajectory of the robot (200) guiding the welding tool (201) based on generated actual size data and stored nominal size data of the workpiece (1-i); and A control device (600) is configured to control the welding tool (201) and the robot (200) using a calculated trajectory to fill the at least one grinding pit (2-i) by creating a weld.

2. The welding system (1000) according to claim 1, characterized in that, The welding tool is a gas metal arc welding tool.

3. The welding system (1000) according to claim 1, characterized in that, The welding system (1000) also includes a plasma torch (202) for removing excess material from the rough version of the workpiece (1-i) by plasma gouging, wherein the control device (600) is configured to control the plasma torch (202) based on the generated actual size data and the stored nominal size data.

4. The welding system (1000) according to claim 3, characterized in that, The plasma torch (202) can be attached to or mounted on the robot (200) via a linear actuator (220), and the control device (600) is configured to use the linear actuator (220) to achieve distance control of the plasma torch (202) to the workpiece (1-i).

5. The welding system (1000) according to claim 3, characterized in that, The robot (200) is configured to guide the plasma torch (202) in addition to guiding the manufacturing welding tool (201) for manufacturing welding, or to alternately guide the manufacturing welding tool (201) for manufacturing welding and the plasma torch.

6. The welding system (1000) according to claim 1, characterized in that, The welding system (1000) also includes a surfacing tool for coating or contouring that is attached to or can be attached to the robot (200).

7. The welding system (1000) according to claim 6, characterized in that, The welding tool is a laser welding tool or a plasma powder welding tool.

8. The welding system (1000) according to claim 7, characterized in that, The welding tool is configured for laser metal deposition or plasma-transfer arc welding.

9. The welding system (1000) according to claim 1, characterized in that, The 3D measuring device (300) is integrated into the robot (200), or the robot (200) is configured to guide the 3D measuring device (300).

10. The welding system (1000) according to claim 1, characterized in that, The robot (200) is configured to guide the grinding tool, and the 3D measuring device (300) is configured to automatically perform three-dimensional measurements of a rough version of the workpiece (1-i) to generate preliminary actual size data. The computing device (500) is configured to automatically calculate the grinding trajectory to be traversed by the grinding tool based on the preliminary actual size data and the stored nominal size data, and The control device (600) is configured to control the robot (200) to form at least one grinding pit (2-i) in a rough version of the workpiece (1-i) by passing through the grinding trajectory to be traversed by the grinding tool.

11. The welding system (1000) according to claim 1, characterized in that, The welding system (1000) also includes a database (400) configured to provide welding parameters. This provides a separate set of welding parameters for each of at least two different orientations in space for the grinding pit (2-i) to be filled, and The manufacturing welding performed by the welding tool is carried out based on the spatial orientation of the corresponding grinding pit (2-i) to be filled, using a corresponding set of associated parameters.

12. The welding system (1000) according to claim 1, characterized in that, The welding system (1000) also includes a busbar (700), wherein the robot has a current collector (270) with a sliding contact (277) configured to maintain electrical contact with the busbar (700) during movement of the robot (200) so as to establish an electrical connection between the electrodes of the robot (200) and the workpiece (1-i) via the busbar (700).

13. The welding system (1000) according to claim 12, characterized in that, The sliding contact (277) is configured to maintain electrical contact with the busbar (700) during the movement of the robot (200) so as to establish a grounding connection between the electrodes of the robot (200) and the workpiece (1-i) via the busbar (700).

14. The welding system (1000) according to claim 12, characterized in that, The workpiece (1-i) in the welding chamber (100-i) is electrically connected or can be electrically connected to the busbar (700) via grounding wires (725, 730, 731), and the combined current-carrying length of the grounding wires (725, 730, 731) and the busbar (700) is 12 meters or less.

15. The welding system (1000) according to claim 14, characterized in that, The combined current-carrying length of the grounding conductor (725, 730, 731) and the busbar (700) is 10 meters or less.

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