A welding system

Abstract

The utility model discloses a kind of welding systems, including robot mechanism, welding mechanism and welding tool, robot mechanism includes robot, hmi controller and control cabinet, control cabinet is equipped with demonstrator;The control cabinet is connected with robot by control line and communication line;The welding mechanism includes gas shielded welding gun, wire feeding mechanism and welding machine, gas shielded welding gun is connected with robot by welding gun holder;The tool holder of welding tool is connected with positioner by screw and positioning pin, the positioning hole of positioning pin and bearing cover workpiece corresponds, workpiece top surface and the symmetrical auxiliary limiting block on tool holder are attached. The utility model provides efficient convenient easy operation's welding mode, improve operating efficiency, reduce operation difficulty, greatly improve welding quality.

Description

Technical Field

[0001] This utility model relates to the field of welding, and in particular to a welding system. Background Technology

[0002] In the welding industry, when cladding steam turbine bearing caps with Babbitt alloy, the conventional welding method is to clad the Babbitt alloy using high-speed centrifugal casting. However, this method has problems such as complex process, low efficiency, unstable quality, and high requirements for operator skills.

[0003] Therefore, it is necessary to develop new welding systems specifically designed to overcome the above problems. Utility Model Content

[0004] Purpose of the utility model: In view of the shortcomings and defects of the existing technology, this utility model provides a welding system that offers an efficient, convenient and easy-to-operate welding method, improves operating efficiency, reduces operating difficulty, and significantly improves welding quality.

[0005] Technical Solution: This utility model discloses a welding system, characterized in that it includes a robot mechanism, a welding mechanism, and a welding fixture. The robot mechanism includes a robot, an HMI controller, and a control cabinet, with the control cabinet equipped with a teach pendant. The control cabinet is connected to the robot via control lines and communication lines. The welding mechanism includes a gas shielded welding torch, a wire feeding mechanism, and a welding machine. The gas shielded welding torch is connected to the robot via a torch holder. The welding fixture's fixture frame is connected to a positioner via screws and positioning pins. The positioning pins correspond to the positioning holes of the bearing cover workpiece, and the top surface of the workpiece is in contact with symmetrically arranged auxiliary limiting blocks on the fixture frame.

[0006] The robot in question is a six-axis robot, located above the robot base.

[0007] The HMI controller is connected to an external power source via a power cord, and it is also connected to a teach pendant via a data cable.

[0008] The power cord is connected to an external 380V three-phase power supply.

[0009] The wire feeding mechanism is connected to the wire feeding buffer, and the wire feeding buffer is equipped with a support.

[0010] The tooling frame is equipped with an L-shaped base, and the L-shaped base has pre-drilled screw holes and pin holes for different types of brackets.

[0011] The tooling frame has four tapered pins on its four supports.

[0012] The workpiece has mounting holes and is fixed by a pressure plate.

[0013] Beneficial Effects: Compared with existing technologies, this utility model has the following significant advantages: This utility model changes the original Babbitt alloy cladding method from centrifugal casting to automatic gas shielded welding, thereby significantly improving the Babbitt alloy cladding bond strength of the bearing cap, reducing the skill requirements of the operator, and improving cladding efficiency. It transforms traditional centrifugal casting into an automated and mechanized welding technology, improving welding efficiency, optimizing welding quality, and reducing welding costs, providing an effective improvement. Attached Figure Description

[0014] Figure 1 This is a schematic diagram of the structure of this utility model;

[0015] Figure 2 This is a schematic diagram of the tooling frame of this utility model;

[0016] Figure 3 This is a schematic diagram of the structure of the L-shaped base of this utility model;

[0017] Figure 4 This is a schematic diagram of the structure of the workpiece of this utility model;

[0018] In the diagram, 1 is the positioner; 2 is the robot; 3 is the HMI controller; 4 is the wire feeding mechanism; 5 is the welding machine; 6 is the robot base; 7 is the control cabinet; 8 is the pressure plate; 9 is the workpiece; 10 is the auxiliary limit block; 11 is the tooling frame; 12 is the power cord; 13 is the wire feeding buffer; 14 is the bracket; 15 is the L-shaped base; 16 is the tapered pin; and 17 is the mounting hole. Detailed Implementation

[0019] The technical solution of this utility model will be further described below with reference to the accompanying drawings and specific embodiments.

[0020] The welding system of this utility model includes a robot mechanism, a welding mechanism, and a welding fixture. The robot mechanism includes a robot 2, an HMI controller 3, and a control cabinet 7. The control cabinet 7 is equipped with a teach pendant. The control cabinet 7 is connected to the robot 2 via control lines and communication lines. The welding mechanism includes a gas shielded welding torch, a wire feeding mechanism 4, and a welding machine 5. The gas shielded welding torch is connected to the robot 2 via a torch holder. The fixture frame 11 of the welding fixture is connected to the positioner 1 via screws and positioning pins. The positioning pins correspond to the positioning holes of the bearing cover workpiece 9 to adjust the position and level of the workpiece 9. The top surface of the workpiece 9 is in contact with the auxiliary limiting blocks 10 symmetrically arranged on the fixture frame 11 to ensure the position of the workpiece 9.

[0021] The robot 2 of this utility model is a six-axis robot, located above the robot base 6. The HMI controller 3 is connected to an external power source via power cable 12 and to a teach pendant via a data cable. Power cable 12 is connected to an external 380V three-phase power source. The wire feeding mechanism 4 is connected to the wire feeding buffer 13, which has a bracket 14. The tooling frame 11 has an L-shaped base 15, which has pre-drilled screw holes and pin holes for different types of brackets. Since the workpiece 9 and the tooling frame 11 will experience collisions and wear during installation, a high-hardness, wear-resistant L-shaped base 15 is added. Four rough-machined mounting holes 17 on the workpiece 9 are used for assembly and positioning. Four tapered pins 16 are provided on the four supports of the tooling frame 11; four or two diagonal positioning pins can be selected depending on the size of the workpiece 9. Arm supports are added to both sides of the front end of workpiece 9 on L-shaped bases 15. These supports provide quick installation and positioning during hoisting and installation, preventing damage to hoisting personnel and equipment. They also bear some of the weight of workpiece 9 when it rotates, preventing it from slipping. The contact surface between the arm on the L-shaped base 15 and workpiece 9 requires a machined reference surface for positioning. The arm is equipped with impact-resistant and wear-resistant tooling blocks. After workpiece 9 is positioned, it is finally secured using pressure plates 8.

[0022] The welding system of this utility model for cladding Babbitt alloy on bearing caps includes the following steps:

[0023] 1) Powering on the equipment: Powering on the operating and control equipment of the welding system to put the welding equipment into an editable state;

[0024] 2) Tooling installation: Install and fix the L-shaped base 15 on the turntable of the positioner 1. The turntable is equipped with a circular boss for processing, and position and install the tooling frame 11.

[0025] 3) Workpiece installation: Select the bracket corresponding to the bearing cover to be welded. The L-shaped base 15 is provided with reserved screw holes and pin holes of different models. Use the 4 mounting holes 17 on the workpiece 9 for assembly and positioning.

[0026] 4) Robot programming: Remotely control robot 2, adjust the nozzle at the lower end of the welding gun to 15mm-19mm from the surface of the workpiece to be welded, set the arc start point and arc end point, and plan the offset path;

[0027] 5) Welding programming: Use HMI controller 7 to debug process parameter curves, gas process curves and wire parameters, save to JOB and call JOB or use welding process parameters online; adjust welding machine parameters: welding current 80A-150A, wire feed speed: 8m / min-9m / min, welding speed: 650mm / min-700mm / min;

[0028] 6) Start welding: Use the robot teach pendant to start welding, and start the welding power supply to activate the main arc; observe the arc status during welding to confirm that the arc is stable;

[0029] 7) Welding completion: After the robot 2 completes the welding program, it automatically stops welding and executes the arc-closing program of the welding control system to complete the arc closing welding; the arc is turned off, and the welding operation is completed.

[0030] The fixture 11 needs to be used in conjunction with the workpiece 9. The fixture 11 is fixed and positioned by screws and a machined circular boss on the turntable of the positioner 1. During installation, ensure that it is placed neatly to prevent misalignment. The workpiece 9 is fixed to the fixture by positioning pins and pressure plate 8. The pressure plate 8 needs to be installed securely to prevent the workpiece 9 from falling off.

[0031] This invention involves mounting a tooling plate onto a positioner, adjusting the tooling's level and center using mounting screws and locating pins. The bearing cover is then placed horizontally with its flat surface facing upwards. The position and level of the bearing cover are adjusted by the engagement of the locating pins on the tooling with the locating holes on the bearing cover. The top surface of the bearing cover aligns with symmetrically distributed auxiliary locating blocks on the tooling, ensuring the workpiece is level. The welding system of this invention is an automatic bearing cover welding system; after secure fixing, workers can program the welding points and achieve rapid welding.

Claims

1. A welding system, characterized in that: The system includes a robot mechanism, a welding mechanism, and a welding fixture. The robot mechanism includes a robot (2), an HMI controller (3), and a control cabinet (7). The control cabinet (7) is equipped with a teach pendant. The control cabinet (7) is connected to the robot (2) via a control line and a communication line. The welding mechanism includes a gas shielded welding torch, a wire feeding mechanism (4), and a welding machine (5). The gas shielded welding torch is connected to the robot (2) via a welding torch holder. The fixture frame (11) of the welding fixture is connected to the positioner (1) via screws and positioning pins. The positioning pins correspond to the positioning holes of the bearing cover workpiece (9). The top surface of the workpiece (9) is in contact with the auxiliary limiting blocks (10) symmetrically arranged on the fixture frame (11).

2. The welding system according to claim 1, characterized in that: The robot (2) is a six-axis robot, and the robot (2) is located above the robot base (6).

3. The welding system according to claim 1, characterized in that: The HMI controller (3) is connected to an external power source via a power cord (12) and is connected to a teach pendant via a data cable.

4. The welding system according to claim 3, characterized in that: The power cord (12) is connected to an external 380V three-phase power supply.

5. The welding system according to claim 1, characterized in that: The wire feeding mechanism (4) is connected to the wire feeding buffer (13), and the wire feeding buffer (13) is provided with a bracket (14).

6. The welding system according to claim 1, characterized in that: The tooling frame (11) is provided with an L-shaped base (15), and the L-shaped base (15) is provided with screw holes and pin holes for different types of brackets.

7. The welding system according to claim 1, characterized in that: The tooling frame (11) has four tapered pins (16) on its four supports.

8. The welding system according to claim 1, characterized in that: The workpiece (9) is provided with mounting holes (17), and the workpiece (9) is fixed by pressure plate (8).

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