Robotic Welding Line With Displacement Table for Complex 3D Workpieces
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Solution Overview
Problem
The existing welding systems for subway grilles face challenges due to the non-uniform structure and various types of grilles, requiring frequent changes in welding parameters, leading to increased operation time and cost, and manual repair welding, which is labor-intensive and inefficient.
Innovation Solution
An automatic welding production line is developed, comprising a base station, welding robot, displacement worktable, auxiliary robot, feeding system, and blanking system, which allows for flexible adjustment of the workpiece's position and angle, enabling multi-point welding and fully automatic operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If manual welding operation is used for subway grilles, then flexibility in handling various types of grilles is maintained, but labor intensity is high and operation environment is poor
Solution Approach 1:
The system uses seam-finding structures and observation structures to automatically detect and identify workpiece features, eliminating the need for manual positioning and inspection. The welding robots autonomously navigate and adjust their operations based on detected features, making the system self-sufficient in handling various grille types without manual intervention.
Solution Approach 2:
The control system dynamically adjusts welding parameters based on the detected workpiece features and selected welding methods. The system can switch between different welding methods (such as arc welding, laser welding) and automatically modifies parameters like welding speed, current, and voltage to adapt to different grille types and positions, maintaining versatility while eliminating manual parameter adjustment.
2Adaptability or versatility
If welding parameters are frequently changed to meet various welding requirements, then adaptability to different grille types is improved, but operation time and cost increase
Solution Approach 1:
The system performs preliminary detection of workpiece features using seam-finding and observation structures before welding begins. The control system pre-plans the welding path and selects appropriate welding methods based on the detected features, so that when welding starts, all parameters and paths are already optimized and ready, eliminating time-consuming parameter adjustments during the welding process.
Solution Approach 2:
The system employs dynamic path planning and real-time parameter adjustment capabilities. The welding robots can dynamically adapt their motion paths and welding parameters during operation based on detected features, allowing the system to handle various grille types efficiently without requiring frequent manual parameter changes, thus reducing operation time while maintaining versatility.
3Adaptability or versatility
If special spatial structure grilles are welded manually, then complex positions can be accessed, but manual repair welding is required due to inability to weld all positions automatically
Solution Approach 1:
The system employs multiple welding robots with different configurations and welding methods (arc welding, laser welding) to handle various spatial positions and complex structures. The displacement worktable can position workpieces in different orientations, and the coordinated operation of multiple robots enables full automation for complex spatial structures that would otherwise require manual repair welding.
Solution Approach 2:
The system introduces auxiliary fixtures and displacement worktables as intermediaries to position and support complex workpieces. These intermediaries enable the welding robots to access difficult-to-reach positions on special spatial structures, allowing complete automation without manual intervention for complex geometries.
4Productivity
If automated welding system is implemented, then labor intensity is reduced and production efficiency is improved, but system complexity increases
Solution Approach 1:
The automated welding system is divided into modular functional units: displacement worktable for positioning, multiple welding robots for different operations, feeding systems for material supply, blanking systems for post-processing, and control systems for coordination. This segmentation allows each module to be independently optimized and maintained, reducing overall system complexity while maintaining high productivity.
Data Source
AI summary
An automatic welding production line for a large complex workpiece includes a base station, a welding robot, a displacement worktable, an auxiliary robot, a feeding system and a blanking system. The displacement worktable has multi degrees of freedom, the position and angle of the workpiece can be flexibly adjusted during welding to meet the welding requirements of any position and angle of the welding equipment, thereby realizing the welding operation of large complex special-shaped three-dimensional components, and multi-point welding at any point can be realized through the cooperation of the welding robot and the auxiliary robot. The control system controls the robot and the feeding and blanking system to cooperate with the displacement worktable to realize automatic feeding, welding and blanking operations, the welding parameters and operations can be automatically adjusted for the special components of the structure, to realize integration and intelligence, improve production efficiency and reduce production costs.