1、 High precision robot body
High joint precision
Welding vents often have complex shapes and require high dimensional accuracy. The joints of robots require high repeatability accuracy, generally speaking, the repeatability accuracy should reach ± 0.05mm - ± 0.1mm. For example, when welding fine parts of small air vents, such as the edge of the air outlet or the connection of the internal guide vane, high-precision joints can ensure the accuracy of the welding trajectory, making the weld uniform and beautiful.
Good motion stability
During the welding process, the robot's movement should be smooth and steady. In the curved part of the welding vent, such as the circular or curved edge of the vent, smooth movement can avoid sudden changes in welding speed, thereby ensuring the stability of welding quality. This requires the robot's drive system (such as motors and reducers) to have good performance and be able to accurately control the motion speed and acceleration of each axis of the robot.
2、 Advanced welding system
Strong adaptability of welding power supply
Different types of welding power sources are required for different materials of air vents, such as carbon steel, stainless steel, aluminum alloy, etc. Industrial robots should be able to adapt well to various welding power sources, such as arc welding power sources, laser welding power sources, etc. For the welding of carbon steel air vents, traditional gas metal arc welding (MAG welding) power sources may be used; For aluminum alloy air vents, a pulse MIG welding power supply may be required. The control system of the robot should be able to effectively communicate and collaborate with these welding power sources to achieve precise control of welding parameters such as current, voltage, welding speed, etc.
Multiple welding process support
Multiple welding processes should be supported, including but not limited to arc welding (manual arc welding, gas shielded welding, etc.), laser welding, friction stir welding, etc. For example, when welding thin plate air vents, laser welding can reduce thermal deformation and provide high-quality welds; For some thicker plate air outlet connections, gas shielded welding may be more suitable. Robots can flexibly switch welding processes based on the material, thickness, and welding requirements of the air outlet.
3、 Flexible programming and teaching functions
Offline programming ability
Due to the diverse types and shapes of air vents, offline programming functionality becomes particularly important. Engineers can plan and program welding paths based on the three-dimensional model of the air outlet in computer software, without the need to teach point by point on actual robots. This can greatly improve programming efficiency, especially for mass production of different models of air vents. Through offline programming software, the welding process can also be simulated to detect possible collisions and other issues in advance.
Intuitive teaching method
For some simple air vents or special air vents produced in small batches, intuitive teaching functions are necessary. Robots should support manual teaching, and operators can manually guide the end effector (welding gun) of the robot to move along the welding path by holding a teaching pendant, recording the position and welding parameters of each welding point. Some advanced robots also support teaching reproduction function, which can accurately repeat the welding process previously taught.
4、 A good sensor system
Weld seam tracking sensor
During the welding process, the air outlet may experience deviation in the position of the weld due to installation errors of the fixture or issues with its own machining accuracy. Weld seam tracking sensors (such as laser vision sensors, arc sensors, etc.) can detect the position and shape of the weld seam in real time and provide feedback to the robot control system. For example, when welding the air outlet of a large ventilation duct, the weld seam tracking sensor can dynamically adjust the welding path based on the actual position of the weld seam, ensuring that the welding gun is always aligned with the center of the weld seam and improving welding quality and efficiency.
Melting pool monitoring sensor
The state of the molten pool (such as size, shape, temperature, etc.) has a significant impact on the welding quality. The melt pool monitoring sensor can monitor the condition of the melt pool in real time. By analyzing the data of the melt pool, the robot control system can adjust welding parameters such as welding current and speed. When welding stainless steel air vents, the melt pool monitoring sensor can prevent the melt pool from overheating and avoid welding defects such as porosity and cracks.
5、 Safety protection and reliability
Safety protection device
Industrial robots should be equipped with comprehensive safety protection devices, such as light curtains, emergency stop buttons, etc. Set up a light curtain around the working area of the welding air outlet. When personnel or objects enter the dangerous area, the light curtain can detect and send a signal to the robot control system in a timely manner, causing the robot to stop working immediately and avoiding safety accidents. The emergency stop button can quickly stop the robot's movement in case of an emergency.
High reliability design
The key components of robots, such as motors, controllers, sensors, etc., should be designed with high reliability. Due to the harsh welding working environment, including high temperature, smoke, electromagnetic interference, and other factors, robots need to be able to work stably for a long time in such an environment. For example, the controller of a robot should have good electromagnetic compatibility, be able to resist electromagnetic interference generated during the welding process, and ensure accurate transmission of control signals.
Post time: Nov-21-2024
