A weld is composed of the collinear MN of the two surfaces and the included angle α. In the above two rotation ranges, after proper rotation, the collinear MN can be made parallel to the horizontal plane, and the two planes are clamped to the horizontal plane. The angles are equal, each is α/2, that is, the ship fillet welding position. This assumption is that any complex weldment, as long as it is installed on a welding positioner with the main degree of freedom of one full revolution and one-half revolution, can meet the requirements of marine welding. We call this double rotary welding positioner a full-featured positioner.
Welding positioner displacement degree of freedom
For some weldments, due to the simple distribution of the welds, the ship welding requirements of most of the weldments and important welds can be solved with one rotational degree of freedom. Perform flat fillet welding. In this way, to simplify the equipment cost, the welding positioner with a single degree of freedom or function degradation, that is, a single-turn positioner is considered in the process. According to the requirements of use, the auxiliary degrees of freedom can also be increased. For example, lift and tailstock mobile and so on.
There are also some station positioners, which are suitable for the process requirements of the welding station, and some degrees of freedom of this welding positioner have nothing to do with welding. In addition, considering the station design and stability, two or more welding positioners are combined and designed, so that a variety of station conversion and combined multi-degree-of-freedom welding positioner products have appeared.
Use of welding positioner
Main application: A welding positioner is a piece of general and efficient welding equipment mainly for circular seam welding. It can be equipped with an argon arc welding machine (wire-filled or not), MIG/MAG welding machine (C02/MAG/MIG welding machine), plasma welding machine, and other welding machine power sources, and can form an automatic welding system with other machines. The product is mainly composed of a rotating head, displacement mechanism, and controller. The rotating speed of the rotating head is adjustable, with an independent speed control circuit, and the DIP switch directly presets the length of the weld. The tilt angle can be adjusted as required. The welding torch can be lifted pneumatically
Welding positioner technical requirements
1. Rotary drive
(1) The rotary drive should realize step-less speed regulation and be reversible.
(2) Within the rotation speed range, the speed fluctuation should not exceed 5% when bearing the maximum load.
2. Tilt drive
(1) The tilt drive should be stable, not shake under the maximum load, and the whole machine should not overturn. If the maximum load Q exceeds 25kg, it should have the power drive function.
(2) There should be a limit device to control the inclination angle, and there should be an angle indicator.
(3) The tilting mechanism should have a self-locking function, which does not slide under the maximum load, and is safe and reliable.
(1) The control part of the positioner shall be provided with a linkage interface for automatic welding.
(2) The positioner should be equipped with a conductive device to prevent the welding current from passing through the transmission parts such as bearings and gears. The resistance of the conductive device should not exceed 1mΩ, and its capacity should meet the requirements of the rated welding current.
(3) Electrical equipment shall comply with the relevant provisions of GB/T 4064.
(4) The structure of the workbench should be convenient for clamping the workpiece or installing the fixture, and the structure form can also be determined through consultation with the user.
(5) The relationship between the maximum load and the eccentric distance and the center of gravity distance should be explained in the instruction manual of the positioner.
Welding positioner type
Welding positioner can be divided into three categories according to the structure:
1. Outrigger welding positioner
Structural features and performance of the extendable welding positioner The rotary table is installed at one end of the outrigger. The outrigger generally rotates at an angle relative to a certainly inclined axis, and the position of this inclined axis is mostly fixed, but some can also be less than 100 tilt up and down within the range of °. The machine has a large displacement range and good work adaptability, but the overall stability is poor. Its scope of application is the turning position of small and medium workpieces below 1t. It is widely used in manual welding. Most of them are driven by electric motors, and the bearing capacity is below 0.5t, which is suitable for small and rare flipping positions. There are also hydraulic drives, which have a large bearing capacity and are suitable for welding parts with small structural dimensions but large self-weight.
2. Seat welding positioner
The seat-type welding positioner worktable has an overall degree of freedom of flipping. The job can be flipped to the ideal welding position for welding. In addition, the table has a rotational degree of freedom. This kind of positioner has been produced in series, mainly used for the welding of some tubes and plates. The worktable side and the slewing mechanism are supported on the inclined shafts on both sides, the worktable rotates at the welding speed, and the inclined side is inclined at a constant speed within the range of 140° through the sector gear or hydraulic cylinder. The machine has good stability, generally does not need to be fixed on the foundation, and is easy to move. Its application range is from 1 to 50t workpiece turning position, is currently the most widely used structural form, often used in conjunction with telescopic arm welding manipulators. A seat type positioner is a device that makes the welding seam in a horizontal or boat-shaped position through the rotation or inclination of the worktable. The rotation of the worktable adopts variable frequency stepless speed regulation, and the worktable is driven to tilt by sector gears or hydraulic cylinders. It can realize joint control with an operating machine or welding machine. The control system can be equipped with three optional configurations: button digital control type, switch digital control type, and switch relay control type. This product is used in the welding of various shafts, discs, cylinders, and other revolving workpieces. It is the most widely used structural form at present.
The seat positioner can be divided into seat positioners and small seat positioners according to different loads.
The machine has good stability, generally does not need to be fixed on the foundation, and is easy to move. It is the structure with the largest output, the most complete specifications, and the most widely used structure. Often used in conjunction with telescopic arm welding manipulators or arc welding robots.
3. Two-seat welding positioner
The two-seat welding positioner of China Mold Intelligent Manufacturing Co., Ltd. is a positioner that integrates the functions of turning and turning. Turning and turning are driven by two shafts respectively. In addition to turning around its axis, the worktable holding the workpiece can also be tilted or turned around another shaft. It can adjust the welding seam at various positions on the weldment to a Horizontal or "boat" easy welding position, suitable for welding frame, box, disc, and other non-long workpieces.
The workbench is seated on the "U"-shaped frame, which rotates at the required welding speed, and the "U"-shaped frame is seated on the machine bases on both sides, and rotates around the horizontal axis at a constant speed or the required welding speed. The machine not only has good overall stability, but if the workpiece is properly designed after the workpiece is placed on the worktable, the center of gravity of the tilting motion will pass or approach the tilting axis, and the tilting driving torque will be greatly reduced. kind of structure. Its scope of application is the turning and shifting of heavy and large-sized workpieces above 50t, and it is mostly used in conjunction with large-scale portal welding manipulators or telescopic arm welding manipulators.
The double-seat welding positioner is suitable for flipping and shifting large-sized weldments above 50t. In welding operations, it is often used in conjunction with a large portal welding manipulator or a telescopic arm welding manipulator.