Domestic welding robot technology development
Our country develops the industry robot to be late to US
and Japan, gets up to the 20th century 70's, the early time is the
university and ç§‘ç ”é™?the institute spontaneous research. To
the 80's intermediate stages, a national bench work industry robot has
not been published. But in overseas, the industry robot already
was the extremely mature industry product, obtained the widespread
application in the automobile profession. In view of the fact
that then domestic and foreign situations, the country "75" the attack
plan has included the industry robot development the plan, has carried
on the attack to the industry robot, specially the application took
the inspection the important content, like this the robot technology
and user in close integration with, caused the Chinese robot to aim at
the start stage the practical direction. At the same time will
develop the robot in 1986 to include the country "863" the high tech
plan. "863" the plan implements when the fifth anniversary in
the country, Comrade Deng Xiaoping proposed "develops high tech,
realizes the industry" goal. In under the domestic market
development impetus, as well as to the robot engineering research
technical reserve foundation in, 863 subjects experts group promptly
carried on to the main attack direction has adjusted and extends, the
industry robot and the application project took research development
key one, proposed applied the impetus essential technology and the
basic research development policy, later will include the country "85"
and "95" center. Continues after several years diligently, in
under the national organization and the support, our country welded
the robot the research in aspect and so on foundation technology,
control technology, essential primary device has made the significant
progress, and entered the use stage, has formed the spot welding, the
arc welding robot series product, could realize the small volume
production.
Our country welds the robot the application condition
Our country welds the robot the application mainly to
concentrate in the automobile, the motorcycle, the project machinery,
the railroad locomotive and so on several main professions. The
automobile is welds the robot the biggest user, also is the earliest
user. As early as in the end of the 70's, the Shanghai electric
welding machine factory and the Shanghai power tool research
institute, the cooperation development rectangular coordinates
manipulator, successfully applies to the Shanghai sign passenger
vehicle chassis welding. "Steam" is our country most early
introduces welds the robot the enterprise, after 1,984 has at first
introduced 3 spot welding robots from KUKA Corporation, used in at
that time "Red Flag Brand" the passenger vehicle automobile body
welding and "the liberation trademark" the automobile body roof panel
welding. In 1986 will succeed will weld the robot to apply the
welding which encircled to front always becomes, and has developed the
robot automobile body in 1988 always 焊线 . At the
end of 80's and at the beginning of 90's, German populace company
separately with Shanghai and a steam establishment joint capital
automotive factory production passenger vehicle, although is the
overseas two equipment, but its welding automaticity and the equipment
level, let us realize and the overseas huge disparity.
Afterwards two steam all introduced in the freight vehicle and
in the light vehicle project have welded the robot. May since
say the 90's the technical introductions and the production equipment,
the craft equipment introduction has made our country the automobile
manufacture level to enhance from the original workshop type
production to the scale production, simultaneously causes the overseas
welding robot massively to enter China. Because the our country
infrastructure construction high speed development has led the project
mechanical profession prosperity, the project mechanical profession
also becomes comparatively early quotes welds one of robot
professions. In recent years as a result of the our country
economy high speed development, the energy massive demands, also all
started with the energy correlation manufacture profession to seek the
automated welding technology, welded the robot budding gradually.
The railroad locomotive profession as a result of demand
quantity the and so on our country freight transportation, passenger
transportation, city subway unceasing increase, as well as the row
truck unloading fast demand, the robot demand continuously is in grows
with steady steps the situation. According to 2001 the
statistics, the nation altogether has each kind of welding robot
1,040, the automobile manufacture and in the automobile spare part
production enterprise's welding robot occupies completely welds the
robot 76%. Welds the robot and the arc welding robot proportion
in the automobile profession center point is 3: 2, other
professions mostly are by the arc welding robot primarily, mainly
distribute in the project machinery (10%), the motorcycle (6%), the
railroad car (4%), the boiler (1%) and so on the profession.
Welds the robot also mainly to distribute in the nation several
big auto manufacturers, also can see from chart 1, our
country welds the robot the profession distribution not to be
imbalanced, also insufficiently is widespread.
Enters for the 21st century because the overseas automobile
giant unceasingly wells up into, the automobile profession swift and
violent development, the our country automobile profession robot
erecting bed number rapid increase, 2,002, 2,003, in 2004 have the
nearly thousand quantities growths every year. Estimated our
country at present welds the robot the erecting bed number about
4,000. The automobile profession welding robot occupies the
ratio regular meeting further enhances.
At present mainly divides in our country application robot Japan
is, Ou Xi and the domestically produced three kinds. The date is
center mainly has An Chuan, OTC, Matushita, FANUC, not two Viet Nam,
Sichuan å´?and so on company's product. Ou Xizhong mainly has
German KUKA, CLOOS, Sweden's ABB, Italy's COMAU and Austria's IGM
Corporation. The domestically produced robot mainly is the Shen
Yangxin loose robot company product.
At present in our country application industry robot,
domestically produced robot quantity insufficient 100, specially in
nearly two year new installment robot welding system already blind
Chinese robot form, although our country already had the independent
intellectual property rights the welding robot series product, but
actually could not the volume production, form the scale, had
following several main reasons:
The domestic robot price does not have the superiority. In
the recent 10 years, import the robot the price large scale to reduce,
reduce from each 7-8 ten thousand US dollars to 2-3 ten thousand US
dollars, causes the ordinary industry robot which our country
independently makes in the price to be very difficult and it
competition. Specially our country is developing the robot the
initial period, does not have the synchronized development
corresponding spare part industry, like the servo electrical
machinery, the speed reducer and so on need to import, causes the
price to reduce with difficulty, therefore the robot production cost
cannot fall down; Our country welding outfit level and overseas
also had the very big disparity, this point indirectly has also
affected the domestic robot development. Said regarding the
robot biggest user - - steam 车白 automobile body production factory
that, at present nearly all equipments all come from the overseas
introduction, the domestically produced robot nearly not to be able to
find the performance the stage.
We should acknowledge the domestically produced robot regardless
of from the control level or aspect and the overseas company and so on
reliability also has the certain disparity. The overseas
industry robot is the extremely mature industry product, has
experienced more than 30 years development course, moreover in actual
production unceasingly consummation and enhancement, but our country
is at one kind of single unit small batch the production condition.
The domestic robot produces the factory to be in the baby time,
but also needs the government policy and the fund support. Welds
the robot is the integration of machinery high-tech product, depends
on the enterprise own ability is only insufficient, needs the
government gives the certain policy and the fund support to the robot
production enterprise and the use domestic product robot assembly
system enterprise, the acceleration our country domestic product robot
development.
Using welds the robot the significance
Welds the robot therefore can occupy the entire industry
robot total quantity above 40%, with welds this special profession
related, the welding took the industry "the tailor", is the industry
lives the mid-production count for much processing method,
simultaneously because the welding mist and dust, the arc light, the
metal splashes the existence, the welding working conditions very
severe, the welding quality quality gets up the decisive influence to
the product quality. Induces uses welds the robot to have the
following main significance:
(1) is stable and the enhancement welding quality,
guarantees its homogeneity. The welding parameter like welding
current, the voltage, the welding speed and the welding does butt weld
result and so on the elongation plays the decision role. Uses
the robot welds when regarding each welded joint welding parameter all
is constant, the welded joint quality is been smaller person's factor
influence, reduces has operated to the worker technical the request,
therefore the welding quality is stable. When manual welding,
the welding speed, does the elongation and so on all is the change,
therefore is very difficult to achieve the quality the homogeneity.
(2) improved worker's work condition. Uses
the robot welder only is uses for to load and unload the work piece,
has been far away the welding arc light, the smog and splashes and so
on, regarding the spot welding said the worker no longer transports
the unwieldy handwork ç„Šé’³, causes the worker to extricate from in
the great intensity physical labor.
(3) enhances the labor productivity. Robot
not weary, one day may 24 hour continuous production, moreover along
with the high speed highly effective welding technology application,
uses the robot welding, the efficiency enhances is more obvious.
(4) the product cycle is clear about, is easy to
control the volume of output. The robot production metre is
fixed, therefore the arrangement productive plan extremely is clear
about.
(5) may reduce product modification update the
cycle, reduces the corresponding equipment investment. May
realize the small batch product welding automation. The robot
and the special plane biggest difference is he may adapt the different
work piece production through the revision procedure.
Our country welds the robot application project
The welding robot application technology is the robot
technology, the welding technology and the systems engineering
technology fusion, whether welds the robot to obtain the application
in the actual production, displays its superior characteristic, is
decided to the people to the above technical fusion degree.
After the nearly 10 years endeavor, our country welded in the
robot installs the jig design aspect to accumulate a richer
experience, the robot peripheral equipment has realized the
standardization, had yearly produces 300 set of welding apparatuses
people workstation the ability. May say domestic system
integration business and simple the design development aspect which
welded installs wiring had the ability in the robot workstation which
contended with with the overseas system integration business, in
recent years for enterprise and so on domestic automobile spare part
has provided the massive robots welding system. But other
serious fact is, we do not have the ability which the manufacture high
level robot complete set welds installs wiring. The domestic
several big automotive factories automobile body welds installs wiring
all is integrates business design manufacture by the overseas robot
assembly system.
As welds the robot the biggest user, estimated the future 10
year our country automobile annual output will have to achieve surely,
the present welding outfit by far will not be able to meet the
production need, the demand quantity which the butt weld equipped
largely increases, welds installs the production line request more
automated and the flexibility, will adapt the multi- varieties, the
small batch production request, the robot massively applies to welds
in the production line. To our country robot assembly system
integration business said how holds the important topic which the
opportunity is current must solve, from on the other hand says also
was deciding the domestic product welds the robot the destiny.
(1) implements the cartel. Robot assembly
system integration business and the automobile manufacturer union, the
digestion absorption overseas automobile welds installs wiring.
(2) establishes own welding outfit design standard
and the digital-analog, raises the design level and the efficiency.
(3) strengthens the talented person raise
construction. The robot welding production line is the complex
systems engineering, involves to the machinery, the electricity, the
thing flows the transmission, the computer, the automobile design
manufacture, the robot technology, the welding technology and so on
the many kinds of disciplines, but our country at present also not
about this aspect more systematic training organization.
(4) strengthens with the overseas company's
cooperation, raises own through the cooperation study design level.
Welds the robot the newest application technology
(1) TCP (tool center point tool central point) automatic school zero
technology
Welds the robot the tool central point is the welding
torch welding wire vertex, therefore the TCP zero position precision
directly is affecting the welding quality stability. But is
inevitable in the actual production can have between the welding torch
and the jig collision and so on cannot the foresighted factor cause
the TCP position deviation. The usual procedure is the use
manual carries on robot TCP school zero, but the general entire
process needs 30 minutes to be able to complete, affects the
production efficiency. TCP automatic school zero is uses in the
robot welding a new technology, its hardware facility is composed by a
trapezoid fixed bearing and group of laser sensors. When welding
torch by different posture after TCP support under, the laser sensor
all will record the data to transmit CPU with to suppose the definite
value to carry on the comparison and the computation at first.
When TCP has the deviation, the robot can automatically move the
school zero procedure, automatically carries on the adjustment to each
axis angle, and restores the TCP zero position in the least time.
(2) double silk welding technology
In recent years as a result of profession the and so on
our country automobile, container, rolling stock, project machinery
high speed development, to high speed welded with Gao Rongfu the
efficiency welding demand are more and more many. The double
silk welds is one high speed highly effective welding method which the
recent years developed, when the welding thin steel plate was allowed
remarkably to enhance the welding speed, achieved 3 ~ 6m/min, when
welding thick plate was allowed to enhance the melt to spread the
efficiency. Besides high speed is highly effective, the double
silk welding also has other craft characteristics: Spreads the
efficiency increase when the melt maintains a lower hot input, the
heat-affected zone small, welding deformation small, the welding
æ°”å”çŽ?is low and so on.
Because the welding speed is extremely high, specially suits
uses the robot welding, therefore may say the robot the application
also impelled this advanced welding technology development.
At present the double silk welds mainly has 2 ways: 1 kind
is Twin the arc law, another 1 kind is the Tandem law.
Welding apparatus basic composition similar, all is by 2
weldings power sources, 2 delivers the silk machine and 1 altogether
uses to deliver the double silk the electric cable. In order to
prevent with the phase 2 electric arcs mutual disturbances, often uses
pulse MIG/ pulse MAG to weld the law, and maintains 2 electric arcs in
turn to burn in turn. Then, requests 1 coordination controller
to guarantee 2 power sources the output current profile phase
differences 180°. When the welding parameter establishes to is
best, the pulse electric arc can obtain the transient process which
not short-circuits, nearly not splashes, truly achieves "1 pulse to
transit 1 melt drop", each melt drop size nearly quite same not less
than, its size is decided by the electric arc power. Twin the arc law main production factory has German SKS,
Benzel and Nimark Corporation, US'S Miller Corporation. The
Tandem law wants the factory to have German Cloos, Austrian Fronius
and American Lincoln Corporation. According to German Cloos
Corporation introduced that, uses when the Tandem law welds 2 ~ 3mm
thin steel plate, the welding speed may reach 6m/min, when welds above
8mm the thick plate, the melt spreads the efficiency to be possible to
reach 24Kg/h.
(3) laser/electric arc compound welding technology
The laser/electric arc compound welding technology is
the laser welding and the shielded welding union, two kind of weldings
heat sources simultaneously affect to welding molten bath. This
technical research most early appears in on century the end of 70's,
but as a result of the laser expensive price, has limited it in the
industry application. Along with the laser and the arc welding
equipment performance enhancement, as well as the laser price
unceasingly reduces, simultaneously in order to satisfy the production
the urgent demand, the laser/electric arc compound welding technology
became one of in recent years welding domain most important research
topics.
The laser/electric arc compound welding technology has the many
kinds of forms the combination, has laser /TIG, laser /MAG and laser
/MAG and so on.
The laser/electric arc compound welding technology therefore
receives the favour is long makes up each one as a result of its
concurrently various heat sources to be short, has 1+1>2 or more "the
coordination effect". Compares with the laser welding, to
assembles the gap the request to reduce front, thus reduced has welded
the work piece preparation cost; Moreover the inherent flaw
which when has the packing welding wire to eliminate laser welding
exists, the welded joint is more compact. Compared with the arc
welding enhanced the electric arc stability and the power density,
enhanced the welding speed and the welded joint 熔深, the
heat-affected zone changed slightly, reduced the work piece
distortion, eliminated time the arc melting not good flaw.
Specially suits the aluminum and its the alloy welding on this.
The laser/electric arc compound welding technology is to the
laser welding significant development, welds the same model thick
material to be possible to reduce the laser power one about the half,
therefore greatly reduced enterprise's investment cost, this technical
development to will impel the laser welding the popularization to play
the vital role.
(4) the servo ç„Šé’³ technology automobile attire
welds in the craft the application
The servo robot ç„Šé’³, is does new for the power supply
one kind using the servo electrical machinery substitution compressed
air ç„Šé’³. Below it has the merit:
(1) enhances the automobile body the surface
quality
The servo ç„Šé’³ because uses is the servo electrical
machinery, the electrode movement speed in contacts in front of the
work piece, may from high speed accurately adjust the low speed, like
this, may form the electrode to the work piece soft contact, reduces
indentation which the electrode impact creates, after thus also
reduced the foreword automobile body surface to resharpen the process
load, improved the automobile body quality. Moreover, may the
butt weld parameter carry on the numerical control management using
the servo-control technology, may guarantee provides the most suitable
welding parameter data, the guarantee welding quality.
(2) improvement work environment
Because the electrode to the work piece is the soft
contact, may reduce the impact noise, when cannot appear the use air
operated ç„Šé’³ creates exhaust noise. Improved the scene work
environment.
(3) high production efficiency
Servo ç„Šé’³ pressurizes the opening movement to come
the automatic control by the robot. With air operated ç„Šé’³
compares, the servo ç„Šé’³ movement way may control is short, reduces
the production metre, enhances the production efficiency.
At present, considered from the investment angle that, purchases
the servo ç„Šé’³ equipment an investment to be higher, therefore, the
servo ç„Šé’³ cannot widely use. But, considered the servo ç„Šé’³
superiority, for example the servo ç„Šé’³ soft contact, the impact may
reduce to the work piece, thus may the relative reduction welding
fixture clamp the organization the quantity, reduces the jig the
expense and so on, also was allowed to reduce the production line the
overall investment cost, the servo ç„Šé’³ still has its broad
application space. Therefore, along with the development, the
servo ç„Šé’³ can more and more apply on the production line.
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