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According to the degree of automation, automated welding equipment can be divided into the following three categories:

Rigid automatic welding equipment can also be called primary automatic welding equipment, most of which are designed according to the principle of open-loop control. Although the entire welding process is automatically completed by the welding equipment, the closed-loop feedback system cannot be used for the fluctuation of welding parameters during the welding process, and the possible deviation cannot be corrected randomly.

2. Adaptive control of automatic welding equipment

Adaptive control of welding equipment is a high degree of automation of welding equipment, it is equipped with sensors and electronic detection circuit, the weld trajectory of automatic guidance and tracking, and the main welding parameters for the implementation of closed-loop feedback control. The entire welding process will be automatically completed according to pre-set procedures and process parameters

3. Intelligent automatic welding equipment

It uses a variety of sensing elements, such as visual sensors, tactile sensors, auditory sensors and laser scanners, etc., and with the help of computer software systems, databases and expert systems have identification, judgment, real-time detection, operation, automatic programming, welding parameters storage and automatic generation of welding record files.

Composition

composition of automated welding equipment:

1, welding power supply, its output power and welding characteristics should be matched with the proposed welding process method, and equipped with the main controller connected to the interface.

2, wire feeder and its control and speed control system, for wire feeding speed control accuracy requirements higher wire feeder, its control circuit should be added speed feedback

3. The welding head uses its moving mechanism, which consists of the welding head, the welding head support frame, the hanging carriage, etc. It is located in the precision welding head mechanism, and its driving system shall adopt a servo motor equipped with an encoder.

4, welding parts moving or displacement mechanism, such as welding roller frame, head and tail frame turning machine, rotary platform and displacement machine, precision type of moving displacement mechanism should be equipped with servo motor drive

5. Weldment clamping mechanism

6. The main controller, also known as the system controller, is mainly used for the linkage control of each component, the control of the welding program, the setting, adjustment and display of the main welding parameters. Extensible control functions such as fault diagnosis and man-machine dialogue.

7, computer software, welding equipment commonly used computer software are: programming software, functional software, process method software and expert systems.

8. Welding head guiding or tracking mechanism, arc pressure automatic controller, welding gun yaw device and monitoring system

9. Auxiliary devices, such as wire feeding system, circulating water cooling system, flux recovery conveying device, welding wire bracket, cable hose and drag chain mechanism structure design, electrical control design three parts.

Welding robot, also known as mechanical arm, is an important part of automatic welding equipment. Its main work includes: welding, cutting, thermal spraying, handling, etc. The application and value of automatic welding equipment in full-position welding, the application of automatic welding equipment in full-position welding, welding execution parts to take the way of rotating sub-drive, the welding torch attitude flexible and reasonable change, is conducive to the full-position welding work.

At the same time, the motor power can also be reduced when driving the same welding execution parts. In the application, the sensor on the welding position is installed on the final deceleration shaft to detect the position of the welding gun. By adopting this installation method, the control accuracy is relatively high. In addition, with the help of the memory on the automatic welding equipment, the parameters of some welding processes and the welding seam tracking control program are stored, and the welding process parameters are stored in the arc welding power supply, so that the arc welding power supply can play its advantages. Through the cooperation of the two, various quality problems that may occur in the full-position automatic welding operation can be effectively solved.

The welding gun is driven by means of a stepping motor (stepping motor refers to an open-loop control element stepping motor device that converts the electric pulse signal into angular displacement or linear displacement). This motor can effectively convert the digital input pulse type into a kind of rotation. The component itself has high precision, not only does not cause drift problems, but also does not cause problems such as cumulative errors. The application of this component in all-position welding not only does not change the speed, but also controls the frequency signal to be more stable and the displacement of the welding gun to be more accurate.

Third, in the all-position welding operation, the organic combination of the welding head and the arc welding power supply can not only achieve the purpose of all-position automatic welding, but also reduce the price of automatic welding equipment to a certain extent. In this way, not only automatic welding can be realized, but also semi-automatic welding can be carried out by means of an arc welding power source and a semi-automatic welding gun.

Automatic welding equipment common welding defects and prevention strategies, air holes.

When automatic welding equipment is applied in full-position welding, porosity is a relatively common problem, and there are many reasons for this problem, such as the cause of the welding material itself, improper operation, environmental reasons, etc. In view of this, in order to effectively prevent this problem, in the implementation of welding, the protection of gas should be strengthened, the welding temperature should not be too high, in strict accordance with the proportion and related requirements to fill the gas, to ensure that the filling purity meets the requirements. At the same time, attention should be paid to the environment around the welding site. If the wind speed of the construction site exceeds 8 meters per second, the windproof shed should be used for protection, and the environmental humidity should not be too high. In addition, to ensure that the welding location remains dry, heating can be performed using a ring fired heater or a medium frequency induction heater.

Unfused. In welding, the problem of incomplete fusion often occurs at the vertical welding position. The reasons for this problem are incorrect weld bead grinding shape, deviation from the weld during welding, or the width of the welding torch swing is not reasonable enough. In view of this, in the welding process, in the implementation of welding bead grinding operations, should try to polish smooth. At the same time, before welding, the welding wire should also be carefully observed to see if its swing width is correct. In addition, in the process of welding, if the center of the weld pool and the weld bead is found to deviate, it should be adjusted in time to avoid the problem of incomplete fusion.

Precautions

1. Flexible and diverse soldering methods support spot welding and drag welding (pull welding). All process parameters of automatic soldering equipment can be set by customers themselves to adapt to various difficult soldering operations and micro-soldering processes. All soldering parameters can be read and saved with solder joint coordinate programs to realize flexibility of soldering operations.

2. The soldering iron assembly can be adjusted at any angle and in any direction, and the R axis of the soldering iron group can be controlled to rotate freely in 360 degrees. The number of tin feeding times, preheating time and soldering time can be arbitrarily set according to different pads and components, thus realizing the complex soldering process of multiple solder joints on one board and realizing the diversification of soldering operations.

3. Four-axis/five-axis linkage manipulator, automatic soldering equipment adopts servo drive and advanced motion control algorithm, which effectively improves the positioning accuracy and repetition accuracy of the moving end-soldering iron head, and realizes accurate positioning of any solder joint in 3D space.