焊接机器人的示教轨迹优化

示教型焊接机器人的自动焊接生产，精确确定焊枪工作位置，对于确保焊接质量，降低产品废品率有重要意义。以桑车踏板焊接件为例，通过基于Petrato定理的误差源分析，对工件焊点的测量和均值计算，并采用优化数控编程，达到焊接轨迹的精确优化。经试验验证，该方法成本低，效率高，使焊接废品率大大下降。     

结构光传感器在机器人焊接中的应用

焊接机器人是实现焊接自动化的重要的标志。当前,在工业生产中应用的焊接工业机器人一般采用示教或者离线编程的方式对任务进行路径规划和运动编程,机器人工作过程中只是简单的重复预先编程设定的动作。当焊接工件的状态（焊缝的位置发生偏差）发生变化时,焊接的质量很难得到保证,焊接传感器是解决这一问题的主要手段。为了提高焊接机器人的智能化和自动化,世界上许多国家焊接研究机构开发焊接过程控制系统,而焊缝跟踪技术是焊接过程控制系统的首要问题。随着几十年电子、软件技术的发展,焊缝跟踪技术已经取得了长足的进步,并且在焊接中得到成功应用。     

Panasonic-TA1400型弧焊机器人应用探析

在应用Panasonic-TA1400型弧焊机器人进行示教编程与焊接操作的基础上,从焊接工艺编制及焊接工艺试验对焊接质量的影响和焊接机器人应用推广对人才能力的要求2个方面进行了分析,总结了弧焊机器人直线摆动和圆弧摆动示教编程的方法及技巧,阐述了弧焊机器人基本操作与基本设置、焊接结构生产工艺编制、焊接工艺试验与分析三个方面对弧焊机器人推广应用的重要性,提出了弧焊机器人推广应用是对焊接工艺与示教技能综合能力的挑战以及弧焊机器人技术的推广应用需要复合型人才的观点。     

焊接机器人在机车构架生产中的应用

针对焊接机器人的特点,分析焊接机器人在GE机车转向架构架生产中的应用,介绍了焊接机器人的工艺要点,在装配和焊接过程中的技术要求,工装设计以及编程等问题。焊接机器人大大提高了焊接质量和效率。     

双丝自动焊接技术应用研究

针对某产品结构特点设计和制造焊接工装,拟定双丝焊接工艺,并采用双丝焊接工艺对该产品进行焊接,进一步摸索其焊接工艺特点,掌握焊接过程中对焊缝成形的影响,通过在线编程优化双丝焊接工艺参数,形成规范性指导文献.     

机器人在不锈钢高压箱体螺柱焊接中的应用

机器人螺柱焊接技术主要是通过机器人编程将不同规格的螺钉焊接到不锈钢高压箱体上,其具有焊接精度高、焊接效率快、焊接质量好等优点.本文从机器人焊枪更换、工件位置偏移检测和工件表面平整度修正这三个方面介绍了机器人技术在螺柱焊接中的具体应用.     

重载万向联轴器接管对焊坡口结构优化

重载万向联轴器中间接管常采用U型焊接坡口对焊,焊接质量直接影响万向联轴器的承载能力及使用寿命。通过超声波无损探伤,发现焊缝根部常存在未焊透、塌陷、未熔合等缺陷。为此提出焊接坡口结构的优化方法,改善了焊接质量。     

基于RobCAD软件的焊接机器人离线编程

针对焊接机器人的离线编程展开,重点介绍了利用RobCAD辅助机器人离线编程的方法.运用了SolidWorks的三维建模技术建立机器人模型并模拟了焊接机器人的工作环境,同时结合RobCAD的虚拟仿真技术实现了焊接机器人的离线编程和仿真,最终得到离线程序.基于RobCAD的编程作为整体离线编程方法的一部分,通过验证,其输出结果能够满足后续编程步骤的需求.     

数控激光焊接汽车用高强钢工艺参数的优化

在CO2激光焊接加工中,影响高强镀锌钢板焊接质量的因素很多。根据试验加工对相关因素进行了分析,并给出了一套可以有效控制焊接高强钢加工质量的优化工艺参数,从而确保汽车用高强铜的焊接质量。     

基于有限元分析钢板焊接温度场的影响因素

利用ANSYS软件的APDL语言以及单元"死活"技术模拟焊接的填充过程,较好的模拟焊接加热过程及整个温度场的瞬态变化并实现了参数化编程;利用有限元分析软件ANSYS对钢板焊接温度场进行动态模拟,建立高斯函数热源模型,对各项焊接参数的合理选择和优化提供有效的参考.     

PENETRATION QUALITY EVALUATION IN ROBOTIZED ARC WELDING BASED ON SUPP0RT VECTOR MACHINE

A quality monitoring method by means of support vector machines (SVM) for robotized gasmetal arc welding (GMAW) is introduced. Through the feature extraction of the welding process signal,a SVM classifier is constructed to establish the relationship between the feature of process parametersand the quality of weld penertration. Under the samples obtained from auto parts welding productionline, the learning machine with a radial basis function kernel shows good performance. And thismethod can be feasible to identify defect online in welding production.     

基于焊接位置数学模型的变位机逆运动学算法

给出了一种通用的2R变位机的逆运动学算法。根据焊缝位置的数学模型,得到了描述焊缝焊接位置的参数——焊缝转角和焊缝倾角与焊缝姿态的关系。以符号的形式表示了变位机的杆件参数及变位机与机器人间的姿态关系。建立了运动学坐标系,推导了满足焊缝转角和焊缝倾角要求的变位机逆运动学公式。该算法解决了不同焊接位置和变位机相对机器人不同安装位置的变位机逆运动学求解,大大地提高了离线编程系统的适用性。     

薄板拼接焊机的结构设计

针对薄板在拼焊过程中不能快速组对和焊缝质量不好的问题,设计研制出薄板拼接焊机。该焊机在板材焊缝处采用琴键压紧装置,能够快速压紧板材接头;焊机前后带有板材调整机构,方便板材接头的调整。焊接过程中,该焊机在结构上能满足焊缝两侧同时通入保护气体的需求,保证焊缝质量。薄板拼装焊机可实现板材厚度在0.5~6 mm范围内的板-板之间的拼接成形。     

桑车踏板自动化焊接误差分析与控制

在示教再现型机器人自动化焊接生产中 ,对焊缝误差进行分析与控制对提高产品质量具有十分重要的意义。以桑车踏板焊接件为例 ,通过对焊缝误差进行统计分析 ,确定了引起焊缝偏差的主要误差源。提出了以最小焊缝误差为目标的机器人优化焊接轨迹示教法。经过试验证明 ,采用优化示教轨迹可使焊接废品率从 2 0 %下降至 5 % ,有效提高了焊接质量。     

后倾式离心风机叶轮机器人焊接工艺优化

在后倾式离心风机叶轮机器人焊接时，为了既保证焊缝质量又最大程度减小焊后变形量，综合运用热弹塑性有限元法和固有应变法对其焊接工艺进行优化。利用基于热弹塑性有限元法的Visual-Environment软件，结合双椭球热源模型对焊缝熔池情况进行数值模拟和实验验证，得到了最优焊接参数。在已知焊缝固有应变的情况下，采用基于固有应变法的Weld Planner软件对后倾式离心风机叶轮在不同焊接顺序和焊接方向下产生的变形进行了预测，得到了最优焊接顺序和焊接方向。运用得到的最优焊接工艺对后倾式离心风机叶轮进行试生产，其焊后变形情况与数值模拟得出的结果较为一致，满足产品的质量要求。     

Optimal design of weld pattern in sheet metal assembly based on a genetic algorithm

In the sheet metal assembly process, welding operations join two or more sheet metal parts together. Since sheet metals are subject to dimensional variation resulting from manufacturing randomness, a gap may be generated at each weld pair prior to welding. These gaps are forced to close during the welding operation and accordingly undesirable structural deformation results. Optimizing the welding pattern (the number and locations of weld pairs) in the assembly process was proven to improve significantly the quality of the final assembly. This paper presents a genetic-algorithm-based optimization method to search automatically for the optimal weld pattern so that assembly deformation is minimized. The application result for a real industrial part demonstrated that the proposed algorithm effectively achieved the objective.     

Multi sensor data fusion for improving performance and reliability of fully automatic welding system

This paper presents a new generation of system for pressure vessel and shipbuilding. Typical pressure vessel and ship building weld joint preparations are either traditional V, butt, fillet grooves or have narrow or semi narrow gap profiles. The fillet and U groove are prevalently used in heavy industries and shipbuilding to melt and join the parts. Since the wall thickness can be up to 6 in. or greater, welds must be made in many layers, each layer containing several passes. However, the welding time for the conventional processes such as submerged arc welding (SAW) and flux cored arc welding (FCAW) can be many hours. Although SAW and FCAW are normally mechanized processes, pressure vessel and ship structures welding up to now have usually been controlled by a full time operator. The operator has typically been responsible for positioning each individual weld run, for setting weld process parameters, for maintaining flux and wire levels, for removing slag and so on. The aim of the system is to develop a high speed welding system with multi-torch for increasing the production speed on the line and to remove the need for the operator so that the system can run automatically for the complete multi-torch multi-layer weld. To achieve this, a laser vision sensor and a special image processing algorithm have been made. Also, the multi-torch welding system can be applicable for fine grained steel because of the high welding speed and lower heat input compared to a conventional welding process.     

TP304不锈钢钢管环焊缝的A-TIG焊接研究

A-TIG焊接技术是基于TIG焊的焊接新工艺,具有大幅增加焊缝熔深、提高焊接生产率,降低成本等优点。本研究采用A-TIG焊接技术对TP304不锈钢50mm×6mm的管子进行全位置焊接,对得到的焊接接头进行射线探伤、显微组织分析以及力学性能测试,结果表明,接头的显微组织优于普通TIG焊接接头、接头质量和力学性能均达到标准要求。     

中厚管材环缝的等离子弧微机自适应控制焊接

为了扩大等离子弧焊接的应用范围，突破不开坡口只适于工件厚度为８ｍｍ以下的限度，本文研究设计了一种微机自适应控制系统，对影响焊接过程稳定性、焊缝表面成形和接头质量的工艺规范参数和工艺措施进行了全面试验，成功地实现了１０ｍｍ厚ＺＧ４Ｃｒ２５Ｎｉ２０钢管的焊接，为等离子弧焊的发展和推广使用开辟了新的前景．     

Weld quality analysis and evaluation of plasma arc welds in electrical stators

The use of plasma arc welding (PAW) has increased in the last years as a substitute for the gas tungsten arc welding in the automotive, electrical and appliance industries. Although the use of PAW in the industry has increased, there are still a limited number of theoretical methods and simulation tools to predict the metal flow characteristics and its interaction with the process parameters during the welding process. Therefore, weld design must still rely on the designer’s experience and the trial-and-error method. As a consequence, the process parameters and the weld quality may not be as originally expected at the design process. In this paper, a weld quality analysis of the PAW process is presented to guarantee a good quality of the product. To measure the influence of process parameters on weld quality, first, “quality” is defined. Weld quality measurement methods are then proposed based on visual inspection, electrical tests and mechanical tests of the welds. Using these methods and the experimental data obtained from the actual welding process at the production line, a new approach to evaluate the weld quality is proposed based on a circular shape model of the weld cross-section area. Finally, a relationship between the weld geometry and weld quality is proposed and intended to be used as a practical online monitoring method of weld quality.