盾构机部件机器人焊接工艺研究

针对盾构机中关键部件的焊接加工特点与要求，建立了适应并满足不同部件焊接生产制造的机器人工作站；采用福尼斯TPS 500i焊接电源中的不同特性的PMC工艺开展了盾构机部件厚板多层多道焊接相关工艺研究。研究表明，Dynamic工艺适合于平焊与横焊位置打底焊接；Universal工艺适合于平焊位置填充与盖面焊接；PCS工艺适合于横焊位置填充与盖面焊接。由于Mix工艺的冷却时间较长，更利于熔融金属的冷却凝固，使用Mix工艺可以获得表面成形良好的立焊焊缝。对于盾构机典型关键部件的焊接制造，采用Dynamic+Universal工艺进行多层多道平焊，Dynamic+PCS工艺进行多层多道横焊，Mix工艺进行多层多道立焊后，焊缝成形良好，无未熔合及咬边等焊接缺陷。上述工艺组合可以用于盾构机部件的机器人自动化焊接中。

Robot Welding Process Research of Shield Machine Parts

Based on the analysis of processing features and welding request of typical parts in shield machine, a robot welding workstation is established to realize the automated welding of shield machine parts. The multi-layer and multi-pass welding processes for parts of shied machine are analyzed by using different process characteristics under pulse multi control (PMC) mode in Fronius TPS 500i welding source. The results show that the Dynamic process is suitable for backing weld in flat and horizontal welding position. For filling and cosmetic welding, the Universal and pulse control spray (PCS) processes can be used in flat and horizontal welding positions, respectively. It is easier for molten metal to solidify because of the longer cooling time during Mix welding process, and good surface forming can be obtained by using Mix process in vertical welding positions. The weld joints with good forming, which means there are no welding defects such as lack of fusion and undercuts in the weld, can be obtained by adopting Dynamic+Universal, Dynamic+PCS and Mix for the welding of critical shield machine parts in flat, horizontal and vertical welding positions, respectively. The aforementioned welding processes can be used in the robot welding of shield machine parts.