CN-117047273-B - Automatic self-weight assembly welding pretreatment system and method based on laser filler wire cross beam

CN117047273BCN 117047273 BCN117047273 BCN 117047273BCN-117047273-B

Abstract

The invention belongs to the technical field of assembly welding pretreatment, and provides a self-weight automatic assembly welding pretreatment system and method based on a laser filler wire beam, which can realize automatic assembly and feeding and discharging of beam assembly, flexible use of multiple vehicle types, the welding and polishing integrated device with the rigidity clamp formed by the cross beams realizes the closed loop detection of the data in the shortest time by utilizing the welding cluster control system and the welding simulation, achieves automatic assembly, visual identification filling, quality process control and adjustment-free data closed loop, and achieves the automation of the assembly and welding quality of the cross beam.

Inventors

WU XIANGYANG
CHEN BEIPING
ZHAN FAFU
MA YIN
ZHANG ZHIYI
MU YUNFEI
TIAN RENYONG
DENG HONGJIAN
MA ZHENGZHENG
LI YANAN
LIU NIANZU
WANG REN

Assignees

中车青岛四方机车车辆股份有限公司

Dates

Publication Date: 20260512
Application Date: 20230831

Claims (7)

1. The automatic self-weight assembly welding pretreatment method based on the laser filler wire cross beam is characterized by comprising the following steps of: Welding and assembling are carried out, and the joint connection of the workpieces in the gravity state is completed; determining the completion position and size of each workpiece, and adjusting the size position of each workpiece, specifically, comparing the datum line according to the outer contour of each workpiece, simultaneously determining the fit proportion of the connecting surfaces to be welded, and judging that the workpieces are unqualified and the materials need to be replaced when the fit proportion is smaller than a set value; performing root welding of laser filler wire welding at each workpiece connecting position, and realizing preliminary rigid fixation of all welding positions; monitoring the quality of a welding process, introducing abnormal data into a simulation step when the welding quality problem occurs, carrying out analysis iteration, and feeding back the quality problem, specifically, considering that the data is abnormal when the accumulated error of the assembled part exceeds the upper limit, inputting the scanned and calibrated size pair standard into a simulation calculation model when the data is abnormal, completing welding deformation and stress calculation, and locally adjusting the welding sequence and the heat input quantity again; performing beam detection and welding effect detection, and optimizing technological parameters in the simulation step according to detection results; in the process of determining the welding process sequence and the process parameters by simulating the welding sequence of the cross beam from the gravity state, the cross beam falls into each workpiece according to the principle that the weight is from large to small, and the principle that the length of the workpiece is from long to short is combined.
2. The automatic assembly welding pretreatment method based on the self-weight state of the laser filler wire beam as claimed in claim 1, wherein a welding robot is used for welding assembly, and a manipulator or a clamping device of the robot is used for clamping each workpiece.
3. The automatic assembly welding pretreatment method based on the self-weight state of the laser filler wire cross beam according to claim 1, wherein the specific process of performing the root welding of the laser filler wire welding at each workpiece connecting position comprises the steps of clamping the workpiece by using a clamping device, grabbing a laser filler wire power supply by using a robot, and completing the root welding of the laser filler wire welding at each position.
4. The automatic beam assembly and welding pretreatment method based on the self-weight state of the laser filler wire beam as claimed in claim 1, wherein the beam detection is performed by using a laser model contrast machine, and the welding effect detection is performed by using ultrasonic or laser scanning.
5. The automatic assembly welding pretreatment method based on the self-weight state of the laser filler wire beam according to claim 1, wherein the specific process of optimizing the technological parameters in the simulation step comprises the steps of carrying out data scanning confirmation on the assembled and fixed components, introducing simulation calculation on assembly difference data, carrying out fine adjustment on the process of exceeding the completion of calculation, calculating welding deformation again, predicting quality change to be caused by assembly difference, and finally determining welding sequence and parameters.
6. An automatic self-weight assembly welding pretreatment system based on a laser filler wire beam, which adopts the automatic self-weight assembly welding pretreatment method based on the laser filler wire beam according to any one of claims 1-5, and is characterized by comprising the following steps: the simulation module is configured to determine a welding process sequence and process parameters through simulation of the welding sequence of the cross beam from the gravity state; The automatic welding device is used for welding and assembling to finish the joint connection of the workpieces in the gravity state, and performing root welding of laser filler wire welding at each workpiece connecting position to realize preliminary rigid fixation of all welding positions; The laser detection mechanism is used for determining the completion position and size of each workpiece so as to adjust the size and position of each workpiece; The monitoring device is used for monitoring the quality of the welding process, introducing abnormal data into the simulation step when the welding quality problem occurs, carrying out analysis iteration, and feeding back the quality problem; and the detection device is used for detecting the cross beam and the welding effect, and optimizing the technological parameters in the simulation step according to the detection result.
7. The automatic assembly welding pretreatment system based on the self-weight state of the laser filler wire beam as claimed in claim 6, wherein the automatic welding device comprises: a tray for lifting the beam or the material; an AGV trolley for movement; A robotic system for gripping a workpiece or material; a clamp for positioning or clamping a workpiece; A laser filler wire welding robot for performing welding.

Description

Automatic self-weight assembly welding pretreatment system and method based on laser filler wire cross beam Technical Field The invention belongs to the technical field of assembly welding pretreatment, and relates to an automatic assembly welding pretreatment system and method based on self-weight state of a laser filler wire beam. Background The statements in this section merely provide background information related to the present disclosure and may not necessarily constitute prior art. The beam in bogie vehicle manufacturing has complex structure, large welding quantity and difficult quality control, the assembly process mostly adopts manual assembly and realizes the quality assurance of beam root layer welding seams through high-level manual welding pretreatment, and the production and the manufacture of workpieces are realized by combining automatic welding of robots, but the manual assembly precision is difficult to ensure, the pretreatment has high requirements on manual skills, and the long-period deformation data statistical optimization is required when the large-scale production is faced. In the process flow, invalid processes such as trimming, scribing and the like occupy a large operation area, and the automatic operation of the whole flow cannot be realized. According to the inventor, the existing technology generally adopts manual assembly or more complex semiautomatic assembly and MAG welding at home and abroad, meanwhile, the back assembly is limited by a tool, the assembly and welding pretreatment of the original station cannot be realized, meanwhile, the MAG welding spot welding needs further cleaning, the manufacturing period is longer, and the high-cost manufacturing caused by repeated adjustment and repair is caused. Disclosure of Invention The invention provides a self-weight automatic assembly welding pretreatment system and method based on a laser filler wire beam, which can realize automatic assembly and loading and unloading of beam assembly, flexible use of multiple vehicle types, welding and polishing integrated device with rigid clamp formed by beams, meanwhile, the welding cluster control system and welding simulation are utilized to realize the shortest data closed-loop detection, so that automatic assembly, visual identification filling, quality process control and adjustment-free data closed-loop are realized, and the assembly of the cross beam assembly and welding quality automation are realized. According to some embodiments, the present invention employs the following technical solutions: a self-weight automatic assembly welding pretreatment method based on a laser filler wire beam comprises the following steps: Firstly, determining a welding process sequence and process parameters through simulation of a welding sequence of the cross beam from a gravity state; welding and assembling are carried out, and the joint connection of the workpieces in the gravity state is completed; Determining the completion position and size of each workpiece, and adjusting the size and position of each workpiece; performing root welding of laser filler wire welding at each workpiece connecting position, and realizing preliminary rigid fixation of all welding positions; Monitoring the quality of the welding process, introducing abnormal data into a simulation step when the welding quality problem occurs, carrying out analysis iteration, and feeding back the quality problem; and (3) detecting the cross beam and the welding effect, and optimizing the technological parameters in the simulation step according to the detection result. In the process of determining the welding process sequence and the process parameters through simulation of the self-weight state of the cross beam, the method falls into each workpiece according to the principle of large-to-small weight and combines the principle of length determination of the workpiece from long to short. As an alternative embodiment, the welding assembly is performed with a welding robot, the robot's manipulator or clamping device being used to clamp the respective work pieces. As an alternative implementation mode, determining the completion position and size of each workpiece, and adjusting the size and position of each workpiece comprises the specific process of comparing the datum line according to the outline of each workpiece, simultaneously confirming the fit proportion of the connecting interfaces to be welded, and judging that the workpieces are unqualified and the materials need to be replaced when the fit proportion is smaller than a set value. As an alternative embodiment, the specific process of performing the root welding of the laser filler wire welding at each workpiece connection position includes clamping the workpiece by using a clamping device, and grabbing the laser filler wire power supply by using a robot to complete the root welding of the laser filler wire welding at each position. In an alternative embodiment, the abnor