Three dimensional flexible welding flat plate 00 level precision cast iron platform

Three dimensional flexible welding flat plate 00 level precision cast iron platform

The welding workbench is designed for welding small welding parts, and the main material is made ofHT200-HT250 cast iron, with T-shaped grooves or holes on the surface for workpiece fixation and cleaning of welding slag, the structural design complies with GB/T 22095-2008 standard. The appearance of the countertop includes rectangular, square, or circular shapes. The blank casting adopts resin sand or cement sand lost foam technology, and some products are annealed and naturally aged to ensure stability.

This device is divided into ordinary and three-dimensional flexible combination types. The three-dimensional flexible welding workbench adopts standardized hole system modules, which are connected by bolts to achieve5 tons clamping force, positioning accuracy controlled within ± 0.1mm The precision model is equipped with a grating pulse counting system and a speed range0.25～3.5r/m The modular design supports three-dimensional space splicing, and is widely used in the fields of automotive manufacturing, engineering machinery, and welding robots to achieve multi station operations with structures such as electric push rods and sliding rails .

The 3D welding platform integrates sensors and machine vision technology, designed to reduce manual involvement and improve welding quality. Typical cases are applied in the fields of shipbuilding and aerospace.

Three dimensional flexible welding flat plate 00 level precision cast iron platform

drawing design

The design of welding workbench drawings should be based on customer requirements, according towelding platformNational StandardGB/T 22095-2008， Mainly including external dimensions, load-bearing capacity, working face T-groove size, working face accuracy, etc. The larger the external dimensions, the higher the overall height of the welding platform, such as a 2000mm × 4000mm welding platform with a T-groove opening of 36mm (using M30 fastening bolts), a T-groove spacing of 250mm, and a load-bearing capacity of less than 20 tons; The total height can be designed to be 300mm, with a working face thickness of 100mm and a reinforcing rib plate thickness of 30mm. The reinforcing rib plate includes a 50mm x 50mm flip edge with an inner height of 150mm-170mm; The overall weight of the welding workbench is 7.5-8 tons.

Casting method

Welding worktable blankcastingDivided into resin sand molding and cement sand molding, these two molding methods are generally used for large cast iron parts, both of which areLost Foam CastingGenerally, for large batches with relatively small castings, wooden molds are used for solid casting, while resin sand molding is more commonly usedLarge scale machine tool castingsThe cost of casting on welding platforms is higher than that of cement sand shaped castings,80% of welding platforms use cement sand molding to cast castings, which can meet the technical requirements of welding platforms and reduce the manufacturing cost of welding platforms. This is the process flow used by most manufacturers when manufacturing welding platforms. The welding platform castings must comply with the national standard GB/T9439-2010.

material

generallyHT200 or HT250

Heat treatment of casting blanks

Welding workbenchheat treatmentIt is fundamental to ensure that flatness does not deform. The quality of the welding platform and whether the heat treatment is qualified are key parameters for evaluating the quality of the welding platform. The heat treatment of the welding platform blank follows national standardsGB/T5614-1985 ， Regardless of time or temperature, it must meet the requirements of national standards.

Processing accuracy of working face

The working surface of the welding workbench is designed according to customer requirements. Generally, the precision requirements for the working surface of the welding platform are not high, and the precision of the working surface refers to the national standards for welding platformsGB/T 22095-2008。

Relevant data of T-shaped groove

Welding workbenchThe size of the T-groove is designed according to customer needs. When the workpiece to be welded is large and heavy, the opening of the T-groove will be larger, which means that the bolts used to fix the workpiece will be larger, and vice versa. The spacing between the T-grooves is also designed according to customer needs. The technical parameters of the T-groove are designed and processed according to the national standard GB/T158-1996. If it is a foreign customer, the T-groove standard should be designed according to DIN650-1985 German standard.

Automatic welding workbench

This workbench consists of a base, columns, compression beams, mobile structures, and a trolley baselinear guideAnd slider structure, motor reducer combination, coupling, gear rack assembly, electric cylinder, gantry work platform, gantry support wing, clamping shaft, clamping shaft shaft, clamping block, airbagManual directional control valveBottom plate composition; Its advantages include synchronous lifting and movement, high precision, smooth electric movement, stable clamping, improved welding quality, shortened preparation time, and improved workbench efficiency.

High power welding workbench

Used for soldering and desoldering through holes and surface mount components. This welding workbench adopts high-power, long-life ceramic heaters and has closed-loop feedback temperature control, thus achieving efficient and precise welding.

Flexible 3D combination welding fixture

A multi angle rotating welding worktable, consisting of a table body, a pedestalhydraulic cylinderComposed of a cylinder seat, worm gear, worm wheel, and worktable, the worktable has a conical shape with a lower end taper of90 degrees, the lower end is connected to the pedestal through a shaft, one end of the hydraulic cylinder is connected to the cylinder seat through a shaft, and the other end is connected to the lower end of the platform through a shaft. The platform is fixed with a worm, which is connected to the worktable, and the operating handle is connected to the turbine. This utility model enables the workpiece to be fixed at any position within a 90 degree range in the vertical direction and a 360 degree range in the horizontal direction along the worktable for easy operation and welding quality assurance.

The three-dimensional combination welding worktable adopts a perforated grid plate form, with a hole diameter ofD28 and D16 series. On high-precision countertops, D28 circular holes are evenly distributed every 100mm or D16 circular holes are evenly distributed every 50mm. These holes can be used to splice various functional positioning modules and fixtures. In addition to the tabletop, various functional modules include positioning blocks, right angle blocks, columns, arbitrary angle adjustment, V-shaped blocks, pins, various quick fixtures, gap adjustment pieces, and various auxiliary modules. The design concept of the module is clever and can be combined and repeatedly applied in various ways. A pin used for fastening and connecting modules to each other, with three concentric steel balls inside. When the bolt is released, the steel ball retreats into the bolt, and the bolt can be easily inserted into the hole of the module. When gradually tightened by hand, the three steel balls gradually pop out, automatically aligning and clamping the module. After tightening with a wrench, the clamping force on the module can reach 5 tons, and the shear force can reach 25 tons.

this kind ofCombination fixtureThe outstanding advantages are:

1) Modularization: All components are classified, standardized, and serialized to match each other. By selecting the minimum number of modules, various quick positioning and clamping functions can be achieved.

2) Flexibility: With various assembly methods, users can achieve almost the same positioning and clamping functions as any specialized fixture as long as they fully unleash their imagination. Quick assembly and easy disassembly; The workbench can be assembled and combined according to the shape and size of the workpiece. The design of the scale and module size on the table allows operators to quickly build the required tooling based on the workpiece size without using measuring tools.

3) High precision: D16 or D28 circular holes are matched every 50 or 100mm on the workbench and various functional modules, with a hole spacing tolerance of less than 0.02mm for any hole. This precision will be reflected in the products processed by the user. So, some users also use this workbench as a benchmark platform for measuring tools.

4) Design: Many of the functional modules are products, such as the pin bolts used for module connections and specially designed elastic fixtures with compensation to prevent workpiece displacement during clamping.

5) Three dimensional design: The columns and right angle blocks in the module can be used for splicing into three-dimensional space, facilitating the production of various three-dimensional components.

With this combination welding workbench, users who constantly repeat the design of fixtures can greatly save time and money spent on the design and production of fixtures through repeated investment. Users can quickly assemble different types of fixtures according to their needs, just like children playing with assembled toys. This three-dimensional flexible fixture can be used in the automotive manufacturing industry, engineering machinery industry, steel structure production industry, sheet metal processing industry, bicycle (motorcycle) manufacturing industry, and can be matched with welding robots or specialized welding machines, etc.

Electrical Design of Precision Welding Workbench

Requirements for precision welding workbench and melting electrodeargon arc welding machineUsed in conjunction, it automatically completes precision welding of horizontal circumferential seams.

1. Requirements of Welding Process for Electrical Control

(1) The spindle speed is 0.25-3.5r/m, with digital display, precise preset and adjustment. Stable work, no impact or oscillation.

(2) Accurate control of the overlap amount of the horizontal circumferential seam and digital display of the welding length.

(3) Digital display of arc initiation and termination time, with adjustable preset settings.

2. Principles of Control Systems

(1) Automatic welding control program

Place the workpiece on the fixtureManually clamp the workpiece, feed the welding gun, start the arc for a certain period of time, and then the workpiece rotates for automatic welding. After the set welding length is completed, the workpiece automatically stops rotating, the arc extinguishing welding gun retreats, and the fixture is released to remove the workpiece.

The entire control program is implemented using relays, which reduces manufacturing costs while ensuring reliability.

(2) Speed control system

In order to adapt to different welded workpieces, it is required that the welding speed has a large adjustment range, good low-speed performance, and high speed stability accuracy. Therefore, the control circuit is composed of operational amplifiersPID controllerThe thyristor automatic regulation system is the central link.

Kp is the amplification factor of the PID regulator; Kd is the amplification factor of the thyristor rectifier circuit; 1/Ce is the amplification factor of the electric motor; α is the feedback coefficient.

installed inDC motorThe grating disk on the end axis converts the speed signal into a pulse signal, which is then converted into a feedback signal through digital to analog conversionUf， At the same time as the system's given signal Ugd, it is fed to the PID controller, and its output signal Up changes according to the PID law. Under the control of Up, the speed of the motor is adjusted to a stable given value. The other two pulse signals are sent to the counter, and the tachometer displays the corresponding information.

This speed control system solves the contradiction between the different gain requirements of general speed control systems in static and dynamic states. It not only improves the system hardness, but also makes the system work stably without impact or oscillation, greatly improving the speed stability performance, and achieving precise preset and adjustment of the speed.

(3) Overlap control

installed inDC motorThe grating disk on the end axis has60 uniformly distributed long holes along the radial direction, the motor rotates once, the counter counts 60 numbers, and assuming the reduction ratio is i, the count value corresponding to one rotation of the workpiece (angle A1=2 π) is C1=60i.

Set the overlap amount of the weld seamThe arc length is L, and its corresponding angle is

A2=2L/D2

The count value corresponding to the overlap quantity meets the requirements

C2/C1=A2/A1

then there isC2=(L/πD)C1

The corresponding count value should be set as

C=C1+C2=(1+L/πD)C1

By setting the counter valueC， Can precisely control the overlap amount.