1 Overview
Radar large components are the main components in the radar, mainly in the antenna of the radar and the turntable. It is complex in production and is mainly welded by steel pipes, titanium pipes and brackets. The large-scale components of domestic production radar mostly use traditional welding methods such as electrode arc welding, gas welding and argon arc welding, and the automatic welding robot has only been applied in automobile manufacturing and space exploration. When China is heading to the international market and all countries in the world are carrying out the transformation of welding automation technology, it is extremely urgent for China's radar industry to transform its past production methods and management models.
Due to the manual processing method, there are problems such as backward process, low production efficiency, high labor intensity, high energy consumption and unstable welding quality, which cannot meet the production needs of modern enterprises. In response to the above problems, the unit has adopted an automatic welding production line for large-scale radar components that realizes the integrated control functions of machine, electricity and gas, so as to achieve the goal of improving production efficiency and reducing labor intensity.
This paper focuses on the structural principles, characteristics, and control and management systems of radar large component automated welding production lines.
2. Production process analysis
In order to ensure that the radar welding production line can process existing products and meet the needs of the company for long-term development, the welding process of radar large structural parts is analyzed.
According to the production process requirements of large-scale structural parts of radar, the welding process is as follows: cutting work table → workpiece work table (machining) → preparation area (tooling, fixture, assembly) → welding manipulator table → welding robot table → Weld inspection station → dressing table → assembly table → surface treatment → antenna base turntable assembly station → antenna assembly test station → radar antenna system integration.
The specific instructions are as follows:
(1) The raw materials are processed through the blanking workbench and the workpiece workbench, and the required workpieces are formed by machining means (sheet metal, stamping, lamination, bending, etc.).
(2) The processed workpiece is transported to the welding preparation area, and is positioned by the tooling and the jig, and then the welding of the workpiece is completed and trimmed by the welding robot and the welding robot according to the stored welding parameters under the control of the control system.
(3) After the welding is completed, the workpiece is transported to the welding inspection station by the welding robot, and the weld seam is inspected to perform the inspection and repair welding work.
(4) After the welding work is completed, the welding deformation of the workpiece is corrected, the surface treatment is performed, and finally the welded workpiece is transported to the assembly station for antenna assembly and detection, and finally the integration of the radar antenna system is completed.
The operation of the welding robot is as follows:
First, the workpiece is clamped. The operator uses the driving to clamp the skeleton workpiece to the whole fixture, fix it by positioning welding, and then lift it to the positioner. The clamping of the skeleton is completed according to a plurality of manual clamps arranged in advance, and the operator leaves the working area of ​​the robot. , press the console "Start" button.
Second, the welding process. The robot walks to the welding position on the gantry, and the robot uses the automatic seam finding function to find the starting point of the weld, and automatically performs single-layer single-track (or multi-layer multi-pass) welding. During the welding process, the robot uses arc tracking or laser tracking to track the butt welds (with bevels), fillet welds and non-bevel welds, to ensure that the welding gun is centered and correct the deviation due to workpiece assembly or welding deformation. At the same time, the robot moves according to the preset program to ensure the welding quality. After the front weld is completed, the robot is returned to the safe position, the skeleton is loosened, flipped 180° and then clamped, and the above process is repeated until the side weld is completed; the positioner is rotated by 90°, and the above process is repeated until the skeleton side welding is completed. The positioner is rotated by another 180°, and the above process is repeated until the side weld is completed; the robot is returned to the safe position and the positioner is reset.
Finally, the workpiece is unloaded. After the welding is finished, the robot returns to the safe position and the operator enters the robot working area again to release the manual clamp.
3. Equipment composition
The welding of large-scale structural components of radars, especially the welding of radar antennas and turntables, the selection of welding equipment is very important. In order to ensure the welding quality and improve the welding efficiency, advanced automatic welding equipment is used to obtain good static (dynamic) characteristics of welding and meet the welding requirements of large-scale structural parts of radar. The radar large-scale structural parts welding production line is mainly composed of two parts: automatic welding equipment and weld quality inspection equipment.
The robot welding workstation is mainly composed of robot system, welding power source, laser tracking system, anti-collision sensor, clearing wire cutting mechanism, forced water cooling device, robot moving mechanism, welding positioner (including welding fixture), electrical control system and safety fence. The system has the characteristics of advanced technology, perfect function, strong adaptability and high reliability, which can effectively improve the welding quality and consistency, reduce the labor intensity of the operator and improve the productivity.
The robot welding station has great flexibility and versatility. It can be used for various skeletons and other similar work (with the weight of the positioner in the working range of the robot) by replacing the relevant fixtures. The following is an explanation of the important automated welding equipment.
(1) Robot system The robot body adopts aluminum alloy casting structure, and obtains the excellent excellent rigid structure through computer aided design and finite element structural analysis to obtain the best fixed load capacity.
All axes are driven by maintenance-free AC servo motors, using gapless drive assemblies and absolute encoders. All robot axes are equipped with brakes and temperature detection safety devices.
Optimized drive capability, high-precision position monitoring system, and high-power servo system ensure high dynamic performance and good accuracy.
The welding robot uses the German KR16 robot with an arc welding software package, including basic arc welding software, contact sensing function package, and arc weld tracking function package.
(2) The new teaching device is designed to be ergonomic. The left and right hands are free to operate. ABB's standard 3-way levers provide precise micro-motion control of the robot and control the direction and speed of movement of the axes of the welding robot system. There is no need to operate the various axis movement buttons on the teach pendant; 8 quick access buttons, 4 fixed and assignable.
The teach-in programmer features a Windows platform that uses the most advanced Microsoft programming tools for fast, powerful customization. Compatible with existing RAPID solutions. Multiple robots and other mechanical devices can be accessed from one access point of the same teach pendant, with hot-swap capability. Connecting and disconnecting during operation does not prevent the system from operating.
Barrier Free Platform Lift For Wheelchairs
Barrier Free Platform Lift, Barrier Free Platform Elevator, Barrier Free Lift, Barrier Free Elevator
Barrier Free lift platform
Wheelchair Lifts, Wheelchair Elevators
Animated Market/Active Market:
Southeast Asia,
Jakarta / Semarang / Surabaya Indonesia,
Penang / Port Kelang / Kuala Lumpur Malaysia,
Manila / Cebu / Davao Philippines
Bangkok / Laem Chabang / Lat Krabang / Songkhla / Phuket Thailand
Danang / Hanoi / ho chi minh,cat lai / ho chi minh,cai mep / ho chi minh,new port / ho chi minh,vict / haiphong / phuoc long / qui nhon / vung tau, Vietnam
Bogota / Barranquilla / Buenaventura / Cali / Cartagena /Medellin / Tumaco / Rio Hacha / Pereira / Pozos Colorados / Puerto Colombia / Manizales / Covenas / Armenia Colombia,
Panama City / Balboa / Colon Free Zone / Cristobal / Manzanillo Panama,
Guayaquil / Quito / Esmeraldas / Manta Ecuador,
San Jose / Puerto Caldera / Puerto Limon Costa Rica,
Guatemala City / Puerto Quetzal / Santo Tomas De Castilla / Livingston / Puerto Barrios Guatemala,
Acajutla / San Salvador / Santa Ana, El Salvador
Mexico City / Manzanillo / Acapulco / Aguascalientes / Altamira / Leon / Cancun / Celaya / Ensenada / Guadalajara / Guaymas / Hermosillo / Lazaro Cardenas / Lerma / Los Mochis / Mazatlan / Morelia / Puerto Morelos / Monterrey / Mexicali / Puerto Madero / Progreso / Puebla / Queretaro / San Luis Potosi / Tampico / Tijuana / Toluca / Veracruz Mexico,
Santos / Brasilia / Fortaleza / Itapoa / Itajai / Itaguai / Manaus / Navegantes / Paranagua / Pecem / Rio De Janeiro / Rio Grande / Salvador / Sepetiba / Suape / Vila Do Conde / Vitoria / Recife Brazil,
San Antonio / Santiago / Valparaiso / Talcahuano / San Vicente / Puerto Montt / Punta Arenas / lirquen / Iquique / Coronel / Caldera / Arica / Antofagasta / Puerto Angamos Chile
Buenos Aires / Rosario / Bahia Blanca / Concepcion / Mar Del Plata / Puerto Deseado / Puerto Madryn / San Lprenzo / Ushuaia / Zarate Argentina
Lima / Ancon / Callao / Ilo / Matarani / Paita Peru
Caucedo / Puerto Plata / Rio Haina / Santo Domingo Dominican Republic
South America, Central America, Latin America
Middle East, Gulf Countries, Gulf States, Iraq, Kuwait, Jeddah / Riyadh / Dammam / Jubail Saudi Arabia, Beirut Lebanon, Dubai / Abu Dhabi / Sharjah UAE, Muscat / Salalah / Sohar Oman, Doha Qatar, Manama Bahrain, Amman Jordan,
Istanbul / Aliaga / Ambarli / Antalya / Asyaport / Avcilar / Evyap Port / Bandirma / Gebze / Gemlik / Haydarpasa / Iskenderun / Izmir / Izmit / Korfez / Kumport / Kusadasi / Mardas / Marport / Mersin / Marmaris / Samsun / Tekirdag / Tirebolu / Trabzon / Ankara Turkey
North Africa, West Africa, Western Africa, East Africa, Southern Africa
Cape Town / Durban / East London / Johannesburg / Port Elizabeth / Pretoria South Africa,
Adabiya / Sokhna / Alexandria / Damietta / El Dekheila / Port Said East / Port Said West / Port Suez / Cairo Egypt,
Abuja / Akassa / Apapa / Lagos / Onne / Port Harcourt / Tin Can Federal Republic of Nigeria,
Algiers / Annaba / Arzew / Bejaia / Djen Djen / Ghazaouet / Mostaganem / Oran / Skikda People's Democratic Republic of Algeria,
Agadir / Casablanca / Port Tangier Mediterranee / Tangier The Kingdom of Morocco,
Tunis / Sfax / Rades / Bizerte Tunisia
Dakar / Kalolack / Zighinkor Senegal
Cabinda / Lobito / Luanda / Namibe The Republic of Angola,
The Federal Democratic Republic of Ethiopia,
Accra / Takoradi / Tema The Republic of Ghana,
The Republic of South Sudan
Kigali Rwanda
Douala / Kribi / Tiko / Victoria,cm / Yaoundé, Cameroon
Lusaka / Chingola / Kitwe / Ndola, Zambia
Beira / Ibo / Maputo / Nacala / Pemba / Quelimane, Mozambique
abidjan / Yamoussoukro / san pedro,ci, Côte d'Ivoire / Ivory Coast
Barrier Free Platform Lift, Barrier Free Platform Elevator, Barrier Free Lift, Barrier Free Elevator
CEP Elevator Products ( China ) Co., Ltd. , https://www.zjelevatortravelingcable.com