Kunshan sheet metal processing is developing in the direction of intelligence and automation

I. Consistency of structural dimension tolerances of welded parts

      Intelligent robots do not have the ability to artificially perceive thinking in real time. We have prepared a processing program to prepare parameters such as weld length, weld height, and weld gap, and the robot will repeat processing according to the entered program. When the size deviation of the part significantly exceeds its tolerance range, during the welding process, the following situations will occur: when the distance between the welding electrode and the weld is larger, the arc cannot be started due to the excessive distance; the distance between the welding electrode and the weld is smaller , The electrode head will touch the part and alarm. In this way, the machine cannot work smoothly, and repeated modification of the program will waste more time.

      Therefore, it is necessary to strengthen the control of dimensional tolerances in the processing of the front part of the welded parts, including shearing, universal punching, digital punching, laser, bending, riveting and other stations, so that the consistency of the size of the product structure is stable . When other abnormalities occur, the processing technology should be adjusted to ensure dimensional stability.

2. Reasonably Designed Welding Fixtures

      The advantage of robots over employees is that the quality of employees' work is affected by fatigue, emotions, concentration, etc., and the robots will only execute from start to finish according to the planned procedures. Therefore, it is as far as possible to satisfy that the robot is in an effective working state to the maximum extent, and make full use of the working time to improve the working efficiency. Figure 3 below is the result of the efficiency improvement.

Initially, when the caster bracket assembly was manually welded, there was no tooling fixture, and it was directly welded by hand. At the beginning of work, I was full of energy and basically met the requirements. However, over time, I was gradually affected by fatigue due to fatigue. After welding, the dimensions obviously exceeded the tolerance.

      In order to eliminate the impact of personnel fatigue, the fast clamping fixture positioning was designed to ensure that the dimensions after welding were within the tolerance requirements. When manual welding is adopted, this tooling can basically meet its requirements; when a welding robot is used to work with this tooling, this tooling will show a defect of significantly lower welding efficiency: manual clamping and robotic welding cannot be performed simultaneously. When the robot is welding, the clamper waits beside it; when the worker clamps the part, the robot is stopped again.

      According to the above situation, the statistics of the clamping, dismantling and robot welding man-hours of a single welding component are separately calculated, and then two sets of fixtures for clamping multiple welding components at one time are redesigned, so that the welding time and auxiliary tooling and picking Time is balanced, which doubles the productivity of the welding robot and the operator.

Preparation of reasonable welding procedures

      The parameters such as welding current, welding voltage, arc starting and closing time, and welding speed formulated in the welding program are to meet the welding quality of the welds that meet the technical requirements of the product; by adjusting the welding sequence and optimizing the walking path diameter, the effectiveness of the equipment is improved. The working time and the rationality of the welding procedure directly determine the high and low production efficiency.

      Sheet metal welding processing is developing towards the trend of automation and intelligence, and even advanced facilities and equipment will have more or less limitations in some aspects. Therefore, it is very important to formulate inspection procedures, strictly control quality, supervise, and strictly implement in the production process of products. Only by strictly controlling the details of each step of the processing can the production be smooth. Only by improving the products can we win excellent reputation in the industry.

Sheet metal processing