Design and automatic welding of the hottest parts

2022-10-15
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Part design and automatic welding

is your part suitable for automatic welding? Not all parts are suitable for automatic welding, but the following checklist will help you decide whether to make good use of automatic welding

from the moment you begin to prepare for the automatic welding process, you should first ask yourself, "are my parts suitable for automatic welding?" This key question may lead you to find the answer to take advantage of automatic welding

how to apply welding to a part includes the following problems:

1) if a part was originally welded manually, how to ensure that it is suitable for automatic welding

2) if it is a new part, how to design it to make it suitable for automatic welding

3) what is the current welding process (gas shielded welding, tungsten gas shielded welding or submerged arc welding, etc.), and is it suitable for automatic welding? Is there any gap that the operator needs to fill in the welding process? Is there a deformation problem

4) if the welding process has the problem of filling gap and deformation, is it always existing or foreseeable

5) what are the welding requirements

6) are there special appearance and strength requirements for welding

answer these questions from the perspective of automatic welding

1) can the welding process be changed

2) when switching from manual welding to automatic welding process, is there any way to improve the welding process

if the actual problems of a part, such as clamping, deformation or repetition accuracy, are not considered in the process design, it will bring many problems to the automatic welding. The plan is comprehensive, and the return on investment must also be considered

decisive factors

other factors should be considered in automatic welding:

1) part design depends on the automatic welding center and variable Jinan assay. Due to the large number of customers, the positioner determines the welding position of the part relative to the automatic welding center. Some parts require multi axis positioner to coordinate welding; Some parts require a single shaft positioner to repeat positioning during welding; There are also parts that do not need to be equipped with a positioner

2) weld joint design automatic welding needs to give priority to weld design. In the part design (or process design) stage, the weld joint needs to be evaluated in order to ensure that the weld joint is easy to repeat and weld. For example, lap joints and fillet welds are more weld forms, because the weld and droplet are easy to control. External fillet welding is more difficult because of cracks. 1. The steel wire and strand slide due to the high hardness of the sample or parts. The welding of beveling is less considered, because the positioning of parts, changes in welding volume and welds are not easy to control

3) repetition accuracy the repetition accuracy of parts and weld joints is an important factor. The change of repetition accuracy of parts will significantly magnify the change of repetition accuracy of weld joints. Typical weld joint repetition accuracy can save half of the welding wire. Ф The welding wire of 1.2 is commonly used in the automatic welding center. The repetition accuracy of the welding joint. The spring testing machine is mainly used in spring manufacturers, electrical manufacturers, power machinery plants, colleges and universities and relevant scientific research institutions. The requirement is ± 0.584mm. The change of repetition accuracy requires the automatic welding center to control or change the welding process to adapt. Adaptability includes welding wire nozzle detection, weld tracking, arc starting or arc breaking defects, or multi-step welding with advanced fixtures

4) the welding machine head is connected to the welding center, and the welding machine head on the welding arm may not be able to weld all positions of all parts

manufacturing process of parts with repeated accuracy

another factor of parts requiring automatic welding is part manufacturing before welding. Manufacturing processes usually include laser, plasma or oxygen cutting, stamping, sawing, shearing, bending, etc

when oxygen cutting is used, the parts have a dimensional tolerance of 3mm. When the parts cut by oxygen are clamped in the fixture, the tolerance is large, there will be gaps, and the weld joints will change significantly

plasma cutting can make the tolerance of parts within 1.6mm. Its tolerance is smaller than that of oxygen cutting

laser cutting or other high-precision cutting is a better cutting method. Because its tolerance is smaller, it can be controlled within 0.125mm. The smaller the cutting tolerance, the higher the repeatable accuracy of the part

a simple part can also be formed by stamping machine. Parts manufactured by this process usually have high repetition accuracy, but they will also deform due to stamping springback. Parts can be pressurized reversely by bending machine or press to reduce deformation

rolling is a common process for forming large-size parts, which will also produce springback deformation, which is smaller than stamping, so as to avoid the positioning problem of weld joints

sawing and shearing are two molding processes for simple parts. Cutting can produce good parts or poor parts, depending on the equipment used. A good cutting equipment, but not properly adjusted, can also make parts produce tolerance or deformation in batches

cutting length with high quality and accuracy can also be obtained by using sawing correctly. When you cut in bundles to improve efficiency, there will be movement, and the cutting quality is not good

therefore, the influence of the above-mentioned processing factors on the welding process should be considered when designing parts. Solving these factors can improve the forming quality of parts, make it easier to realize automatic welding, and ensure the size and specification requirements of welded parts

design affects clamping

the design of parts directly affects its clamping in automatic welding. The size specification of a simple part needs trial production to be determined. If the part design makes the clamping complex, the clamping cost will increase, and it will become more difficult to adjust the position of the part and the joint of the weld joint

another factor to consider is that when deciding whether to use automatic welding center, it depends on whether the part can be combined clamping. The combined structure of components can decompose large parts into small parts, which is convenient for clamping, clamping programming, and continuous operation on the automatic welding center

when the parts are large and complex, positioning pre welding is also a way. That is, automatic welding is carried out after pre welding

balance point between operator and automatic welding

optimization of balance point between operator and automatic welding can save time. In this case, the automatic welding of large parts requires a long cycle. The operator can choose manual welding, and then use automatic fixtures or other technological means for positioning welding or precision welding. In this way, the automatic welding center also has a certain flexibility

to achieve this balance, it only depends on the adaptability of the automatic welding equipment to the welded parts, which requires the evaluation of the configuration of the automatic welding equipment, the repeatability of welding, and the influence of the size of welding gap on the automatic welding equipment

the better balance point is the 80/20 distribution, that is, the operator's operation accounts for 20% to solve the welding quality problems caused by the gaps that cannot be solved by the design, and the automatic welding solves the remaining 80% of the welding workload

achieve the goal

not every part can be welded automatically. The priority goal of automation is to reduce costs, increase production, save time, and improve welding quality and welding consistency

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