KELITE WELD TECH (CHINA) LIMITED

Steel structure inner rib plate welding robot workstation

KLTBA006LXZ7-15- Panasonic YD500GL5 (Workstation List)

Custom machine requirements

1. Workpiece data

Welding products：Steel structure inner rib plate

2. Welding robot workstation workflow

(1) First, fix the product to be welded on the platform, and then fix it with a special fixing fixture (the special fixture is designed and manufactured by the customer). This ensures the repeatable installation of the product, prevents the workpiece from falling off during the welding process, and avoids welding deformation in certain areas.

(2) Obtain the required processing program in the robot welding control

(3) Press the start button in the positioner, and the welding robot automatically performs the positioning welding required by the work position.

(4) After the welding of the station is completed, the operator manually removes the product on the platform. Repeat the installation again.

(5) Repeat the above steps

3. Workpiece precision requirement：

（1）The surface of the work shall not affect the quality of welding oil, rust, moisture；

（2）Must not affect the positioning of burrs, etc.；

（3）The clearance shall be no more than 1mm；

（4）The consistency error of the same weld group is less than 0.5m。

4. Component：

The workstation is mainly composed of 6-axis welding robot, robot controller, Robot servo walking track, Robot 3D Vision Intelligent Welding System, Panasonic YD-500GL5 welding power supply, welding gun cleaning station, carbon dioxide gas cylinder, external start button box.

5. Numerical control welding robot workstation layout:

Picture for reference only

1、6 Axis Welding Robot（BA006L）;2、Welding power supply (Panasonic YD-500GL5);3、Robot control cabinet and teach pendant(E01);4、Robot servo walking track; 5、Robot 3D Vision Intelligent Welding System; 6、Welding gun cleaning station;7、External start button box;8、Carbon dioxide gas cylinder; 9、Transformer;

1.1 Robot introduction

Kawasaki -BA006L(R=2036mm, Repeatability ±0.06 mm)

The BA series is a robotic series developed specifically for welding and is specifically designed for welding. It is simple to operate and can perform skilled welding operations with a simple teach-in operation. On the pendant is equipped with visual effects and easy to operate touch LCD color display. Robots and welders only need a cable connection, welding conditions can be classified storage, a key call。

Kawasaki BA series robot with E01 control cabinet, compact, suitable operating system, feature-rich, easy to maintain and has high scalability.

6.5-inch color LCD screen, touch screen 640 × 480 pixels. Using backlight, the LCD screen easier to see.

Operating system using WINDOWS CE. The window display uses the drop-down menu, making the editing operation simple and easy.

BA006L Range of motion

1.2 Panasonic YD-500GL5 Welding power system

It has good welding performance for carbon steel and stainless steel materials, and can realize light splash short circuit transition under small current. It is equipped with Root root welding function as standard, suitable for bottoming and large gap welding.Scalable Deepen deep arc function for thick plate deep penetration and thick plate bottom welding, GL5 welder also has a wealth of process software packages for purchase, good for many special materials or special processes.Sex.It is also possible to customize the development of dedicated process software.Standard built-in IOT module and analog communication interface, expandable digital interface, as automatic welding machine and robot power supply.

Main welding methods: CO2, MAG, MAG pulse, stainless steel MIG, stainless steel MIG pulse.

1.3 Welding gun clearing station(KLT-QH2000S)

Introduction:

The automatic clearing gun station is designed for robotic welding guns and automatic welding guns equipped with an automatic welding system. The cleaning station controls the operation of the equipment by the robot, and the equipment also provides corresponding feedback signals to the robot.

Features:

1, clear gun cutting mechanism in the same position of the gun and fuel injection design, the robot only needs a signal to complete the clearing, cutting, fuel injection and other actions, the entire process only 6-7 seconds, the clearance time is short, High system availability and improved robot productivity.

2, using a multi-function reamer, clearing the gun to the root of the conductive nozzle, the effect of clearing the gun is thorough. The cleaning process is completed automatically, without manual operation.

3. The built-in fuel injection device of the Qinggun Station is controlled by the robot through the solenoid valve, which is safe and reliable and convenient for maintenance. The atomized anti-splash agent can reach the root of the torch tip.

4, the wire cutting device is controlled by a solenoid valve, and the wire cutting is more accurate. Make sure the cut wire falls into the collection box.

5, the electrical arrangement of the gun station is very simple, all control units are installed in the chassis, and the pipe fittings are rarely exposed.

Technical Parameters

1.4. WL-20   temperature control cold water tank

Temperature control of the water tank by the efficient condenser, EBM fan motor, imported thermostat and water detection sensors and water tanks and other components.

Is the TIG/plasma welding process and high load continuous welding torch cooling an important ancillary equipment.

Technical Parameters
Power supply rated voltage: 1 × 220V 50Hz
Rated load: 205 W
Effective head：20m

Size:540*340*500mm

Weight: ~19kg

1.4. Robot 3D Vision Intelligent Welding System

By using TracerP1 camera to take high-precision 3D photos of steel structure components, and then search the position of the target weld, use TracerStudio software platform to analyze the acquired 3D point cloud data, identify the target weld in the steel structure components, and then feed back the initial position, direction vector, seam width and other parameters of the weld to the robot to guide the robot to weld.

Features of automatic welding solutions for steel structures：

1. Connection with Tekla: Through cooperation with Tekla, the global leader in steel structure design software, this scheme uses Tekla digital analog to automatically identify welds without manual picking up of welds.

2. Automatic welding: the scheme can automatically plan the camera photographing position and automatically generate robot welding program without any manual programming.

3. High efficiency and accuracy: use high-precision 3D camera with weld seam recognition function to quickly take photos to locate the weld seam.

4. Open ecology: support a variety of robot brands, and help partners create personalized automatic welding schemes for steel structures.

1.4.1 Welding surface scanning 3D camera - Tracer P1

Tracer P1 uses the fully independently developed micro structured light technology to break the conventional point and line laser positioning principle. It uses a surface scanning 3D camera to take photos to obtain the complete 3D point cloud of the workpiece, quickly identify the 3D characteristics of the workpiece, and output the welding trajectory and posture. It can be used with robots or special welding machines to realize automatic and intelligent welding and help users significantly improve production efficiency.

1. High speed real-time scanning. 2~10 frames of point cloud data can be output within 1 second.

2. Industrial precision. The repeatability of 3D point cloud can reach 0.1 mm at most.

3. Anti spatter protection device to prevent the lens from being damaged by spatter of welding slag.

4. Small size, light weight, easy to integrate the robot end.

5. High temperature resistance and reliable operation.

6. Cooperate with the company's self-developed TracerStudio software to realize automatic position finding of complex weld robots.

1.4.2 3D visual welding software; TracerStudio

TracerStudio welding visual software, with a graphical adjustment interface and one key startup, is simple and easy to use. It can handle the application requirements of multi scene welding of complex workpieces such as steel structures, rebars, tube sheets, and mesh structures. At the same time, it supports multiple communication protocols, can adapt to domestic and foreign multi brand robots, and supports simultaneous access of multiple stands to complete tasks stably and efficiently.

The steel structure welding plug-in of TracerStudio is seamlessly connected with Tekla design software. With the Tracer P1 3D camera, it can realize the automation of the whole process from design drawings to robot welding procedures to on-site welding.

1. Seamlessly butt Tekla, automatically generate the welding seam information of steel structure, and export the data package.

2. Automatic programming, automatically generate robot program according to input drawing information.

3. The extraction efficiency of welds is high, and multiple welds are extracted at the same time.

4. Fast position finding speed, complete photographing and track attitude calculation within 2 seconds.

5. Strong deviation correction ability. The position deviation of workpiece within ± 20mm can be automatically identified and the robot can be guided to complete welding

1.4.3 TracerCalibration software

TracerCalibration calibration software integrates 3D camera internal parameter calibration, eye to hand and eye in hand calibration functions, graphical operation, simple operation, and fully automatic calibration and detection through communication with robots.

1.5 Robot walking track

Robot servo travel track (KLTXZ-15000)

Features:

1. In order to increase the working range of the robot and solve the shortcomings of limited working range due to the limited reach of the robot body, our company specially designed the robot walking track.

2. The robotic servo travel track manufactured by our company mainly consists of integral fixed base, servo power unit, power transmission mechanism, guiding mechanism, robot mounting guide rail, protection mechanism, limit mechanism and walking attachment.

3. The whole base of the robot walking track is welded by high-strength steel and steel. After the post-annealing treatment and professional mechanical processing, it can ensure the stability and high precision of its long-term use. The track walking adopts well-known brand servo motors at home and abroad. (Customer servo motor can be customized according to customer's requirements) with high-precision planetary reducer (Japan Xinbao reducer) as the power mechanism.

4. The transmission part consists of high-precision rack and pinion (helical tooth) and high-precision linear guide rail, which ensures the smooth running of the robot and the high precision of positioning.

5, In order to ensure the safety of the robot walking, a hard limit is added at the extreme positions of the two ends of the robot walking track to protect.

6. We also equipped the walking track with a bracket for the torch cleaning station and a bracket for the barrel wire.

7, can customize the effective length of the robot walking track according to the customer's workpiece length.

1.6 Installation and Trial Operation.

Remarks :The above quotation does not include overseas installation, commissioning, training and other technical expenses

1.6.1   Installation and training on the correct operation shall be carried out by the experts from the sellers. The buyer shall provide necessary machines and tools to be used for installation. The arrival date of the experts from the seller shall be discussed by the two parties.

1.6.2 Technical Service Fees on the Installation Trial Operation: The buyer shall pay for each technician USD $500 per day based on 8 working hours each day. The technical service fees shall be transferred to the Seller's account before the technicians leave the Seller's factory.

1.6.3   All the following fees shall be born by the buyer:

Consulage, round trip air ticket, accommodation, food and beverage, communication ( the buyer shall provide the communication equipment and pay for the fees from the telephone and Internet), transport ,installation fee,translation fee, accident insurance as well as the possible medical cost. Besides, the buyer shall guarantee safety of the technicians during this period.

1.6.4 Upon the seller's requirements,the buyer shall prepare water supply,three phrase power supply,air supply,air compressor,welder,hoisting machine manual tools,cutting tools and other tools as well as consumptive materials within 7days before the technicians leave the Seller's factory.

The buyer shall supply sufficient space for the ball mill and flotation machine.

1.6.5   After installation and trial operation,the buyer shall sign the Installation and Trial Operation Document' within two days.

1.7 Production,transportation and delivery.

1.7.1   All the equipment shall be shipped within five working days after the payment was paid supposed that the transportation ship could be arranged.

1.7.2   Acceptance of all the equipment shall be done according the following terms.

Acceptance of parts quantity——based on the quantity marked in the Bill of loading.

Acceptance of equipment quantity——Based on the quantity specified in the Detailed List and Packing List

Acceptance of quality——qualified with the seller's standard and meets the standards specified by the People's Republic of China.

1.8 Package

After the production is finished for all the equipment, the seller should make suitable package for certain equipment parts and label the parts. Besides, the equipment package shall be intact during the loading, unloading and transportation.