焊接機器人出現偏焊咬邊等問題該如何解決

閱讀:419次    日期:2020-09-25
 

焊接機器人漸漸的取代了焊工的工作,雖然焊接機器人好用,但是因為他是機器難免會出現一些故障,那麽焊接機器人常見的故障有哪些呢?應該怎麽解決,山東xrk93xyz下载中舜焊接機器人廠家為您解答。

1.出現焊偏,可能是因為焊接的位置或焊槍出現了問題;首先考慮TCP是否準確,然後進行調整。

2 .出現咬邊可能為焊接技術參數選擇使用不當、焊槍角度或焊槍位置信息不對;可適當調整功率的大小來改變焊接工藝參數,調整焊槍的姿態發展以及焊槍與工件的相對重要位置

3.氣孔外觀可能氣體保護不良,工件底漆過厚或保護氣體不夠幹時,可進行相應調整..

4.過度飛濺可能不適合於所選擇的焊接參數,所述外氣體成分引起或線材伸長率過長;功率可被調節以改變焊接參數的大小,比調整裝置調整所述混合氣體的氣體比率,來調整割炬與工件的相對位置;

5.焊縫以及結尾處進行冷卻後形成一弧坑,編程時在工作步中添加埋弧坑功能,可以通過將其充分填滿。

6.打了槍。 可能是由於工件裝配偏差或焊槍TCP不準確;可以檢查裝配或糾正焊槍TCP;。

7.當電弧故障,而不是弧。可能是由於與工件或過焊接工藝參數沒有接觸;手動線,調整距離和焊接炬或適當地調整工藝參數;

8.出現電弧進行故障,不能引弧。可能是企業由於焊絲沒有可以接觸到工件或工藝技術參數太小。

Welding robot gradually replaced the welder's work, although the welding robot is easy to use, but because it is a machine, it will inevitably have some faults, so what are the common faults of welding robot? How to solve this problem, Shandong ellite Zhongshun welding robot manufacturer will answer for you.

1. The welding deviation may be due to the problem of welding position or welding gun; first consider whether TCP is accurate, and then adjust it.

2. Undercut may be caused by improper selection of welding technical parameters, incorrect angle of welding torch or incorrect position information of welding gun; proper adjustment of power can change welding process parameters, adjust the posture development of welding gun and relative important position between welding gun and workpiece

3. The appearance of the air hole may not be well protected by gas. If the primer of the workpiece is too thick or the protective gas is not dry enough, the corresponding adjustment can be made

4. Excessive spatter may not be suitable for the selected welding parameters, which is caused by the external gas composition www.amital-nechasim.com or the wire elongation is too long; the power can be adjusted to change the size of the welding parameters, and the ratio adjusting device can adjust the gas ratio of the mixed gas to adjust the relative position between the cutting torch and the workpiece;

5. The weld and the end of the weld are cooled to form an arc crater. When programming, the submerged arc pit function is added in the work step, which can be fully filled.

6. Shot. It may be due to assembly deviation of workpiece or inaccuracy of welding gun TCP; the assembly can be checked or corrected;

7. When the arc fault, not the arc. It may be due to no contact with workpiece or over welding process parameters; manual line, adjust distance and welding torch or properly adjust process parameters;

8. If there is an arc fault, the arc cannot be started. It may be because the welding wire can not contact the workpiece or the process technical parameters are too small.

焊接機器人

一、焊接機器人焊接通常出現的一些現象

xrk93xyz向日葵下载常見的機器人焊接一般采用的是二氧化碳氣體保護焊,焊接過程中出現的焊接缺陷一般有焊偏、咬邊、氣孔等幾種,具體分析如下:

(1)出現焊偏可能為焊接的位置不正確或焊槍尋找時出現問題。這時,要考慮TCP(焊槍中心點位置)是否準確,並加以調整。如果頻繁出現這種情況就要檢查一下機器人各軸的零位置,重新校零予以修正。

(2)出現咬邊可能為焊接參數選擇不當、焊槍角度或焊槍位置不對,可適當調整功率的大小來改變焊接參數,調整焊槍的姿態以及焊槍與工件的相對位置。

(3)出現氣孔可能為氣體保護差、工件的底漆太厚或者保護氣不夠幹燥,進行相應的調整就可以處理。

(4)飛濺過多可能為焊接參數選擇不當、氣體組分原因或焊絲外伸長度太長,可適當調整功率的大小來改變焊接參數,調節氣體配比儀來調整混合氣體比例,調整焊槍與工件的相對位置。

(5)焊縫結尾處冷卻後形成一弧坑,編程時在工作步中添加埋弧坑功能,可以將其填滿。

1、 Some common phenomena of welding robot welding

Carbon dioxide gas shielded welding is commonly used in robot welding. Welding defects such as welding deviation, undercut and air hole are generally found in the welding process. The specific analysis is as follows:

(1) The welding deviation may be due to the incorrect position of welding or the problem of welding gun searching. At this time, it is necessary to consider whether TCP (welding torch center point position) is accurate and adjust it. If this happens frequently, it is necessary to check the zero position of each axis of the robot and correct the zero again.

(2) The undercut may be due to improper selection of welding parameters, incorrect angle of welding gun or incorrect position of welding gun. The welding parameters can be changed by properly adjusting the power, the posture of welding gun and the relative position of welding gun and workpiece.

(3) The porosity may be due to poor gas protection, too thick primer or insufficient drying of protective gas, which can be treated by corresponding adjustment.

(4) Excessive spatter may be due to improper selection of welding parameters, gas composition or too long wire extension length. The welding parameters can be changed by properly adjusting the power, adjusting the gas proportioner to adjust the proportion of mixed gas, and adjusting the relative position of welding gun and workpiece.

(5) A crater is formed at the end of the weld after cooling, which can be filled by adding the function of submerged arc pit in the working step during programming.

焊接機器人

二、焊接機器人常見故障

(1)發生撞槍。可能是由於工件組裝發生偏差或焊槍的TCP不準確,可檢查裝配情況或修正焊槍TCP。

(2)出現電弧故障,不能引弧。可能是由於焊絲沒有接觸到工件或工藝參數太小,可手動送絲,調整焊槍與焊縫的距離,或者適當調節工藝參數。

(3)保護氣監控報警。冷卻水或保護氣供給存有故障,檢查冷卻水或保護氣管路。

2、 Common faults of welding robot

(1) There was a gun collision. It may be due to the assembly deviation of the workpiece or the TCP of the welding gun is not accurate. You can check the assembly or correct the TCP of the welding gun.

(2) Arc fault occurs, no arc ignition. It may be because the welding wire does not contact the workpiece or the process parameters are too small, the wire can be manually fed, the distance between the welding gun and the weld, or the process parameters can be adjusted appropriately.

(3) Protection gas monitoring alarm. If the cooling water or protective gas supply is faulty, check the cooling water or protective gas pipeline.

三、焊接工件對機器人焊接的影響

目前大多數焊接機器人都采用示教編程,要求工件的裝配質量和精度必須有較好的一致性。

應用焊接機器人應嚴格控製零件的製備質量,提高焊件裝配精度。零件表麵質量、坡口尺寸和裝配精度將影響焊縫跟蹤效果。可以從以下幾方麵來提高零件製備質量和焊件裝配精度。

(1)編製焊接機器人專用的焊接工藝,對零件尺寸、焊縫坡口、裝配尺寸進行嚴格的工藝規定。一般零件和坡口尺寸公差控製在±0.8mm,裝配尺寸誤差控製在±1.5mm以內,焊縫出現氣孔和咬邊等焊接缺陷機率可大幅度降低。

(2)采用精度較高的裝配工裝以提高焊件的裝配精度。

(3)焊縫應清洗幹淨,無油汙、鐵鏽、焊渣、割渣等雜物,允許有可焊性底漆。否則,將影響引弧成功率。定位焊由焊條焊改為氣體保護焊,同時對點焊部位進行打磨,避免因定位焊殘留的渣殼或氣孔,從而避免電弧的不穩甚至飛濺的產生。

3、 Influence of welding workpiece on robot welding

At present, most welding robots use teaching programming, which requires that the assembly quality and accuracy of the workpiece must be consistent.

The application of welding robot should strictly control the preparation quality of parts and improve the assembly accuracy of welding parts. The surface quality of parts, groove size and assembly accuracy will affect the effect of seam tracking. The following aspects can be used to improve the quality of parts preparation and assembly accuracy of weldments.

(1) The special welding process of welding robot is compiled, and the part size, weld groove and assembly size are strictly regulated. The tolerance of general parts and groove size is controlled within ± 0.8mm, and the assembly dimension error is controlled within ± 1.5mm. The probability of weld defects such as porosity and undercut can be greatly reduced.

(2) The assembly tooling with high precision is used to improve the assembly accuracy of weldments.

(3) The weld shall be cleaned and free of oil, rust, welding slag, cutting slag and other impurities, and weldable primer is allowed. Otherwise, the success rate of arc striking will be affected. The locations welding is changed from welding rod welding to gas shielded welding, and the spot welding parts are polished to avoid residual slag shell or air hole due to positioning welding, so as to avoid the instability of electric arc and even spatter.

四、機器人焊接變位機及工裝夾具對焊接的影響

1)對零件的定位精度要求更高,焊縫相對位置精度較高,應≤1mm。

2)由於焊件一般由多個簡單零件組焊而成,而這些零件的裝配和定位焊,在焊接工裝夾具上是按順序進行的,因此,它們的定位和夾緊是一個個單獨進行的。

3)機器人焊接工裝夾具前後工序的定位須一致。

4)由於變位機翻轉的變位角度較大,機器人焊接工裝夾具盡量避免使用活動手動插銷。

5)機器人焊接工裝夾具應盡量采用快速壓緊件,且需配置帶孔平台。以便將壓緊快速裝夾壓緊。

6)與普通焊接夾具不同,機器人焊接工裝夾具除正麵可以施焊外,其側麵也能夠對工件進行焊接,可以無限延伸。

以上六點是機器人焊接工裝夾具與普通焊接夾具的主要不同之處,對於機器人焊接質量的好壞有直接影響。

4、 Influence of robot welding positioner and fixture on welding

1) The relative position accuracy of welding seam should be less than or equal to 1 mm.

2) Because the weldments are usually assembled and welded by several simple parts, and the assembly and positioning welding of these parts are carried out in sequence on the welding fixture, so their positioning and clamping are carried out separately.

3) The positioning of robot welding fixture must be consistent before and after the process.

4) Due to the large deflection angle of the positioner, the robot welding fixture should avoid using the movable manual bolt as far as possible.

5) The robot welding fixture should adopt fast clamping parts as far as possible, and need to be equipped with hole platform. In order to compress the quick clamping.

6) Different from the common welding fixture, the robot welding fixture can weld the workpiece on its side as well as the front side, which can be extended infinitely.

The above six points are the main differences between robot welding fixture and ordinary welding fixture, which have a direct impact on the quality of robot welding.

五、焊絲對焊接機器人焊接過程中的影響

機器人根據需要可選用桶裝或盤裝焊絲。為了減少更換焊絲的頻率,機器人應選用桶裝焊絲,但由於采用桶裝焊絲,送絲軟管很長,阻力大,對焊絲的挺度等質量要求較高。當采用鍍銅質量稍差的焊絲時,焊絲表麵的鍍銅因摩擦脫落會造成導管內容積減小,高速送絲時阻力加大,焊絲不能平滑送出,產生抖動,使電弧不穩,影響焊縫質量。嚴重時,出現卡死現象,使機器人停機,故要及時清理焊絲導管。

5、 Influence of welding wire on welding process of welding robot

The robot can choose welding wire in barrel or in coil according to the need. In order to reduce the frequency of changing welding wire, the robot should choose barreled welding wire. However, due to the use of barreled welding wire, the feeding hose is very long and the resistance is high, which requires high quality of welding wire such as stiffness. When the welding wire with poor copper plating quality is used, the copper plating on the surface of the welding wire will reduce the volume of the pipe due to friction, and the resistance will increase when the wire is fed at high speed. The welding wire can not be sent out smoothly, resulting in shaking, which makes the arc unstable and affects the weld quality. When it is serious, the robot will be stopped due to the jamming phenomenon, so the welding wire guide pipe should be cleaned in time.

六、機器人操作工編程技巧總結

1)選擇合理的編程焊接順序。以減小焊接變形、焊槍行走路徑長度來製定焊接順序。

2)焊槍空間過渡要求移動軌跡較短、平滑、安全,過程中不能發生碰槍。

3)優化焊接參數。為了獲得最佳的焊接參數,製作工作試件進行焊接試驗和工藝評定。

4)合理的變位機位置、焊槍姿態、焊槍相對接頭的位置。工件在變位機上固定之後,若焊縫不是理想的位置與角度,就要求編程時不斷調整變位機,使得焊接的焊縫按照焊接順序逐次達到水平位置,同時,要不斷調整機器人各軸位置,合理地確定焊槍相對接頭的位置、角度與焊絲伸出長度。工件的位置確定之後,焊槍相對接頭的位置通過編程者的雙眼觀察,難度較大。這就要求編程者善於總結積累經驗。

5)及時插入清槍程序。編寫一定長度的焊接程序後,應及時插入清槍程序,可以防止焊接飛濺堵塞焊接噴嘴和導電嘴,保證焊槍的清潔,提高噴嘴的壽命,確保可靠引弧、減少焊接飛濺。

6)編製程序一般不能一步到位,要在機器人焊接過程中不斷檢驗和修改程序,調整焊接參數及焊槍姿態等,才會形成一個好程序。

6、 Summary of robot operator programming skills

1) Choose reasonable programming welding sequence. In order to reduce the welding deformation and the length of the welding torch path, the welding sequence is established.

2) The welding torch space transition requires short, smooth and safe moving track, and gun collision is not allowed in the process.

3) Optimize welding parameters. In order to obtain the best welding parameters, the working specimens are made for welding test and procedure qualification.

4) Reasonable positioner position, welding torch posture, welding torch relative to the joint position. After the workpiece is fixed on the positioner, if the welding seam is not the ideal position and angle, it is required to adjust the positioner continuously during programming to make the welding seam reach the horizontal position one by one according to the welding sequence. At the same time, the position of each axis of the robot should be adjusted continuously to reasonably determine the position of the welding gun relative to the joint, the angle and the extension length of the welding wire. After the position of the workpiece is determined, the position of the welding gun relative to the joint is observed by the programmer's eyes, which is difficult. This requires programmers to be good at summarizing and accumulating experience.

5) Insert the cleaning procedure in time. After a certain length of welding procedure is compiled, the cleaning procedure should be inserted in time, which can prevent welding spatter from blocking welding nozzle and conducting nozzle, ensure the cleanness of welding gun, improve the service life of nozzle, ensure reliable arc striking and reduce welding spatter.

6) In general, the program can not be completed in one step. It is necessary to check and modify the program, adjust the welding parameters and welding torch posture during the welding process of the robot, so as to form a good program.

七、企業內部規範管理對設備使用好壞的影響

嚴格控製機器人操作工的規範及操作流程,焊接過程加強維護,可以減少易耗件如噴嘴、導電嘴等的平均每天使用數量。另外,對機器人係統進行定期點檢維護,可以有效提高元器件的使用壽命。

高素質的管理人員、技術人員和操作人員是機器人充分發揮效率的必要條件。一個企業焊接機器人使用的好壞,很大程度在於人(其實還是機器人應用工程師),因此要保證有一支穩定的工作隊伍真的很重要。

7、 The influence of enterprise internal standard management on the use of equipment

Strictly control the robot operator's specification and operation process, strengthen the maintenance of welding process, can reduce the average daily use of consumable parts such as nozzle, conductive nozzle, etc. In addition, regular inspection and maintenance of the robot system can effectively improve the service life of components.

High quality managers, technicians and operators are the necessary conditions for the robot to give full play to its efficiency. The use of welding robots in an enterprise depends largely on people (in fact, they are robot application Engineers), so it is really important to ensure that there is a stable working team.