Corrugate steel plate welding machine control system (laser welding gap tracking system)

1, system composition

1) Driving trolley control system: motherboards, drives, smart set, relays, motors, zero detection switch.

2) Trajectory tracking system: ranging laser, 24V power supply, signal converter.

3) Others: Main electric control box, auxiliary electric control box, total electric control box, reactor, connection terminal, air switch, cooling fan, alarm, button switch and control cable.

2, technical principles and functions

1) Laser range sensor for ripple detection, the central controller calculates the distance data collected by the tracking system, and then sends a command to the four-axis adjusting motor,the motor will automatically adjust the horizontal position of the welding gun to realize the automatic welding of the corrugated plate.

2) Wave form tracking laser using an independent structure, the laser and the driving trolley are relatively static in the  process of welding.

3) Laser will avoid the interference from workpiece for the welding gun  

4) The design of  driving trolley and tracking system according to the vertical state of workpiece(90 degrees).

5)Corrugated welding machine can be combined control, can also be individually controlled, the driving trolley can communicate with each other, you can determine the position and status of other driving trolley, the driving trolley are coordinated operations to meet the quality requirements of  the welding joints.

6) Splash and arc are blocked effective and reliable. make the iron baffle or other smoke, dust, splash-proof measures according to the local situation .

3, technical indicators

3.1 System Function

1) Adapt to different colors of the workpiece identification tracking.

2) Automatic identification for wave peak, wave trough, ramp .

3) Automatic identification for corrugated plate and corrugated plate angle.

4) Position compensation for wave peak,wave trough, uphill, downhill  wave form direction and height direction.

5) Set separately for the welding speed of wave peak, wave trough, uphill, downhill..

6) Track correction.

7)Repair and reverse welding.

8) Fast forward and rewind during welding

9) Back, remove gun cleaning function during welding.

10) Welding speed, return speed, reset speed can be set free.

11) Drive power switch and manual welding function.

12) Parameter download, upload function (need to use the computer).

13) Setting password for parameter protection.

14) Electrical protection system with air switch .

3.2 Other requirements

1) The wiring inside the control box is tidy and beautiful, and must add trunking, all the output, input terminals must add line

number,line number must correspond to the drawings, all equipment standards are consistent, does not allow multiple versions appear on the scene.

2) Cavity size of tank chain must larger than 75mm * 55mm.

3) Distinguish the air pipe color, easy to maintenance.

4) Air pipe, welding positive cable and control cable separately.

5) Laser range sensor, welding gun and other parts easy loading and unloading, maintenance, dismantling time less than 5

minute.

6) Straightness, parallelism error for linear guide rail and rack installation  must within 1mm.

7) Driving trolley running smoothly, no vibration and unstable operation.

8) Driving trolley track should parallel with  positioning and support surface , the error is no more than 1mm.

9) Laser protection is reliable and requires shielding measures.

10) The rack's air pipe (referring to the hard tube) arrangement requires beautiful and tidy, must fixed with a reliable tube clip or non-standard tube clip

11) The switch and button layout on main control panel and small control panel should optimization, easy to operate and service.

12) Solenoid valve, proximity switch, laser ranging sensor, motherboard, stepper motor and driver, etc should safety and reliable,and conform  with the standard of domestic, international or industry standards, collision avoidance, anti-slip off

13) Power off or air cutting device to prevent driving trolley and tracking mechanism from falling.

14) Strict control the quality of Y-axis timing belt and pulley assembly, Y-axis direction adjustment step error should control within ± 1 dmm.

15) The main control box should equip with digital ammeter (HB5735B-DA-0 ~ 75mv, display 0-300A), voltmeter

(HB5735B-DV-0 ~ 200V, display 0-199.9V) and potentiometer (2 * 5KΩ).

16) Special control cable with chain to avoid the tank chain broken cable.

17) Buttons, switches and other signs clear, standardized and intuitive.

18) Welding arc starting point, arc closing point can be automatically found, but also through the parameter settings.

19) After the welding or the welding process, the system will automatically determine whether the driving trolley will collide,and take actions to avoid trolley collisions due to non-synchronization.

4, key parameters

1) The error of wave form tracking should be control within 0.2mm.

2) Welding speed faster than 0.8m / min.

3) The handling and adjustment time of laser sensor should control within 4 minutes.

4) The handling and adjustment time of height detection sensor should be control within 5 minutes.

5) The handling time of welding gun should be control within 2 minutes.

6) Laser range sensor’s life should more than 2 years.

7) Drive, motor’s life should more than 3 years.

8) Linear slide slider’s service life should more than 1 year.

9) Motherboard, intelligent setter’s life should more than 1 year.

10) Fan, alarm’s service life should more than 1 year.

11) The vitality life of other parts should more than 1 year.