Application of ABB robot system in the production of road roller

This paper takes the company's structural parts factory to improve the welding quality of the left and right fuel tanks and hinged joints of the roller, and introduces the application of ABB welding robots in the construction machinery.
First, ABB robot technology features
ABB robots run fast, especially ABB's QuickMoveTM dynamic self-optimizing motion control technology, which allows each axis to always move at maximum acceleration without any adjustments, which is 25% faster than the production tempo of other robots.
ABB robots also feature intelligent anti-collision based on LoadIdentification technology, which reduces the impact force to 30% in the event of a collision.
Second, the main features and applicable conditions of ABB robot system
Our company's ABB robot system is mainly used for welding the left and right fuel tanks and hinged seats of road rollers. Manually hoist the workpiece and manually clamp the workpiece. The workpiece is rotated using the ABB robot IRBP500A positioner to coordinate movement with the robot during welding to ensure that all welds are in the optimum weld position. In addition, the ABB arc welding robot system communicates with the Kemppi Kendorf pulse welder to ensure the welding quality and the weld seam is more beautiful. The operator operates the device through the button, and the whole control system is easy to operate and easy to be mastered by general engineering and technical personnel.
The ABB robot system is suitable for the following industrial and mining applications: ambient air temperature, 5~+45°C during welding; 5~+55°C during transportation and storage. Relative humidity of air, ≤50% at 40 °C; ≤90% at 20 °C. Altitude ≤ 1000m. The robot power supply is three-phase 380V, 50Hz.
Third, the main structure of ABB robot system
A system generally consists of three parts: robot, control cabinet and teach pendant. This system uses ABBSRT-Robot-IRB2400L6 axis robot (see Figure 1). It can theoretically reach any position of working radius (f1810mm), and repeat positioning accuracy. Up to 0.06mm; the arc welder is Kemppi Kemppi pulse welder. The welder has the characteristics of energy saving, high power factor, less spatter, reliable welding quality, etc. It can store 128 sets of welding parameters to meet various welding of different plates and make welding. More detailed; three sets of fixtures use independent upper and lower parts, greatly improving production efficiency. Floor-standing positioner to meet the welding of all parts of the workpiece. The overall layout of the system is shown in Figure 2. The external dimensions of the device are 3300mm × 2300mm × 3000mm. In addition, the relevant components shown in the attached table are also provided.
To meet the demanding unitary professional welding of robots, the matching welding power source must have specific functions. This system is equipped with digital pulse welding power supply Kempar-Pulse450 gas shielded welding machine. The main features of this welder are: high efficiency, high power welding power supply; compact structure, light weight, modular design; 90 (for unified welding power supply) / 100 ( For the pulse welding power supply, a storage channel is used to store different welding processes; TouchSensing is a standard configuration function; the numerical control version realizes full digital communication through the data bus; supports various bus protocols and the like.
The robot system mainly controls five output signals: welder switch signal (Do_Weld), air supply signal (Do_Gas), manual wire feed signal (Do_Feed), welding current control signal (Ao_Current) and welding voltage control signal (Ao_Voltage); Input signal: Arc setup signal (Di_ArcE). In the automatic welding system, only five welding parameters need to be configured in the PROC of the robot: Do_Weid1, Do_Gas, Ao_Current, Ao_Voltage1, Di; the robot controls the two analog signals of Di_ArcEAo_Current and Ao_Vo1tage according to the different welding parameters set. Welding current and voltage control.



The wire feed motor of the welder uses Kemppi's latest DURATorque. Wire Feeding Mechanism - the DT400 wire feeder and is designed with an all-metal wire feed wheel. The DT400 wire feed motor has a feedback signal meter attached to the 24-pin plug inside the wire feeder. The welder also features Touchsensing and anti-sticking.
Fourth, the control system software
First, the worker manually installs the workpiece. After the installation is in place, there are workpiece models in the fixture. The robot selects different welding procedures according to different types of workpieces, and realizes automatic detection and automatic welding, so that the robot and the external equipment are closely combined. In the welding process, the positioner continuously optimizes the welding posture according to the position set in the program.
V. Conclusion
ABB's robotic arc welding control system improves production efficiency and guarantees welding quality. It has been working continuously for two years, producing 10,000 pieces of various parts, with high stability and reliability, and brings great economic benefits. If a floor-standing positioner is added to form a double-station, the production efficiency will be higher.

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