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The welding manipulator is a device that sends the welding head or welding gun to and keeps it in the welding position, or moves the welding machine along the specified track at the selected welding speed. It is usually composed of a trolley, a column, a walking arm, a control cabinet, etc. Generally, the columns and beams are its basic components, and the remaining components can be selected according to the user's requirements. The columns and beams are bent and welded structural parts with good rigidity. Light, medium and heavy welding manipulators all use triangular guide rails, and super heavy-duty ones use flat square guide rails. They are all processed by planers to ensure the high precision and wear resistance of the guide rails.
Welding manipulators are widely used. When used in conjunction with welding positioners, welding roller frames, etc., they can complete welding of internal and external longitudinal seams, circumferential seams, spiral seams, and surface cladding. They are classified into telescopic arm type, platform type, and gantry type, among which the telescopic arm type is the most widely used. Their structural forms are divided into multiple models according to different product sizes.
Platform welding manipulators are divided into two types: single-track trolley type and double-track trolley type. The single-track trolley type welding manipulator actually has another track, but the track is generally set on the column of the workshop. The movement of the workshop bridge crane often causes the platform to vibrate, thus affecting the normal progress of the welding process.
The horizontal arm welding manipulator is divided into cantilever welding manipulator and telescopic arm welding manipulator according to the different structures of the horizontal arm.
There are two structures of gantry welding manipulators: one is that the welding trolley is located on a work platform that can be raised and lowered along the gantry and can move horizontally along the track on the platform; the other is that the welding head is installed on a set of lifting devices, which are located on a sports car that can move along the beam track. The welding manipulator has a large structure and is widely used in large metal structure factories and shipyards.
The welding manipulator consists of an operating device, a control device, a power source device, and a process guarantee device. The operating device includes a guide rail, an inclination adjustment mechanism, a vertical guide mechanism, a welding gun clamp and a welding gun. The inclination adjustment mechanism allows the welding gun to rotate forward and backward around the center. The control device consists of an electrical control system that can control the working state of the welding manipulator. The power source device consists of a cylinder and uses pneumatic drive for power transmission. The process guarantee device consists of a wire guide mechanism, a welding wire guide tube and a wire guide nozzle, which can realize automatic guiding and positioning of the welding wire and ensure the quality of the weld.
The welding manipulator can cooperate with the special welding positioner to realize the one-time clamping of the cylinder body, and two welding guns weld the left and right sides at the same time, which greatly improves the processing accuracy and production efficiency. It is used for longitudinal and circumferential welding of the inner and outer seams of cylindrical workpieces such as boiler drums in pressure vessels and petrochemical containers. The unique cross-beam and column cross-section design, stress relief treatment after welding, and planing and grinding. Light weight, high strength and good stability. The design of the telescopic arm inside the beam can effectively increase the horizontal telescopic distance of the beam. The beam lifting adopts the constant speed mode of AC motor, which is stable and uniform, with a high safety factor and a safety anti-fall device. The beam telescopic, column electric rotation and electric trolley all adopt AC motor variable frequency stepless speed regulation, constant torque output, stable speed (especially at low speed), quick start or stop, and digital speed display and preset. The column rotation is divided into manual and electric types, with high-precision gears, flexible rotation, and can be manually locked, safe and reliable. The trolley uses standard railway tracks as the walking track, which is divided into manual and electric types. Manual operation is suitable for light-duty manipulators with a small range of movement, while electric operation is suitable for heavy-duty manipulators with a large range of movement. The manned manipulator is equipped with a manned operation platform that moves with the cross arm. The manual control box and the head control box (welding control box) are used to form a local control and remote control mode, which is flexible and convenient to operate. A linkage interface is reserved in the electrical box, which can be synchronized with other welding auxiliary equipment such as welding roller racks and welding positioners.