Original title: Welding Industrial Robot Training System Welding Industrial Robot Training Platform Welding Industrial Robot Training Box

VS-IRHJ02 Welding Industrial Robot Training System

1. Functional objectives of robot welding system

1. The robot, wire feeding bucket, wire feeding machine, and cleaning gun wire reduction mechanism are installed on the guide rail, and the control cabinet and welding power supply are integrated into one basket.

2. When the robot welding system performs welding tasks, it first lifts the robot and the guide rail base as a whole to one side of the weld seam, and at the same time lifts the other section of the guide rail base. The two sections of the guide rail base are connected by bolts, so that the robot can travel a distance of 13m. The guide rail base is parallel to the weld seam and maintains a certain distance. The levelness of the guide rail base is adjusted by bolts, and the guide rail base is fixed using eye plates.

3. Lift the hanging basket where the control cabinet and welding power supply are located to a convenient location for workers to operate. Control cables connecting robots, control cabinets, and welding power sources.

4. The operator uses a teaching box to move the robot near the starting point of the weld seam, and calls the trajectory pre scan command written through offline programming software. The robot, together with a 3D laser, pre scans the weld seam and records its actual coordinate position.

5. After the pre scan of the weld seam is completed, the robot returns to the vicinity of the starting point of the weld seam and calls the welding command written through offline programming software. The robot automatically locates the starting point, and welding begins. Through arc tracking and the online real-time tracking function of the 3D laser, the welding quality of the weld seam is ensured. Due to the thickness of the workpiece and the length of the weld seam, a water-cooled welding power supply and water-cooled welding gun with a rated current of ≥ 500A are selected to ensure the continuity of the welding machine's operation. Install collision sensors at the end of the robot to protect the 3D laser and welding gun.

6. During welding, the air compressor works to provide compressed air for the cleaning gun and wire reduction mechanism. After the first welding is completed, the robot automatically cleans the gun and reduces the wire, preparing for the next welding of multi-layer and multi pass welding of the workpiece.

7. To ensure the safety of the welding operation environment, the laboratory is equipped with a comprehensive alarm device to timely alarm for dangerous situations such as water leakage, electric leakage, and fire in the laboratory.

2. System functional requirements

1. Robot system: It has 6 degrees of freedom, supports external extension axes, and has a large horizontal action radius to meet the welding needs of different types of welds; Equipped with anti-collision function; The control cabinet has functions such as automatic control, detection, protection, and alarm, and is equipped with software and hardware to achieve multi-layer and multi pass welding.

2. Welding system: The water-cooled welding power supply has a current of up to 500A, a rated temporary load rate of ≥ 60%, and supports CO2/MAG/MIG welding; The wire feeding mechanism is matched with the welding power supply; Anti collision water-cooled welding gun; Automatic gun cleaning and wire cutting station; The control cabinet and welding power supply need to be integrated together for easy overall lifting.

3. Tracking system: equipped with laser online/offline 3D tracking function; Equipped with automatic positioning and arc tracking functions.

4. Walking system: meet the robot's walking distance of 13m; The guide rail base needs to be made in two sections according to the basic style provided by our institute, and meet the needs of quick positioning on steel structures; The two-stage guide rail base can be spliced to ensure the normal walking of the robot; The guide rail base also needs to be equipped with lifting eye plates to ensure the overall structural strength when the robot is fixed on the guide rail base; The supplier shall provide a finite element analysis report on the stress and strain of the guide rail base under the static, walking, and swinging welding states of the welding robot.

5. Guarantee system: Equipped with an air compressor to provide compressed air for the gun cleaning mechanism, and installed with a laboratory comprehensive alarm device to achieve timely alarm of dangerous states such as water leakage, electric leakage, and fire in the laboratory.

3. The technical parameters of the equipment require the system name to include the robot body, control cabinet, teaching box, control cable, etc.

Robot body: 6-axis, effective load ≥ 6kg, repeatability accuracy within ± 0.08mm range, robot * large action radius range in the horizontal direction ≥ 1900mm, weight ≤ 300kg; The entire robot system is equipped with collision sensors that immediately stop working in the event of a collision.

Control cabinet: equipped with automatic control, detection, protection, alarm and other functions; Equipped with multi-layer and multi pass welding software.

Teaching Box: Menu style bilingual in Chinese and English.

Control cable: length ≥ 20m. The welding system includes welding power supply, wire feeder, welding gun, cleaning gun and wire cutting station and other devices.

Welding power supply: One set of imported water-cooled welding power supply, supporting CO2/MIG/MAG welding, * high current 500A, rated temporary load rate ≥ 60%.

Wire feeder: compatible with welding power supply, with stable performance.

Welding gun: anti-collision water-cooled welding gun.

Gun cleaning and wire cutting station: automatic gun cleaning and wire cutting. The tracking system includes devices such as 3D laser, arc tracking, and automatic positioning.

3D laser: laser integrated with robot, with welding online tracking and offline weld seam trajectory recognition functions;

Arc tracking: equipped with arc tracking function.

Automatic positioning: with starting point positioning function. The security system includes devices such as air compressors and comprehensive alarms.

Air compressor: The air compressor provides compressed air for the gun cleaning mechanism.

Comprehensive alarm device: Install a laboratory comprehensive alarm device to achieve timely alarm of dangerous states such as water leakage, electric leakage, and fire in the laboratory. The walking system includes a base, guide rails, and other devices.

Base: at least one expansion shaft, including servo motor and reducer; Reserve a wire feeding bucket installation platform on the base.

Guide rail: meet the robot's walking distance of 13m; The guide rail base needs to be made in two sections according to the basic style provided by our institute, and meet the needs of quick positioning on steel structures; The two-stage guide rail base can be spliced to ensure the normal walking of the robot; The guide rail base also needs to be equipped with lifting eye plates to ensure the overall structural strength when the robot is fixed on the guide rail base; The supplier shall provide a finite element analysis report on the stress and strain of the guide rail base under the static, walking, and swinging welding states of the welding robot. After sales service provides transportation, installation and commissioning, personnel training and other services.

Provide training on welding robot operation and offline programming software for no less than 2 people, with each person having at least 80 hours of training hours, and provide relevant training materials;

The equipment warranty period is ≥ 1 year (calculated from installation, commissioning, and normal use). 4. Main equipment configuration of robot welding system:

System Name Main Equipment Brand Model Parameters Quantity Robot System Robot Body KUKAKR 16L6-2 Load 6KG* Large working range 1911mm; Number of axes: 6; Repetitive positioning accuracy: ± 0.05mm; 1 set of control cabinet KUKAKRC4 multi-layer and multi pass welding software package: KUKA Multilayer；

A software package that combines with 3D sensors to achieve online welding tracking and offline weld seam trajectory recognition functions: KUKA.seamtech.find and KUKA.seamtech.tracking 1 set of teaching boxes KUKAsmartPAD, used in conjunction with KUKA robots to use 1 set of control cables KUKA180184 ≥ 20 meters 1 set of robot offline programming software KUKASIM PRO offline simulation simulation 1 set of anti-collision sensor TBIKS-2 external; Fully mechanical; Spring support* Large twist angle: 10 °; 1 set of welding system welding power supply EWMPhoenix 551 digital inverter, welding current 5-550A, temporary load rate 550A/60%, weight 125kg 1 set of wire feeding device EWM matching automatic wire feeding 1 set of welding gun Binzel ABIROB W500 rated current 500A1 set of cleaning gun cutting mechanism TBIBRG-2000D automatic cleaning gun, cutting wire 1 set of water cooling device domestic matching to meet water cooling requirements 1 set of tracking system 3D laser SERVO-ROBOTPOWER-TRAC equipped with POWER-CAM sensor, including advanced joint processing software module, Trac-3D trajectory generation module, with welding online tracking and offline weld seam trajectory recognition function; 25 replaceable protective lenses for Power Cam laser sensors; 1 set of automatic positioning KUKATouchsense software: equipped with automatic positioning function 1 set of arc tracking KUKAArcsense software: equipped with arc tracking function 1 set of guarantee system air compressor Feibao FBV-0.17-8 exhaust pressure: 0.8MPa; Power: 1.5KW; Exhaust volume: 0.17m3/min. 1 set of comprehensive alarm device, Sibe SPD-T58GSM, for timely alarm of laboratory water leakage, power outage, fire and other dangerous states. 1 set of walking system servo motor, Yaskawa outer shaft matching 7 series, position control, AC power supply ≥ 1000W1. 1 set of guide rail base with a depth of LS-DG-013 and a total length of 13 meters (6.5+6.5 or 6+7). Referring to the form provided by Jiangsu University of Science and Technology, it meets the strength requirements during work or lifting; Install lifting eye plates on the guide rail base and configure lifting cages for the guide rail base and robot lifting; Provide a hanging basket for loading welding power supplies and control cabinets, meeting the functional requirements for movement and lifting. 1 set of reducer with Longshen outer shaft matching and Yaskawa waiting for the opportunity to use 1 set. 5. Introduction to robot system equipment

The robot system mainly consists of the robot body, control cabinet, teaching box, control cables, etc.

1. Technical parameters of KUKA KR 16 L6-2 robot:

The innovative concept of KR C4 for floor and ceiling has laid a solid foundation for the automation of tomorrow, with a model load axis number * large operating range, repeated accuracy, weight, installation position KR 16 L6-26kg61911mm ± 0.05mm240kg. Reduced integration, maintenance, and upkeep costs in automation, while consistently improving system efficiency and flexibility. So KUKA developed a brand new system architecture that is structurally clear and emphasizes the use of open and efficient data standards. All Safety Control, Robot Control, Motion Control, and Logic Control integrated in this system architecture have the same data foundation and infrastructure, and can be intelligently used and shared, making the system highly performance, upgradable, and flexible. Leading the times, creating the future - and not limited to KUKA robots.

2. KR C4 functional features:

(1) Simplified planning, operation, and maintenance

(2) Continue to adopt validated computer-based control technology

(3) By continuing to adopt existing standards to achieve fast and simple operations

(4) The extended instruction set facilitates more user-friendly trajectory programming

(5) Highly compatible with existing KR C2 programs

(6) Integrate safety control, robot control, logic control, motion control, and process control into one control system

(7) Real time communication between dedicated control modules

(8) Achieved maximum data consistency through the central infrastructure service system

(9) Seamless integration of security technologies for new application areas

(10) Integrated software firewall for a more secure network

(11) Innovative software features optimize energy efficiency

(12) A technology platform suitable for future development without dedicated hardware

(13) Multi core processor support for more upgradable performance

(14) Utilizing Gigabit Ethernet for Fast Communication

(15) Integrated storage card for storing important system data

(16) Specially designed for 380-480VAC

(17) New fan design optimized for energy efficiency

(18) The cooling device does not require maintenance and does not come with a filter felt

(19) Achieve maximum performance in a small space

(20) Maximizing availability

3. SmartPAD features:

SmartPAD touch screen, graphic assistance, flexible interaction. The more powerful the functions of a robot, the more important the intuitive perception based robot operation interface becomes. The new KUKA smartPAD displays how to intuitively control robots on a large high-definition non reflective touch screen with excellent performance. The intelligent interactive dialogue window clearly displays various processes to the user. At any time, the user will be provided with the operating elements they need exactly at that moment. Its purpose is to attract users' attention to the most important factors, so that they can work intuitively, simply, quickly, and effectively. Truly achieving comprehensive intelligence.

(1) The touchpad has context sensitive floating windows, making operations more intuitive

(2) Directly control eight axes/additional axes through separate run keys, without the need to switch back and forth

(3) Efficient programming using 6D mouse, with a keyboard designed based on ergonomics on the touchpad

(4) Steadfastly continued to develop KUKA's proven operational and programming solutions

(5) No training cost

(6) Can directly store and read configurations on smartPAD

(7) Hot swappable function. If you don't need to use smartPAD, you can simply unplug it

(8) During work, high-definition, oversized, and anti reflective display screens can protect the eyes

6. Introduction to Welding System Equipment

The welding device mainly consists of a welding power supply, a welding gun, a wire feeding mechanism, a cleaning and cutting mechanism, an anti-collision sensor, a water cooling device, etc. The welding device serves the welding robot, and communication between the two is through a bus, which can be equipped with mainstream communication methods such as Ethernet, InterBus, Profibus, DeviceNet, etc. The welding robot communicates directly with the cleaning gun and wire cutting mechanism through I/O, enabling automation of the cleaning and wire cutting processes.

The EWM Phoenix 551 Puls inverter split type welding power supply from Germany is a fully digital inverter welding power supply, which has high working efficiency, low spatter, and strong repeatability; EWM - forceArc technology enables more concentrated arc energy, increasing the efficiency of welding thick plates by 30%; A clear operation panel suitable for various applications; Optimized preset welding tasks (JOBs) and a unified operating system make your work effortless; Strong mobility: large-sized casters, narrow body, suitable for passing through standard doors, easy to load and unload; The upright pole at the front of the welding machine can serve as a handle and also protect the welding machine from collisions; The excellent shell design makes the cooling system effective and has strong dust resistance; PROCESS, EXPERT panel: supports automated communication interfaces, making it easy to integrate welding power into robots, industrial buses, and automated production lines; Excellent welding gun cooling system, centrifugal pump, 12 liter super large water tank.

1. Application areas of EWM Phoenix 551 Puls inverter split welding power supply in Germany:

(1) Non alloy steel, low-alloy steel, high alloy steel, aluminum alloy, copper and copper alloys, special metals.

(2) Solid core and flux cored welding wires (0.8-2.4mm), titanium type and alkaline welding rods.

(3) Chemical and food industries, machinery manufacturing, vehicle manufacturing, pipeline construction, containers, high-pressure vessels, shipbuilding, offshore operations, etc.

2. German EWM Phoenix 551 Puls inverter split welding power supply features:

(1) The multifunctional DC inverter welding power supply can be used for MIG/MAG pulse welding, TIG conventional welding, TIG contact arc ignition, and MMA.

(2) Mobile, air-cooled or water-cooled, independent wire feeding mechanism, can be moved by crane, 5-meter power cord.

(3) Powerful temperature control fan.

(4) Coolant pressure monitoring system, temperature controlled water pump, and cooling fan.

(5) PHOENIX DRIVE 4-wheel drive (standard 1.0+1.2mm steel wire feeding wheel) 37mm, equipped with European or Dinse interface.

(6) 100% actual welding inspection.

3. Technical parameters of EWM Phoenix 551 Puls inverter split welding power supply from Germany:

Model Welding current Temporary load rate MIG/MAG Size Weight 40 ° C25 ° C EWM Phoenix 551 Puls5A-550A550A/60%

420A/100%550A/60%

450A/100% 1100 x 455 x 1000mm 125kg

Figure 1.6 TBi BRG-2000D gun cleaning station

4. German TBi BRG-2000D cleaning gun cutting mechanism features:

(1) The cleaning gun and oil spraying design of the German TBi BRG-2000D cleaning gun cutting mechanism at the same position allows the robot to complete the cleaning gun and oil spraying action with just one signal.

(2) The German TBi BRG-2000D cleaning and cutting mechanism only takes 6-7 seconds to complete the cleaning process, which is 12 seconds compared to other similar products, greatly saving robot cleaning time and improving robot work efficiency.

(3) The important components of the German TBi BRG-2000D cleaning gun wire cutting mechanism are protected by high-quality casings to prevent collisions, splashes, and dust.

(4) The new TBi BRG-2000D gun cleaning station in Germany has a built-in fuel injection device that is controlled by a robot through an electromagnetic valve (photoelectric induction fuel injection is optional, saving robot signals) for safe and reliable maintenance. The atomized anti splash agent can effectively reach the root of the welding gun head, and the relatively closed oil spray chamber greatly reduces the problem of oil mist pollution in the design.

(5) The German TBi BRG-2000D wire cutting device adopts electromagnetic valve control for more accurate wire cutting. At the same time, the compact structure of the new safety protection hood ensures that the cut welding wire falls into the collection box, avoiding secondary pollution.

(6) Compared with other brand products, the electrical layout of the German TBi BRG-2000D wire cutting device is very simple. All control components are safely placed inside the chassis, and there are very few exposed pipelines.

5. Technical parameters of TBi BRG-2000D cleaning and wire reduction mechanism in Germany:

Model TBi BRG2000D air source oil-free dry compressed air, 6 bar air flow rate approximately 7L/s Start signal 24V DC gun cleaning time approximately 4-5 seconds Spray silicone oil device Oil absorber 300ml size 34.5x24.0x16.25cm Weight approximately 13kg (excluding gun cleaning station base) 7. Tracking system equipment introduction

1. POWER-TRAC features:

Hardware visual software ● The complete standard system includes light sensors, control units, and software.

A very sturdy sensor housing with cooling channels.

Compressed air flow nozzle design, protecting replaceable lenses and resisting smoke and splashes.

● Automatic detection of protective lenses.

A very compact control unit. Real time control of welding gun trajectory.

Not affected by arc environment interference (splashing, heat, smoke, magnetic field, shock, and vibration).

Not affected by environmental lighting conditions.

● Able to track on all weldable materials.

Real 3D laser measurement of joint geometric dimensions.

A rich database of weld joints can be used for tracking, locating, and measuring all types of welds.

High speed digital laser sensors achieve fast and reliable joint recognition.

● Automatic connector recognition. ● Adaptive welding software package, compensating for joint changes.

Advanced joint algorithms meet various possible weld joint requirements.

Process monitoring displays whether the process is controlled. Compatible with all welding processes:

GMAW (optional super strong protection for double wire welding)

GTAW (optional high-frequency protection)

FCAW (optional super strong protection)

Laser composite welding (optional high-precision laser sensor model)

Laser welding (optional high-precision/long-distance laser sensor models) options and accessories

The grounding fault detector protects the visual system from damage caused by welding current due to accidental contact with the workpiece.

The safety interlock I/O has been integrated into the control unit for easy use of the robot unit.

The Super Powerful Sensor Protection Component (SHDCK) is an optional component for high-strength welding processes (with an optional air knife nozzle). Advanced features

The concept of "plug and solder" enables simple and fast replacement of laser sensors through preset calibration

● Automatic laser power control

Automatic optical adjustment during welding process, easy to use

Automatically turn off the laser when the protective lens is not installed

Using precision calibration blocks to achieve automatic calibration of sensors and tools

● Programmable laser sensor field of view range

Connect directly to most welding robots through digital interfaces

● Remote diagnosis and service through Ethernet HMI connection

● Integrate offline weld seam positioning, online real-time weld seam tracking, and pre weld and/or post weld detection into a unique system function

● High cost-effectiveness and intelligent solutions

● Reduced size of system components, making it easy to integrate within robot units

● Can be used for weld seam tracking in high-speed welding processes, such as double wire gas shielded welding and laser composite welding

● Adaptive welding module, responding to changes in joint geometry, optimizing weld seam size, thereby eliminating welding defects and reducing excessive welding

Ensure that the welding wire is accurately aligned with the weld seam, improve the stability of the welding process, thereby reducing spatter and improving welding quality. 8. Introduction to the guarantee system equipment

The protection system consists of two parts: an air compressor and a comprehensive alarm device.

1. Internal parameters of air pressure

Brand, model, power, cooling method, exhaust volume, exhaust pressure, Feibao V-0.17-81.5KW, air-cooled 0.17m3/min0.8MPa

Figure 1.9 SPD-T58GSM Alarm Device

2. SPD-T58GSM has four major features:

(1) Fully functional

Temperature monitoring, humidity monitoring, water leakage monitoring, UPS voltage monitoring, remote control of air conditioning, and automatic start of air conditioning when powered on.

(2) Simple structure

Building block structure: one main controller+several sensors, which can discard unnecessary functions according to their own situation, reducing unnecessary花费。

（3）性能稳定

采用进口32位工业级微控制芯片，工作稳定可靠。

（4）安装简单

独创积木式结构，把传感器插入相应的控制器接口即可。设置报警温度等操作均可通过手机键盘远程设置。

9、行走系统设备介绍

行走系统长度13米，导轨底座分为两段制作，满足在钢结构上快速定位的需求；两段导轨底座能够实现拼接，并保证机器人的正常行走；至少包含一个扩展轴，含伺服电机和减速机；底座上预留送丝桶安装平台，导轨底座设置吊装眼板，当机器人固定在导轨底座上时，保证导轨底座吊装时的整体结构强度；配置用于导轨底座和机器人吊装的吊笼，该吊笼能够将机器人罩住；提供用于装载焊接电源和控制柜的吊篮，满足移动和吊装的功能要求。

图1.10行走导轨底座示意图

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