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機器人燈桿底板焊接電門切割焊接一體機
機器人燈桿底板焊接電門切割焊接一體機
MODEL: RW-DC120/300
型號 : RW-DC120/300

Application: 用途:
本焊接系統用于路燈桿底板焊接生產。通過機器人與焊接電源的實時通訊,根據不同的焊接位置采用不同的工藝參數,取得優質的焊縫。
The welding system are applied for light pole base plate welding production. By real time communication between robot and welding power, according to different welding position to gain good quality welding seam,。
本機具備路燈桿生產中的六大應用,如下:
This machine has six major applications in the production of street light poles, as follows:
?數控桿子的底部切整齊,
?CNC cut flat of the pole bottom 
?底板的定位裝配,
?Positioning and assembly of the bottom plate,
?底板和桿子之間的內外環縫焊接,
?Welding the inner and outer seams between the bottom plate and the pole,
?底板加強筋的焊接,
?Welding the base plate stiffener,
?數控切割電門,
?CNC electrical door cutting
?門框焊接
?Door frame welding
適用于圓錐形桿,圓桿,八角桿,多棱桿,等徑桿
Suitable for conical poles, round poles, octagonal poles, polygonal poles, equal diameter poles

主要技術參數Main parameter:

編號NO. 項目Item 參數Parameter
1 燈桿底部最小直徑Pole min diameter 120mm
2 燈桿最大直徑Pole max diameter 300mm
3 最大長度Pole max.length 14m
4 最小厚度Pole min. thickness 2.5mm
5 燈桿最大厚度Pole max. thickness 12mm
6 脹管可以變形的最大厚度 The maximum thickness of the expanded tube that can be deformed 8mm
7 適合的單根桿子最大重量Pole max weight 500kg
8 底板三角加強筋的數量Max QTY of base plate stiffener 4~8說明:如果數量多,加強筋間距小而影響焊槍進入,可以焊接一半的加強筋Note: If the quantity is large and the spacing of the stiffeners is small and the welding torch is affected, half of the stiffeners can be welded
9 底板三角加強筋尺寸Size of base plate stiffener 一般的普通路燈桿,智慧桿均適合(不同尺寸的加強筋需要不同的模具,可以按照隨機提供的模具,后續用戶自己加工制作)Normal street light poles and high mast are suitable(Different sizes of stiffener require different molds, which can be processed and manufactured by the user in accordance with the mold provided in the machine)
10 焊接速度Welding speed 參考速度 300~500mm/分鐘不同厚度不同焊接速度 Reference speed 300~500mm/minDifferent thickness and different welding speed
11 底板形狀Base plate shape 圓形,正方形,八邊形,四邊的倍數邊型Circle, square, octagon, multiple sides of four sides
12 底板最小厚度Min thickness of base plate 10mm(建議值,太薄內外焊接有難度,容易燒穿Recommended value, too thin, difficult to weld inside and outside, easy to burn through)
13 底板最大厚度Max thickness of base plate 一般桿子都適合Suitable for normal poles
14 底板最小尺寸Min size of base plate 150mm×150mm
15 底板最大尺寸Max size of base plate 700直徑,或者對邊尺寸700700 diameter, or opposite side size 700
16 對加強筋和底板尺寸一致性的要求Requirements for the consistency of the size of the stiffener and the base plate 尺寸公差在1mm以內建議用激光切割或者等離子切割,以確保尺寸的一致性,來獲得比較好的機器人焊接效果Dimension tolerance is within 1mmIt is recommended to use laser cutting or plasma cutting to ensure the consistency of the size to obtain a better robot welding effect
17 對門框尺寸一致性的要求Requirements for the size consistency of the door frame 一般門框為外購,無法達到尺寸公差小于1mm所以,需要人工裝門框,點焊牢后(或者卡緊后,機器人再焊接,如果公差比較小,也可以直接機器人焊接(注:如果門框的尺寸公差比較大,會引起門框和門之間間隙比較大導致局部漏焊,需要后期局部人工補焊)Generally, the door frame is purchased from outside, and the size tolerance is more than 1mm.Therefore, it is necessary to manually install the door frame, and after the spot welding is firmly (or after the clamping, the robot will weld again, if the tolerance is relatively small, it can also be directly welded by the robot(Note: If the dimensional tolerance of the door frame is relatively large, it will cause the gap between the door frame and the door to be relatively large, leading to local leakage of welding, and local manual repair welding is required later)
18 關于電門等離子切割位置,電門的最高點離開底板的最大距離Regarding the position of the switch plasma cutting,The maximum distance from the highest point of the door to the base plate 1400mm
19 切割形狀Cutting shape 方管平面切割+管類切割(4軸控制)Square tube plane cutting + tube cutting (4-axis control)
20 電門尺寸和形狀Door size and shape 在切割范圍內沒有限制There is no limit in the cutting range
21 關于電門門框焊接的位置,電門的最高點離開底板的最大距離Regarding the welding position of the door frame,The maximum distance from the highest point of the door to the base plate 2000mm
22 適合桿型Suitable for pole type 圓錐桿,圓桿,八角桿,八角以上多棱形,等徑桿都適合Conical poles, round poles, octagonal poles, polygonal shapes above octagonal, and equal diameter poles are all suitable
23 等離子電源 Plasma source Hypertherm Powermax 65(Made in USA) 美國海寶
24 最大穿孔和質量切割厚度 Max perforation and quality cutting thickness 12mm(建議值suggested value)
25 切割速度 Cutting speed 一般路燈桿一個電門切割時間為30~40秒 The cutting time of a door on a normal street light pole is 30~40 seconds
26 數控系統 CNC system Si Dafeng(SF-2100S)
27 套圖軟件 Nesting SOFTWARE SmartNest
28 等離子切割槍 CNC Plasma cutting torch 1 套 1 set
29 弧壓調高控制器 Arc voltage height controller HEAVTH HP105
30 調高裝置Height device 等離子調高裝置一套Plasma Torch height moving device, 1set
31 生產速度(包括底板內外焊,電門切割,門框焊接)Production speed(Including inner and outer welding of base plate, electric door cutting, door frame welding) 普通路燈桿:12~16 分鐘 5G桿:40~45 分鐘具體的時間,決定于桿子尺寸,加強筋的尺寸,電門尺寸Normal street light pole: 12~16 minutes5G pole: 40~45 minutesThe specific time depends on the size of the pole, the size of the stiffener, and the size of the door

特殊要求:special requirements:
1.最大管子直徑400,(原來為300)并且底部為250x250方管(最大可以滿足方管350x350), 電動卡盤增加為內孔直徑620(原來為360),The maximum tube diameter is 400 (originally 300) and the bottom is a 250x250 square tube (the maximum can meet the square tube 350x350), the electric chuck is increased to an inner hole diameter of 620 (originally 360),
2.方管上,一個側面有2個加強筋,需要加強筋裝置,可以上下移動,適合加強筋的不同位置On the square tube, there are 2 stiffeners on one side. A stiffener device is required, which can be moved up and down, suitable for different positions of the stiffener
3.如果小頭位置為方管,小頭支承無法旋轉, 需要更改支承型式,結果討論,決定增加12米導軌和小頭的活動支承,以提高切割和焊接的精度,適合圓桿,方管,八角桿。小頭支承為伺服同步旋轉。這樣就不再需要制作方轉圓的工裝夾具了。If the small end position is a square tube, the small end support cannot be rotated, and the support type needs to be changed. After discussion, it was decided to increase the 12-meter guide rail and the movable support of the small end to improve the accuracy of cutting and welding. It is suitable for round poles, square tubes, and octagonal poles. The small end support is servo synchronous rotation. In this way, it is no longer necessary to make a tooling fixture that turns square to round.
4.因為在方管的單側面開門,等離子切割系統,需要增加一個控制軸。Because the door is opened on one side of the square tube, the plasma cutting system needs to add a control axis.
5.門框所在位置,離開底板最大1300,更改為懸掛式機器人,為了得到離開底板2米處的焊接,懸掛式機器人懸掛框往外移動500mm.  The position of the door frame, the maximum distance from the base plate to highest of the door is 1300mm, and it is changed to a suspended robot. In order to obtain welding at a distance of 2 meters from the base plate, the suspended robot suspension frame moves 500mm outward.

總體布局如下圖:the general layout is as followings: 


專有特點:Proprietary features:
1.本機集成了六個功能,一次上下料,就可以完成,桿子的底部切整齊,底板的定位裝配,底板和桿子之間的內外焊接,底板加強筋的焊接,切割電門,門框焊接。大大減少了獨立工序間的物料流動和上下料時間,節約了生產空間。This machine integrates six functions, which can be completed in one loading and unloading. CNC cut flat of the pole bottom, the positioning and assembly of the base plate, the internal and external welding between the base plate and the pole, the welding of the bottom plate stiffener, the electrical door cutting , and the door frame welding . The material flow and loading and unloading time between independent processes are greatly reduced, and the production space is saved.
2.帶有漲管功能,消除底板內孔和桿子之間的間隙,順利實現自動焊接。With pole expansion function, eliminate the gap between the inner hole of the base plate and the pole, and realize automatic welding smoothly
3.具有底板加強筋自動放置和焊接功能,加強筋裝置可以上下位置自動調節,以滿足方管一側邊上下2塊加強筋的自動送料。With the function of automatic placement and welding of the stiffener, the auto feeding system can automatically adjust the up and down positions to meet the automatic feeding of two stiffeners on one side of the square tube。
4.采用日本川崎重工機器人,操作性好,質量過硬。It adopts Japanese Kawasaki Heavy Industries robot with good operability and excellent quality.
5.采用著名焊接電源,焊縫質量好,焊接效率高。Adopting famous welding power source, good welding seam quality and high welding efficiency
6.變位機翻轉角度大,可實現最合理的角度焊接。The positioner has a large turning angle, which can realize the most reasonable angle welding
7.焊接成型美觀,可靠性高。Beautiful welding shape and high reliability
8.燈桿電門的數控切割,切割形狀可以是圓形,正方形,矩形,橢圓形等,任何電腦CAD 可以繪制的圖形都可以通過隨機附帶的專用軟件來切割。The CNC cutting of the light pole door , the cutting shape can be circle, square, rectangle, oval, etc. Any graphics that can be drawn by computer CAD can be cut by the special software that comes with the machine.
9.切割源是自動等離子,因此切割速度會很快,并且切口光滑圓整。The cutting source is automatic plasma, so the cutting speed will be very fast, and the cut will be smooth and round
10.由于使用美國產海寶等離子的電源和割槍,切割縫隙比較小,割下的件,可以作為門蓋使用。Due to the use of the Hypertherm Powermax 65 plasma spurce and cutting gun, the cutting gap is relatively small, and the cut pieces can be used as door covers
11.電門切割完成后,如果需要門框的焊接的,機器人可以完成門框的自動焊接,門框焊接需要配置激光尋位功能。After the electric door is cut, if the door frame needs to be welded, the robot can complete the automatic welding of the door frame. And the door frame welding needs to be equipped with the laser positioning function
12.整個機器單向流水線的形式設計,桿子堆放在機器的左邊,通過操作人員可以一根接一根向右邊移動,完成焊接,焊接完成的桿子堆放到右邊。桿子移動升起,無需行車,操作人員勞動強度低。The entire machine is designed in the form of a one-way assembly line. The poles are stacked on the left side of the machine. The operator can move one by one to the right to complete the welding, and the welded poles are stacked on the right. The pole moves and rises, no crane is required, and the labor intensity of the operator is low
13.增加12米導軌和小頭的活動支承,以提高切割和焊接的精度,適合圓桿,方管,八角桿。小頭支承為伺服同步旋轉。這樣就不再需要制作方轉圓的工裝夾具了。Add the 12-meter guide rail and small end movable support to improve the accuracy of cutting and welding. It is suitable for round poles, square tubes and octagonal poles. The small end support is servo synchronous rotation. In this way, it is no longer necessary to make tooling fixtures that turn square to round.
14.節省大量人工成本Save a lot of labor costs
15.可適應全天候長時間工作Can adapt to long hours of work throughout the day

照片Similar photos:


機器人系統介紹 Robot welding system

1.川崎機器人Kawasaki Robot BA006N (Japanese brand)
BA系列是專為焊接開發的機器人系列,專用于焊接,操作簡單,可以通過簡單的示教操作即可達到熟練的焊接作業操作。在示教器上設有可視效果極佳及便于操作的可觸摸液晶彩色顯示屏。機器人與焊機僅需要一根電纜連接,可將焊接條件分類存儲,一鍵調用。
BA series is a series of robots developed for welding specially. It is designed for welding specially. It is easy to operate and can achieve skilled welding operation through simple teaching operation. A touch LCD color display screen with excellent visual effect and easy operation is installed on the teaching device. Robot welding machine only need a cable connection, can classify welding conditions of storage, and one key call. 


示教方式 Teaching methods 簡單操作示教AS語言編程 Simple Operation Teaching AS Language Programming
動作方式 Manner of execution 手動模式 Manual mode 各軸獨立、基本坐標系、工具坐標系 Independent axes, basic coordinate system and tool coordinate system
再現模式 Reproduction mode 各軸/直線、圓弧插補動作 Interpolation action of each axis/line and arc
存儲容量 Storage capacity 8MB(8000步相當)8000 steps are equivalent
通用信號 General signal 外部操作信號 External Operating Signal 緊急停止,外部保持信號 Emergency stop, external hold signal
輸入輸出 Input and output 32+32

川崎BA系列機器人采用 E01控制柜,外形緊湊,操作體系適宜,功能豐富,易維護和具有高擴展性。6.5英寸彩色液晶屏幕,觸摸屏640×480像素。采用背照光,使液晶畫面更容易看清。操作系統采用WINDOWS CE。窗口顯示采用下拉式菜單,使編輯操作過程簡單易行。
Kawasaki BA series robots use E01 control cabinet, compact shape, suitable operation system, rich functions, easy maintenance and high scalability. 6.5 inch color LCD screen, touch screen 640 x 480 pixels. Backlighting is used to make the LCD screen easier to see. The operating system adopts WINDOWS CE. The drop-down menu is used for window display, which makes the editing process simple and easy.


功能Fuctions 標準弧焊Standard arc welding
型號Model BA006N
手臂形式Arm form 垂直多關節Vertical multiple joints
動作自由度DOF 6軸axis
最大負載能力Maximum load capacity(KG) 6
最大動作范圍Maximum range of action[DEG] JT1電源線及控制線 ±165
JT2 +150~-90
JT3 +45~-175
JT4 ±180
JT5 ±135
JT6 ±360
最大動作速度Maximum speed of action[DEG/S] JT1電源線及控制線 240
JT2 240
JT3 220
JT4 430
JT5 430
JT6 650
慣量Inertia[N.M] JT4 12
JT5 12
JT6 3.75
慣性力矩Inertial moment[KG.M2] JT4 0.4
JT5 0.4
JT6 0.07
重復定位精度Repeated positioning accuracy [MM] ±0.05
水平伸長度Horizontal elongation [MM] 1445
本體重量Weight[KG] 150
電源容量Power capacity [KVA] 3.0
安裝方式Installation mode 地面、頂裝Ground、Top loading
安裝環境Installation environment 溫度Temperature 0~45°
濕度Humidity 35~85%(不能結露No dew)
振動Vibration 0.5G以下Less than 0.5
其他Others 機器人安裝必須遠離:易燃或腐蝕性液體或氣體 電器的干擾Robot installation must be away from the interference of flammable or corrosive liquid or gas appliances
IP等級Level IP65
推薦控制器Recommended Controller E01

動作范圍Range of action:


焊槍防撞器介紹 Introduction Collision Preventer of Welding Torch
350 焊槍系統為二氧化碳焊槍,普遍用于亞洲區域的弧焊工作。The 350 welding torch system is a CO2 welding torch, which is commonly used for arc welding in Asia.
可換槍頸焊槍系統具有額定值高及暫載率高等優點:智能接口可實現快速維護和可重復定位功能,縮短停工時間。
The replaceable gun neck welding gun system has the advantages of high rated value and high duty cycle: intelligent interface can realize fast maintenance and repeatable positioning functions, and shorten downtime
該焊槍系統有多種針對所有常用機器接頭的槍頸和夾持器供選擇。The welding gun system has a variety of gun necks and holders for all common machine joints to choose from. 
優點:Advantage
(1)典型的亞洲式二氧化碳設計Typical Asian CO2 welding design
(2)可換槍頸可縮短設備停工時間, 減少維護、維修的費用Replaceable gun neck can shorten equipment downtime and reduce maintenance and repair costs
(3)******的溫度特性可確保易損件使用壽命長Optimal temperature characteristics ensure long service life of wearing parts
(4)高質量電纜組件可確保系統的使用壽命長High-quality cable assemblies ensure a long service life of the system
(5)堅固耐用的焊槍結構可實現高碰撞穩定性Rugged welding torch structure can achieve high collision stability


型號Model 350
冷卻方式Cooling way 風冷Air
暫載率Duty cycle 100%
額定值Rated value 350A CO2
300A 混合氣體 (mixed composition)
送絲直徑 Wire diameter 0.8-1.4mm
槍頸 Welding gun neck 35°

NBC-350RL 焊接電源系統 NBC-350RL Welding Power System
設備說明:
NBC-350RL 機器人專用焊機具有低飛濺、恒壓兩種焊接模式,可以實現碳鋼富氬與 CO2 氣體保護焊。本產品采用全數字的控制方式,適應性極強,能與弧焊機器人通過數字/模擬接口完成通訊。
Device Description:
The NBC-350RL robot special welding machine has two welding modes: low spatter and constant pressure, which can realize carbon steel rich argon and CO2 gas shielded welding. This product adopts an all-digital control method, which is highly adaptable and can communicate with the arc welding robot through a digital/analog interface.

性能特點:Performance characteristics
(1)能與Kawasaki(川崎)機器人完成配套。Can be matched with Kawasaki robot
(2)數字接口控制種類豐富, 能直接調用客戶存儲的焊接參數。Numerous types of digital interface control can directly call the welding parameters stored by the customer
(3)焊接飛濺極小,焊縫成型美觀。Very small welding spatter, beautiful welding seam shape
(4)優化的引弧、收弧以及去球功能。Optimized arc ignition, arc closing and ball removal functions

全數字化控制系統,實現焊接過程的精確控制、弧長穩定。The fully digital control system realizes precise control of the welding process and stable arc length.
強大的數字報錯功能,多種故障都有錯誤代碼進行顯示。Powerful digital error reporting function, a variety of faults have error codes to display.
系統內置焊接專家數據庫,自動智能化參數組合。The system has a built-in welding expert database and automatic and intelligent parameter combination.
操作界面友好,一元化調節方式,易于掌握。Friendly operation interface, unified adjustment mode, easy to master.
軟開關逆變技術,整機可靠性高、節能省電。
Soft-switching inverter technology, the whole machine is highly reliable, energy-saving and electricity-saving.

焊接電源參數:Welding power parameters

序號No. 類別Item 參數Parameters
1 額定輸入電壓/頻率Rated input voltage/frequency 380V±25% 3P/50Hz
2 額定輸入容量( KVA)Rated input capacity 14
3 額定輸入電流(A)Rated input current (A) 21
4 額定輸出電壓(V)Rated output voltage (V) 31.5
5 額定負載持續率(%)Rated load duration (%) 60%
6 輸出空載電壓(V)Output no-load voltage (V) 96
7 輸出電流/電壓范圍(A/V)Output current/voltage range (A/V) 60A/17V~350A/31.5V
8 焊絲直徑(mm)Welding wire diameter (mm) 0.8、1.0、1.2
9 送絲類型Wire feed type 推絲Push wire
10 氣體流量(L/min)Air flow rate (L/min) 15~20
11 焊槍冷卻方式Torch cooling method 氣冷Air cooling
12 外殼防護等級Enclosure rating IP23
13 絕緣等級Insulation class H
14 外型尺寸 L*W*H (cm)Dimensions L*W*H (cm) 66*32*56
15 重量( Kg)Weight 55
16 EMC 發射等級EMC emission level A


清槍、剪絲和噴硅油裝置(選配件) Option:Gun cleaning, wire cutting and silicone oil spray device 
如圖所示。清槍和噴硅油裝置用于清理焊槍噴嘴內的飛濺和向噴嘴內噴防飛濺硅油。剪絲裝置用于剪除焊絲尖端小球并保證焊絲干伸長度一致, 保證起弧成功率和焊接過程穩定,以及始端檢出的精度。
As the picture shows. The gun cleaning and silicone oil spraying device is used to clean the splash in the nozzle of the welding torch and spray anti-splash silicone oil into the nozzle. The wire cutting device is used to cut off the small ball at the tip of the welding wire and ensure that the dry elongation of the welding wire is consistent, to ensure the success rate of arc starting and the stability of the welding process, as well as the accuracy of the detection at the beginning.


運行環境Operating environment
1、接地:C種接地,接地電阻小于10歐姆。
Grounding: C grounding, grounding resistance less than 10 ohms.
2、焊絲:盤裝焊絲Welding wire: disc-mounted wire
3、使用環境條件(室內)Use of environmental conditions (indoor)
環境溫度Ambient temperature:-5℃~40℃。
相對濕度Relative humidity:≤80%。不結露。No dew

編程及工作流程Programming and Workflow
編程流程Programming flow


工作流程Workflow


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