Development Of Truss Automatically Forming And Welding Production Lines

In this paper, a suit of automatic forming and welding equipment for truss is researched and designed, which has being produced by manpower and manual arc welding in one company.Regard meeting the requirement of practical production as the starting point, this paper introduces the design,manufacture,installation and adjustment in the whole process of forming and welding equipment of trusses, including making scheme,planning,drafting for part and assembly drawing,installation and adjustment. Development of truss automatically forming and welding production lines is realized in the integrative application of mechanical design,CAD,SolidWorks,system simulation and theoretical knowledge of some application soft wares.According to the mechanical design of forming and welding equipment of trusses, the detailed description about its design idea is illustrated and the implementation process of each step is analyzed for a given structure of truss. In the course of analysis on forming of truss, the main problems solved are the forming and torsion of triangle within a small space. In order to solve the problem of end butt welding, spatial inclined Spot-welding Electrode is used for meeting the demand of welding shape. Two schemes are designed to resolve the forming and welding of truss. Through integrated compare, one more rational scheme is applied finally. Various assembly diagrams and all parts and elements diagrams can be done by AutoCAD, the sizes of forced parts are calculated and checked. Then use the building model software, namely SolidWorks, to build every part of the equipment in the computer, then virtual assemble the general architecture in the computer, not only to check and judge whether or not have the interferences, but also can revise the mistakes in on the course of design and assemble the equipment. After that, assembly animation demonstration is implemented by using the plug-in Animator in SolidWorks to examine spatial positions and the interference situation between the moveable components. Moreover, stress analysis of the main parts is done by the stress analysis software of COSMOSXpress, in order to forecast the loading condition and deformation state of all parts. Based that, the sizes of original design are optimized and the final sizes are determined. And then, the existing problems which occurred in the process of installation and debugging are conducted detailed analysis and solved. Some problems are detailed discussion such as bad shape of rectangular-ring,irregular forming and welding of triangle-ring,unsatisfied shape requirement of truss end. Then solutions are Proposed. Technology specification of every welding point is determined by multi-group and different specifications of steel bar of many experimented data. The optimum is obtained. After the equipment is installed and adjusted, passing through a period of operation to show that the line is reliable operation, high accuracy, good forming and the requirement of the practical production is satisfied and the production efficiency of truss is increased.