| As the key equipment of fully mechanized mining, hydraulic support belongs to box welding structure mostly. Dense weld beams, complex structure and high strength requirements are the difficulties. And manual welding become the traditional process in both home and abroad, but there are many shortcomings, such as large labor intensity, poor working environment for instance. In addition, due to the effect of man-made factors, the quality of weld beam is instable, consistency is rather poor and the appearance shape is not good, thus the production efficiency is low. According to the structural problems of hydraulic support in the production process, a high efficiency welding system for hydraulic support was designed and relevant key technologies was studied in this paper, main research work including:(1) Process analysis and design of top beam welding production line.The three-dimensional structure, weld form and beam style of the top beam was analyzed, suitable procedures of beam welding production line was drawn up, welding simulation and process analysis for key parts was done, the relevant basic plate experiment was done, determined the actual welding process, confirmed the plate welding characteristics and determined reasonable welding parameters. To further verify welding parameters and confirm welding effectiveness, the fillet welding and single V groove welding which occupies the largest proportion of the weld beam structure was simulated through experiments.(2) Layout design and station implementation of the welding production line.According to welding production practice, production line equipment configuration for the main station was carried out.Based on the requirements of lean production, the entire production line layout was completed. Then the special machine for each main plane welding station of the production line was designed and the main characteristics of each plane was discussed, mainly including the structural characteristics, teaching characteristics, welding properties, etc..Then the production line auxiliary equipment and logistics was designed,including transportation cart,assembling plate,weliding positioner.(3) Kinematics modeling and process simulation of top beam transverse seams welding machineAfter the analysis of structure of top beam transverse seam, equations of motion and the theoretical solution was given. Virtual machine was built using DELMIA software, according to the transverse seam hydraulic support welding process, welding path was planned and simulation implemented. Not only the rationality of the special machine designing was verified, but also realized the virtual debugging, it plays a guiding role in the development and debugging of actual welding machine. The method proposed in this paper has great practical value, and is not only suitable to this machine, but also applicable to other similar welding machine process simulation and verification.(4) Design of welding seam tracking system for locating structure of hydraulic supportTechnology research of current seam tracking finding, exploring the implementation of seam tracking system suitable for hydraulic support seam welding, the seam tracking system based on five surface laser ranging sensor was designed creatively, tracking search principle was illustrated in detail, together with theoretical exploration of error evaluation and compensation, finally, the final tracking system was implemented in industrial applications and could meet the demand of industry. The tracking system is not only applicable for the hydraulic support structural welding, but also suitable for shell structure, such as ship section, engineering machinery. |
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