| The aluminum alloy thin-wall booster shell structure is widely used in the booster system of large launch vehicles.In response to the requirements for longitudinal seam welding of large rocket booster shells proposed by Capital Aerospace Machinery Company,this paper completes the design and application of an automated longitudinal seam welding system for booster shell segments,which effectively improves production efficiency by reducing failure problems caused by welding quality.This paper analyzes the welding process of three welding methods such as variable-polarity TIG flat welding,variable-polarity plasma arc deep penetration vertical welding,and variable-polarity plasma arc perforated vertical welding to determine the required functions of the welding system and use welding test pieces The shape and size are based on the design plan and performance index of the equipment.According to the determined design plan,based on the concept of flexible manufacturing,the mechanical structure of the system was modularized,and the threedimensional drawing software Solid Works was used to virtually assemble the mechanical structure.At the same time,the optimized design of the plasma welding machine was completed,and it was successfully applied to the welding walking parts of the molding system,thus completing the structural design of the entire welding fixture.Using the theory of reliability analysis,the mechanical reliability of the whole mechanism of the longitudinal seam welding forming system of the booster shell is analyzed.Based on the ABAQUS simulation software,finite element analysis of the main load-bearing components in the mechanism's overturning motion is performed to complete the stress analysis of the structure;through mathematical modeling,static load analysis and calculation,and dynamic kinematics simulation based on Adams,the overall mechanical structure size and overturning are determined The structure selection of the power element servo electric cylinder completes the strength calculation of the mechanical structure.The construction of the welding operating system includes the control system of the welding tooling,the motion control of the welding machine and the compilation of the welding control program.The modular control program increases the stability of the equipment operation.On this basis,a humanized human-machine interface is designed for setting process parameters and monitoring operating status.In order to further improve the welding environment and improve the welding quality,the laser arc height control is designed into the control system of the welding machine,which can realize the automatic adjustment of the arc height.At the same time,a welding process acquisition system based on Ether CAT and a dedicated welding video monitoring system were introduced to greatly improve the welding quality and efficiency.Finally,through the welding commissioning experiment and excellent forming welds,the application reliability of the forming system is determined,and the acceptance task of boosting the longitudinal seam welding forming system of the shell section is completed.Starting from the actual needs of the project,this subject combines scientific theoretical analysis to design and manufacture a special welding system for aerospace welding with practical application value. |
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