Weld-planning And Simulation For Roof Spot-welding Of The Urban Railway Carriage

With the continuous development of our national economy, the urbanization of our country is put on agenda, as an inevitable process of urbanized, the urban railway carriage product will have a new period of rapid development. For its low cost, low energy consumption, friendly to the environment, in line with sustainable development and so on, stainless steel urban railway carriage became the best choice of urban rail vehicle. Because the roof is a very important part of the urban railway carriage, a reasonable plan to this station will not only increase the product efficiency but also will save time and so on, it's very meaningful to shorten the entire product cycle, and also a good guidance to the design and plan of other station.With the continuous development of science and technology, globalized and intensified competition, in order to reduce costs, improve productivity and save time, virtual manufacturing technology is being increasingly used in automobile, aviation, aerospace and other fields of actual production, and put forward the concept of"Digital factory". Stainless steel roof station is a typical spot welding robot station, in order to design and plan rationally, we fully study the characteristics of stainless steel roof production, learn the experience of automobile industry, use the virtual manufacturing technology to design and plan the roof of the urban subway carriage in virtual environment..Weld planning involves many factors, such as the workplace structure, welding technologies, welding clamp, robot and so on. So before planning, we should know the roof of the urban railway station very well, we study the roof component and the welding spot on it to make out the influence of the technology characteristics, the number of welding spot, the location of welding spot, the property of welding spot to the weld planning. We analyze the affection of the spot-welding technologies to this station, such as the influence of the welding sequence to the shunting current and welding deformation. We learn the manufacturing resources, such as the robot's position, posture, movement, clash and interference and so on.We design the station of carriage roof, determine the reasonable amount of welding robot, the placement of robot and the placement location., discuss the task and realization of weld planning, in order to improve the rationality of welding robot station and reduce the production cycle to increase the welding productivity, we have to find a good welding sequence. The mathematical model of the welding sequence optimization is travelling salesman problem, we compare the advantages and disadvantages of various algorithms, considering the actual situation of the research, we choose genetic algorithm as the solution of the question, determine the steps, then use the VC++ to implement the program, find the optimal solution of welding sequence.We use Delmia software as a virtual simulation platform, draw on the experience of automobile industry, try to plan and simulate the station of urban railway carriage. First, we finish the physical modeling, create the 3D modeling of the part, fixtures, robots, welding guns and so on, put them into the simulation environment, and make the layout. We simulate the welding process, create the welding path, detect the clash and interfere, adjust the gesture of robot, optimize the robot's trace to obtain a reasonable weld process planning, and do the off-line programming.In this paper, we use mathematical algorithms and visual simulation to plan the station of urban railway carriage roof, this method save planning time and working time, reduce manufacturing costs, improve the robot's capacity, create a considerable economic benefits, it is also a good guidance for the further study.