Research And Development Of Welding Workstation For Aluminum Alloy Structural Parts With Long Weld Seam

Aiming at the problems in welding of aluminum alloy structures with long weld features,a special welding workstation based on welding robot is developed in this paper.First,the welding process analysis and workstation layout planning are carried out according to the size requirements and welding characteristics of the workpiece.The automatic welding workstation including welding robot,CMT welding power supply and the external axis is designed to improve the welding efficiency.Through the design of two workstations and dual robot welding,the production rhythm is 130s/p,which meets production requirements.Secondly,according to the characteristics of the energy absorbing box parts and bumper assembly,the positioning and clamping side strategy is analyzed,and a special tooling is designed.According to the body of the robot,the D-H parameters of the robot are obtained.The parameterized model of the robot is established and the welding trajectory simulation and collision detection are carried out.The design of the tooling and the variable position machine is improved.Third,according to the characteristics of bumper main beam with long weld,the welding temperature and strain fields are simulated.According to the results of simulation analysis,the heat transfer from long weld under natural condition to the model is determined.In order to strengthen the heat dissipation and reduce the welding deformation and thermal stress,stainless steel is used as the material of the imitation die mold,and the water cooling channel is set up to further accelerate the rate of heat exchange.A special mold closing water-cooling tooling and sliding table for station switching are designed to improve welding accuracy.Finally,the welding workstation and related tooling were developed and applied to the actual bumper welding process.