Design And Implementation Of Automobile Body Flexible Welding Workstation

With more and more automobiles,people’s demand for automobiles today is also diversified,and the traditional large number of single production methods can no longer meet different needs.How to realize rapid shifting in production is a major problem facing by auto plants as vehicle models iterative upgrading faster and faster.Automobile manufacturing has the problem of high investment in equipment and low flexibility of fixture.In order to realize quick production swatch,production line requires great flexibility.Therefore,flexible welding workstation is proposed and used as the basic unit for flexible production line to solve the problem of poor flexibility of equipment and slow switch.The design and implement of flexible workstation has practical significance for automobile plants in improving the production line utilization rate and reducing investment.This paper starts from the function realization of flexible welding workstation and finish the layout of the workstation,key equipment type selection and flexible fixture design.Through verifying the layout,type selection and design by using of software ROBOGUIDE,outputs installation files to guide the equipment installation and commissioning on site.And finally verify the rationality of the flexible workstation by vehicle body welding.The major research content of this paper includes:(1)Layout of flexible welding workstation.The major components of flexible workstation are robots,locating fixtures,welding equipment(welding gun)and other auxiliary equipment.Flexible body frame merging station layout design is completed according to the rules of workstation layout,robot selection process,resistance spot welding principle,robot welding gun selection etc.Finally evaluate the work of flexible robot welding station and check the flexibility rationality.(2)The design of flexible fixture and griper in workstation.Flexible welding fixture is the key equipment to realize flexible workstation.According to fixture design principle,complete the math data model building of locating structure,clamping structure,griper and switching structure of merging station in UG.Finally,according to the MCP requirements of the platform of BIW,complete the merge location with flexible fixture design positioning platform model.(3)The simulation and off-line programming.Through building simulation environment to do the interference check of robot moves and payload verification.And verify the preliminary design plan feasibility according to the simulation results.Outputting simulation deliverables after comprehensive simulation and use it to guide the field equipment installation,debugging,improving commissioning efficiency through offline program.Investment risk is greatly reduced by accelerating the process of put into production so as to ensure the smooth production of the product.(4)Establishment and application of welding parameter database.By defining the material and thickness of the dominant welding plate,finding a quick approach for parameters selection and thus reduce the artificial influences.Establishing the welding controller parameter database by serialization of current and pressure parameters in welding and then welding robots invoke parameters from parameter database directly.(5)Construction of the workstation control system.Specifying control system structure,including the power distribution part,control part and network parts.Design the control system of body frame merging station according to the specification.Design mechanical protection and electrical protection for the workstation to ensure the whole workstation equipment can run smoothly and safe.