Design And Research Of Automatic Production Line For U-shaped Ladder Beam

There is a large demand for ladder beams and high requirements for welding quality in mine safety support.However,the traditional ladder beam has the disadvantages of complex welding process,low manual welding efficiency,uneven welding quality and high production cost.In view of the above problems,this thesis designs an automatic production line based on a new U-shaped ladder beam structure to realize the automatic and high-quality production of the new ladder beam.Analyze the difficulties of production line design,and design and plan the overall plan of the new ladder beam production line.The ANSYS Workbench platform is used to simulate the residual stress and displacement of the new ladder beam and the traditional ladder beam,which verifies the advantages of the new ladder beam structure;Based on the existing equipment,the production line is divided into four steps: straightening,shearing,bending,handling and welding.Supplement the hardware equipment that the production line lacks,improve the welding tooling steps of the production line,and design a dual station welding platform.Due to the variety of actual products and the wide range of length and size,in order to solve the adaptability problem of the welding platform,a flexible fixture with one end fixed and the other end movable is designed;In order to meet the requirements of doublesided welding of the new ladder beam,the platform uses a stepper motor to drive the belt to complete the turnover of the fixture.At the same time,in order to meet the movement requirements of the welding gun that can switch freely on the dual station platform,combined with the needs of efficient production,a movable support equipped with four welding guns is designed.ABB IRB1520 ID robot is selected to complete the moving tooling and complete the trajectory planning of the manipulator.To ensure the smooth and stable movement of the manipulator and the accurate position of the moving objects,the mathematical model of the robot is established and the forward and inverse kinematics processes are derived.The trajectory planning method of arc oblique street is used to complete the trajectory planning of the manipulator’s moving process,to ensure the smooth and stable movement of the manipulator,and to achieve the automation of the moving process.The overall control system of the production line is designed to ensure the overall operation of the production line.In order to realize the precise control of welding torch in welding tooling,a fuzzy PID controller is designed based on Siemens S7-200 SMART and fuzzy control theory;The wiring of the motor in the control equipment is completed,the overall control program of the production line is compiled,and the upper computer monitoring system is designed to realize the automatic control of the production line.Finally,combining the design and operation of the production line,the production indicators are formulated;The possible problems of the production line are analyzed and the solutions are given,which provides a theoretical basis for the normal use of the production line.The establishment of the production line ensures that the daily production capacity of the ladder beam is more than 1200 m,which is of great significance to improve the production efficiency of the new ladder beam,standardize the product quality and reduce the cost of the enterprise.