Solder the robot application in Chang'an car joint-stock company and existence problem

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1, the progress of the preface development as the society and science and technology, robot in the society each domains received increasingly wide application, and application is most is industrial robot. Since industrial robot comes out at the beginning of 60 time oneself, passed 40 old development, apply extensively already at industrial domain, become automobile manufacturing industry to produce the main Electromechanical unifinication equipment in automation. The main purpose of robot of production industry application is producing personnel at cutting down work out, improve labor productivity, reduce labor intensity to reach improve product quality. Robot and traditional machine photograph are compared, have two main good points: 1) implements the complete automation that produces a course easily. 2) gets used to ability to producing the height of equipment. 2, solder the robot solders the robot is at present the biggest industry robot uses a field. Because automobile manufacturing industry is right of a lot of component solder the index such as precision and speed raises taller and taller requirement, average worker already was competent hard this one job; In addition, the scintilla when soldering and aerosol, cause a harm to human body, accordingly, solder the complete automation of the process already made main research task, among them, most important is to want application to solder robot. 3, receive the robot application in Chang'an car joint-stock company 3. 1, KUKA robot receives on-line application in 100 thousand minibus solder 1996, chang'an car joint-stock company builds minibus of miniature of series of 100 thousand SC6331 to solder product line, this line introduces robot of spot welding of pneumatic of the KRC32 of German KUKA company 6 axes first, application is on the frame with craft top demand and wiring of the solder that become a vehicle. On wiring of original and manual solder, frame adds a solderer and add a solderer into the car because solder check the number is measured much, solder spare parts structure is complex, it is the bottleneck labour that restricts all fronts production, worker basic cycle time intensity of long, labor quality of drop of tall, solder does not stabilize fault rate of big, equipment and cause easily touch press, restricted the manufacturing rate of all fronts badly, product quality also is couldn't get assure. After introducing robot of KUKA spot welding, above all, the manufacturing metre of wiring of 100 thousand solder rises considerably, the Chanbansheng of miniature minibus produces an amount to increase considerably, achieve 5 times of crop of manual solder wiring; Next, labor intensity of the worker gets be reducinged considerably, working hours shortens greatly, working requirement gets great improvement; The 3rd, miniature minibus quality gets rising significantly, automobile body is touched press an injury to be reduced greatly; The 4th, KUKA solders robot fault rate is extremely low, spare parts is supplied enough, systematic stability is tall, it is easy that the operation is safeguarded, many and managing equipment maintains staff, managing manpower resource. 3. 2, robot of COMAU, KUKA, OTC solders in 80 thousand stars of Chang'an on-line application introduces KUKA to solder in the success after the robot, chang'an car joint-stock company is in SC6350 - " the star of Chang'an " deliver a child of 80 thousand solder produces a line to go up to be introduced again solder robot, include robot of spot welding of H4 of Italian COMAU company servo among them, robot of solder of column of H1 of Italian COMAU company snail, japanese OTC arc welding machine implement person, KUKA company KRC detect robot. SC6350 solders 80 thousand times the applied level of the robot on the line is advanced, robot of servo solder clamp, arc welding machine implement person, detect the robot is the delegate with the at present most advanced level of application of robot of domestic automobile industry. Among them, detect the robot is used at present on international advanced online detect means, application detects of technical world's lead German Perceptron company detect the German KUKA robot with equipment and systematic highest stability is integrated, in masterstroke (into the car) the last labour of solder wiring online real time detects each " the star of Chang'an " white automobile body, in order to control precision of automobile body dimension. It is normal that testing system designs white automobile body 2mm of dimension deviation ± , when out of tolerance of dimension of white automobile body, product line will call the police clew, and testing system lieutenant general stores the measurement of every white automobile body data, analyse in order to offer from the line. Arc welding machine implement the DR series that the person introduces Japanese OTC company robot of 7 axes solder, design of OTC robot noumenon is cabinet, the structure is understood simply, arc solder function is all ready, special agree with the component gas protection with complex structure solders. The arc solder of the join beam that goes up like assembly of structural frame of SC6350 series small car, because this beam is a circle, need undertakes circumferential solder, and this component position is inferior, solder artificially labor strength is great, gas protects solder to belong to poisonous exercise again, use OTC arc welding machine implement the person overcame these to restrict production badly, cannot assure product quality, damage the defect with healthy handlers. Of robot of another servo spot welding that those who deserve attention is high accuracy, high reliability introduce, this model robot chooses robot of COMAU company H4 spot welding, system of clamp of solder of integrated SIAKY servo, solder spot welding receives quality stable, location is exact. Servo solder clamp and photograph of pneumatic solder clamp compare the most outstanding characteristic, it is to soldering in the process, of servo solder clamp solder quality is high, solder dot figuration is good, great those who improved white automobile body solder quality, make " the star of Chang'an " the small car high-quality goods that be worthy of makes China. 4, solder the applied experience of the robot solders the robot already had 7 years of time in the application on product line of Chang'an company car, according to actual application, a few experience study together for everybody under: 4. 1, solder the use of the robot, must satisfy safe requirement to solder the robot can replace the mankind to work in dangerous, harmful harsh environment, brought another kind of potential risk again at the same time, namely the robot hurts human affairs reason. For this, soldering the robot is online when moving, absolutely cannot somebody enters his to move safe limits is in area, and its move extent a person operating from within in coordination with outside forces should assure experience of have nothing to do with, this is to solder a most important principle that robot safety manages. In addition, besides current industrial safe practice, notice to solder even the characteristic of the robot, take corresponding and reliable the way to deal with a situation. For example the safety precaution that we are using now: (1) to solder robot and safety of its peripheral installation defend column, enter dangerous area in order to prevent someone to cause accident harm. (The setting on the exit that 2) protects column to enter the mouth in safety is inserted unplug switch of form report contact, this switch and solder the join of photograph of road of safe wire back of the robot, once exit is opened, robot controller will cut off the drive power source of the robot, the robot suspends campaign instantly. (3) is in be apart from solder robot place is versed in a recent place, installation many urgent stop switch, once produce urgent or hazardous condition, the staff member is OK nearby presses stop urgently, let a robot suspend campaign. (4) is shown when teaching school assignment, reduce solder the athletic speed of the robot, undertake showing teaching by the personnel that grooms through professional technology operation. (5) solders robot safety circuit and couplet of circuit of product line safety are an organic whole, when product line encounters emergency, manufacturing worker can press this line assumes office why to be versed in urgent stop switch, let a robot suspend campaign. 4. 2, solder although the control equipment of the robot solders robot itself owns very perfect control system, but every solder the automation equipment system that the robot becomes independent as, an appurtenant workstation is only forever in a product line or system of a production, must want to corresponding peripheral control equipment undertakes be controllinged remotely to its, in order to get used to all sorts of automation on line of automation assembly line production synchronous, orderly production asks between equipment. Solder the relevant control equipment with commonly used robot has but program controller and online supervisory and control arrangement. Can make up Cheng controller to solder to including on product line robot inside the job of all sorts of automation equipment undertakes harmony with cooperate, implement the automation that produces a course in order thereby. Online supervisory and control arrangement is the man-machine interface between handlers and manufacturing system, it collects real time data from inside producing a system, can be opposite conditionally manufacturing data undertakes real time is revised, achieve real time to monitor circumstance of product line spot, long-range real time dominates the end that product line runs consequently. Use online supervisory and control arrangement to be able to issue exercise statement conveniently, start or stop to include to solder robot inside all automation equipment, know the position that produces a system in real time. On the astral solder wiring of 80 thousand Chang'an of Chang'an company, use CC of 　 of Xi Menzi WIN online supervisory system and Xi Menzi can make up Cheng controller, all soldering the robot moves automatically besides the control that gets oneself to control a system outside, still must accept can make up Cheng controller and WIN 　 CC the long-range control of online supervisory system, in order to make sure the synchronism of as automatic as product line other equipment moves. 4. 3, solder of robot system patulous to satisfy Chang'an company 80 thousand " the star of Chang'an " the effective demand of solder wiring, when COMAU company is undertaking controlling systematic design, the stability of the stability that considered product line system at the same time and quality of product of white automobile body, choose finally solder the robot has the following and patulous function: (1) increases exterior and slip axis to solder the exterior and slip axis of the robot and other 6 basic axes are same, all contain servo driver and servo electric machinery, close suitably with corresponding mechanical gearing, can enlarge the territory of the robot effectively, and can be inside complex or cramped space achieve first-rate exercise attitude, still can teach through showing will locate arbitrarily, in order to maintain highest fixed position precision. Apply actually in spot welding in, those who include exterior axis drive solder robot can accurate reach a place of spot needing solder, achieve optimal solder attitude, spot welding effect is consequently better and splatter without noise and solder drop, the solder dot shell after soldering is beautiful, solder quality is high. For example, masterstroke of wiring of 80 thousand solder 730 always spell labour, use full automatic component to assemble with welder art, this labour share 6 COMAU to solder robot, should finish left / of right side wall and frame assemble those who reach whole white automobile body to solder, together with is versed in included coping to assemble, frame assembles those who reach other part, the device such as clamp of clamping apparatus, conveyor, automatic solder is numerous, the space is extremely limited, to assure car group solder, shared 4 robots to use slip formula exterior axis, in order to be inside cramped space, high quality, high rate, most complete all works surely. (2) arc solder swings mediumly solder arc welding machine implement the proper setting that the person passes software, can be while edge welding line is ongoing, welding wire is most advanced implementation is transverse swing, wobbly means, frequency reachs extent to wait to all can ask to have set by craft, achieve the goal that improves arc solder quality thereby. (The tool of 3) robot is automatic switch is likewise in wiring of 80 thousand solder 730 labour, for managing work place, shorten working hours, 15 (16) solder the robot should be finished at the same time always go all out be versed in the welder of a white automobile body is made, want to be in charge of from side wall product line pays side wall part and putting masterstroke and frame, coping to assemble again, consequently these two solder the robot used the world to precede " gun / hand " automatic switch technology, by the control when can making up Cheng controller to need in product line the robot undertakes the automatic switch of servo solder clamp and grasper tool. Such, a robot can finish two robots to need finished work, already managing cost managing field. 4. 4, the KUKA robot on the wiring of 100 thousand solder of company of process designing Chang'an of the robot, its process designing uses the APS software below WINDOWS operating system, those who use a program must make carrying go up below WINDOWS environment carry reach download; The process designing of the COMAU robot on wiring of 80 thousand solder uses aleatoric text editor, after repass is compiled, with PCINT computer emulation software downloads the program robot controller. The common characteristic of process designing of these two kinds of robots is all can come true process designing leaving a line, online show religion, the design that is product line and emulate provided effective help. Different point depends on, COMAU robot used the language structure of similar PASCAL advanced programming language, for the person that passes computer programming language to learning, can understand easily, accept a few the basiccest after grooming, can weave quite perfect robot controls a process namely. And KUKA robot uses programming language of its appropriative robot, technical personnel must accept the process designing of KUKA company major to groom, ability competence process designing works. The control program process designing of OTC robot is relatively easy, use the athletic statement that understands simply, easily basically, meaning be clear at a glance. 4. 5, the robot of 5 KUKA spot welding that the success of servo solder clamp introduces the application on wiring of 100 thousand solder, all use clamp of pneumatic spot welding to undertake bodywork solder, because cap of solder clamp electrode is put in tatty problem, control system uses computational solder check the number, to soldering electric inpour increases by degrees all right type compensatory method. Tell from the principle, this is the compensation method of means of a kind of open loop, can not reflect the actual loss condition of cap of solder clamp electrode actually, consequently bodywork solders the instability with quality constant presence. On wiring of 80 thousand solder, average per capita of machine of all COMAU spot welding uses the servo solder clamp of SIAKY and control system. Servo solder clamp exists as a of the robot exterior axis, software of a drive increases in robot control system, this are exterior axis with other 6 basic axes are same, get the control of robot controller completely. Such, exterior axis and this other a be in harmony is 6 axes an organic whole, the robot controls a system to pass the drive software of exterior axis, can calculate in real time the real position of this axis. In applying actually, after the welder that finishs each bodywork is made, robot control system will be outside to this axis - servo solder clamp, execute automatic and corrective function, through checking this axis (servo solder clamp) actual the position produced change to affirm whether electrode cap wears away at 0 o'clock, ensured so solder the automatic closed-loop control of pressure, make bodywork solders quality stability rises considerably. 4. 6, application solders robot implementation is flexible car of miniature of manufacturing Chang'an company is phyletic much, breed is mixed, be in before on manual product line, if need to mix a line to produce the model with same different and phyletic type, solder artificially speed because of the difference of workpiece, tool reduce greatly, car product quality of production also presents an instability subsequently. Introduce solder after the robot, need those who get used to different model to produce place to need to had woven beforehand only a certain number of covering different motion and solder program, the robot will dictate according to the job of product line, call corresponding working program and different bodywork automatically to solder requires tool, namely the complex variation of the model on can self-reacting product line, even if on wiring of 80 thousand solder high frequency second, the production confusing a line of much more phyletic model, also can rise to the occasion. The wrong solder that because Chanbanduo is planted,won't produce manual line to appear extremely easily absolutely, leakage solder and be adjusted by accident or do not adjust the bodywork that solders to often appear the standard to solder quality accident, speed of product line movement also a bit won't be reduced. Solder the wide application of the robot, the car that is Chang'an company makes implementation flexible automation production brought unprecedented lease of life. 5, solder although the problem that the robot exists in application solders the car that the robot is in Chang'an company gets applied extensively in production production, make the car solders quality got great improvement, the labor that increased a business effectively manufactures efficiency, but the problem that still has a lot of sides is worth us to study further and be improved. 5. 1, taught problem is shown afresh after positional deflection religion emersion solder if the robot happens solder when positional deflection, must undertake online show religion next emersion moves, this job needs to take up now many manufacturing time. If can use advanced computer trends to emulate a technology to make be showinged from the line teach and be emulated to its, will be to solder of robot application to be improved revolutionarily. 5. 2, arc welding machine implement the problem that person welding line dogs. Show instruct emersion arc welding machine implement when the person undertakes arc solder, cannot undertake to welding line trends dogs feedback, when consequently welding line has slight change, quality of unwarrantable welding line, if can use intelligent technology, trends dogs welding line condition, with respect to the dependability that can assure arc solder quality effectively and stability. 5. 3, solder the spare parts problem of the robot. Current, because the application of domestic robot still is not very extensive, domestic robot technology still remains at great progress, the special component home of the robot still cannot be designed by oneself make, a large number of Chang'an company application solder after the robot, fittings problem becomes the most headachy issue in robot application. Because the component of the robot belongs to special component more (especially electric equipment controls partial) , technical level demand is quite high, must import from abroad consequently, and the tall look forward to of price of robot spare parts of the entrance, domestic representative company does not wish to cause capital keep long in stock because of be being purchased beforehand in great quantities mostly, the time cycle that imports spare parts grows again, caused quite great difficulty to car product line. 5. 4, the school axis process of the robot takes up overmuch time. Robot of the KUKA that Chang'an company place applies, COMAU, OTC, the corrective process of its axis all needs to expend longer time, for the automatic product line that turns to running water, the pecuniary loss that its stop machine place to cause is very huge. If can apply what tall intelligence changes,detect method, make the robot is in after the basic parameter of its axis is lost or changing, can regain the position to the front of malfunction automatically quickly, will bring tremendous manufacturing benefit to automation product line 5. 5, the problem of system of control of robot electric equipment. 3 kinds when Chang'an company place applies solder robot, its are noumenal mechanical dependability and production level homogeneous phase are become tall, noumenon occurrence breakdown (point to mechanical failure) probability is extremely tiny. However, under photograph comparing, the fault rate of electric control system is very high however, the circuit that the part that appears the most easily is drive part reachs yuan of parts of an apparatus, the breakdown frequency that receives plug-in unit additionally is quite tall also. The robot control circuit on current world is compositive change rate taller and taller already, the ceaseless progress that controls a technology already made control part fault rate is reduced greatly. But in be being made to the car solder exercise this kind of environment intensity of abominable, exercise for the application with bigger wave motion of great, voltage, if can be aimed at the particular case that the car produces, improve a system further compositive change rate, enhance the ability of systematic interference rejection further, chang'an company applies a large number of robots to come true not to have the ideal that the person turns product line completely to will turn into in future reality. 5. 6, robot and other equipment or labour go up fraise collision problem. On the two solder wiring of Chang'an company, all had appeared for many times to exchange error and produce the accident of robot and robot collision, robot and other equipment or fraise collision because of signal. Analyse robot work program through after the event, when discovering at present the robot controls a system to be exchanged in processing signal, use exterior I/O signal to exchange each other job status, signal detects still is only with " dot " means is measured, it is namely in travel of some exercise program, affirm certain exchanges signal to whether exist will decide whether the robot continues the job below, is not detect continuously in section of a sports other fraise or robot condition, such, once detect,the athletic contrail of the robot produces a mistake or when signal exchange is abnormal, collision happened. The applied scale of the robot is larger and larger now, the circumstance that much stage robot works in coordination inside cramped space is increasing, signal exchange already became extremely common between each other, if can be in the control system of the robot, the tiring-room that uses operating system of similar Microsoft WINDOWS handles means to monitor the working status of other fraise or robot in real time, work in order to decide whether the robot should continue inside the area that interferes likely, collision problem should gain effective control quite, solve this problem thoroughly even. The place on put together is narrated, solder the robot makes big batch of automobile manufacturing industry, efficient, high quality undertakes automation line car is made provided advantageous safeguard, in the meantime, solder the robot reveals exposed problem in applying actually, also make us try hard to learn an advanced technique ceaselessly, seek more significant step ceaselessly, let solder the robot is automobile manufacturing industry of China to make larger contribution. CNC Milling CNC Machining