ROBOT BASE PLATE WELDING AND DOOR CUTTING COMBINATION MACHINE
The welding system are applied for light pole base plate welding production. By real time communication between robot and welding power, according to different welding position to gain good quality welding seam,.
This machine has six major applications in the production of street light poles, as follows:
Suitable for conical poles, round poles, octagonal poles, polygonal poles, equal diameter poles
|1||Pole min diameter||120mm|
|2||Pole max diameter||300mm|
|3||Pole max.length||12m or 14m|
|4||Pole min. thickness||2.5mm|
|5||Pole max. thickness||
For welding :12mm
For door cutting thickness 8mm, Option=12mm)
The maximum thickness of the expanded tube that can be deformed
Pole max weight
Max QTY of base plate stiffener
Note: If the quantity is large and the spacing of the stiffeners is small and the welding torch is affected, half of the stiffeners can be welded
Size of base plate stiffener
Normal street light poles and high mast are suitable
(Different sizes of stiffener require different molds, which can be processed and manufactured by the user in accordance with the mold provided in the machine)
Reference speed 300~500mm/min
Different thickness and different welding speed
Base plate shape
|Circle, square, octagon, multiple sides of four sides|
Min thickness of base plate
Recommended value, too thin, difficult to weld inside and outside, easy to burn through)
Max thickness of base plate
Suitable for normal poles
Min size of base plate
Max size of base plate
Diameter:500mm, or square plate 500x500.
Option: Diameter:700mm, or square plate 700x700.
Requirements for the consistency of the size of the stiffener and the base plate
Dimension tolerance is within 1mm
It is recommended to use laser cutting or plasma cutting to ensure the consistency of the size to obtain a better robot welding effect
Requirements for the size consistency of the door frame
Generally, the door frame is purchased from outside, and the size tolerance is more than 1mm.
Therefore, it is necessary to manually install the door frame, and after the spot welding is firmly (or after the clamping, the robot will weld again, if the tolerance is relatively small, it can also be directly welded by the robot
(Note: If the dimensional tolerance of the door frame is relatively large, it will cause the gap between the door frame and the door to be relatively large, leading to local leakage of welding, and local manual repair welding is required later)
Regarding the position of the switch plasma cutting,
The maximum distance from the highest point of the door to the base plate
Standard:pipe type cutting(3 axis)
Option flat surface type cutting + pipe type cutting (4 axis)
Door size and shape
There is no limit in the cutting range
Regarding the welding position of the door frame,The maximum distance from the highest point of the door to the base plate
Suitable for pole type
Conical poles, round poles, octagonal poles, polygonal shapes above octagonal, and equal diameter poles are all suitable
Hypertherm Powermax 45
(Made in USA)
Max perforation and quality cutting thickness
|The cutting time of a door on a normal street light pole is 30~40 seconds|
CNC Plasma cutting torch
Arc voltage height controller
Plasma Torch height moving device, 1set
(Including inner and outer welding of base plate, electric door cutting, door frame welding)
Normal street light pole: 12~16 minutes
5G pole: 40~45 minutes
The specific time depends on the size of the pole, the size of the stiffener, and the size of the door
The general layout is as following:
Door cutting plasma: Hypertherm Powermax45,suggestion max. thickness 8mm. Option: Hypertherm Powermax65,suggestion max. thickness12mm.
The maximum pole diameter is 400mm, and square tube maximum size 350x350, the electric chuck inner diameter 620mm, suitable for 5G heavy pole (as 500kg) , Base plate max. diameter 700mm , or square base plate 700x700mm
3. flat surface type cutting + pipe type cutting (4 axis)
can provide production management data: power on time, welding time, cutting time, non welding time, production quantity, etc
After the machine is connected to the Internet, the machine supplier can assist the customer in remote fault diagnosis and remote parameter adjustment. Convenient for customers to quickly resume production.
Robot welding system
1.Kawasaki Robot BA006N (Japanese brand)
BA series is a series of robots developed for welding specially. It is designed for welding specially. It is easy to operate and can achieve skilled welding operation through simple teaching operation. A touch LCD color display screen with excellent visual effect and easy operation is installed on the teaching device. Robot welding machine only need a cable connection, can classify welding conditions of storage, and one key call.
|Teaching methods||Simple Operation Teaching AS Language Programming|
|Manner of execution||Manual mode||Independent axes, basic coordinate system and tool coordinate system|
Interpolation action of each axis/line and
|Storage capacity||8000 steps are equivalent|
|General signal||External Operating Signal||Emergency stop, external hold signal|
|Input and output||32+32|
Kawasaki BA series robots use E01 control cabinet, compact shape, suitable operation system, rich functions, easy maintenance and high scalability. 6.5 inch color LCD screen, touch screen 640 x 480 pixels. Backlighting is used to make the LCD screen easier to see. The operating system adopts WINDOWS CE. The drop-down menu is used for window display, which makes the editing process simple and easy
|Fuctions||Standard arc welding|
|Arm form||Vertical multiple joints|
|Maximum load capacity(KG)||6|
Maximum range of action
Maximum speed of action
|Repeated positioning accuracy [MM]||±0.05|
|Horizontal elongation [MM]||1445|
|Power capacity [KVA]||3.0|
|Installation mode||Ground,Top loading|
|Humidity||35～85%( No dew)|
|Vibration||0.5G以下Less than 0.5|
|Others||Robot installation must be away from the interference of flammable or corrosive liquid or gas appliances|
Range of action
Introduction Collision Preventer of Welding Torch
The 350 welding torch system is a CO2 welding torch, which is commonly used for arc welding in Asia.
The replaceable gun neck welding gun system has the advantages of high rated value and high duty cycle: intelligent interface can realize fast maintenance and repeatable positioning functions, and shorten downtime
The welding gun system has a variety of gun necks and holders for all common machine joints to choose from.
(1)Typical Asian CO2 welding design
(2)Replaceable gun neck can shorten equipment downtime and reduce maintenance and repair costs
(3) Optimal temperature characteristics ensure long service life of wearing parts
(4) High-quality cable assemblies ensure a long service life of the system
(5) Rugged welding torch structure can achieve high collision stability
|Rated value||350A CO2|
|300A (mixed composition)|
|Welding gun neck||35°|
The NBC-350RL robot special welding machine has two welding modes: low spatter and constant pressure, which can realize carbon steel rich argon and CO2 gas shielded welding. This product adopts an all-digital control method, which is highly adaptable and can communicate with the arc welding robot through a digital/analog interface.
(1)Can be matched with Kawasaki robot
(2)Numerous types of digital interface control can directly call the welding parameters stored by the customer
(3)Very small welding spatter, beautiful welding seam shape
(4)Optimized arc ignition, arc closing and ball removal functions
The fully digital control system realizes precise control of the welding process and stable arc length.
Powerful digital error reporting function, a variety of faults have error codes to display.
The system has a built-in welding expert database and automatic and intelligent parameter combination.
Friendly operation interface, unified adjustment mode, easy to master.
Soft-switching inverter technology, the whole machine is highly reliable, energy-saving and electricity-saving.
Welding power parameters
Rated input voltage/frequency
|2||( KVA)Rated input capacity||14|
|3||(A)Rated input current (A)||21|
|4||(V)Rated output voltage (V)||31.5|
|5||(%)Rated load duration (%)||60%|
|6||(V)Output no-load voltage (V)||96|
(A/V)Output current/voltage range (A/V)
|8||(mm)Welding wire diameter (mm)||0.8,1.0,1.2|
|9||Wire feed type||Push wire|
|10||(L/min)Air flow rate (L/min)||15～20|
|11||Torch cooling method||Air cooling|
Dimensions L*W*H (cm)
|16||EMC emission level||A|
Option:Gun cleaning, wire cutting and silicone oil spray device
As the picture shows. The gun cleaning and silicone oil spraying device is used to clean the splash in the nozzle of the welding torch and spray anti-splash silicone oil into the nozzle. The wire cutting device is used to cut off the small ball at the tip of the welding wire and ensure that the dry elongation of the welding wire is consistent, to ensure the success rate of arc starting and the stability of the welding process, as well as the accuracy of the detection at the beginning.
1,Grounding: C grounding, grounding resistance less than 10 ohms.
2,Welding wire: disc-mounted wire
3,Use of environmental conditions (indoor)
Relative humidity:≤80%..No dew
Programming and Workflow