The hottest welding robot shortens the manufacturi

2022-08-16
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Welding robot reduces the production and manufacturing time

editor's note: for a long time, the fillet weld and v-weld welding completed on the heavy gas turbine have been welded manually. Now, after the welding robot is installed on the C-shaped support, the welding time is reduced from 114h to 80h, and the subsequent cleaning workload is also reduced by 10%., It can replace manual welding to complete 80% of production tasks

the working hours of welding robots working on C-shaped supports almost 10m high are reduced by 35h compared with manual welding

with the aggravation of the global energy crisis, energy production technology conducive to environmental protection is becoming more and more popular. For a long time, gas turbines have been used to generate electricity in large thermal power plants, and countries with rich natural gas reserves use their rich natural gas resources and gas turbines to generate electricity, and export the remaining electric energy abroad. It can continuously maintain the development of its infrastructure. At present, Siemens gas turbine can generate 340kw of power, and it is also the world's largest gas turbine engine with the largest power generation. Such gas turbines can supply electricity to the residents of a city

gas turbine parts made of high-quality stainless steel weigh about 30t and have a diameter of 5m

in order to manufacture more gas turbines, Siemens company continues to optimize its production process and invest in the purchase of advanced production and processing equipment. Among them, the robot welding production equipment developed and produced by CLOOS company can accurately complete the gas turbine parts with a weight of 30t, The casing of the gas turbine can be welded faster

originally, the fillet weld and V-shaped weld with a length of about 340m were manually welded by the welding workers, so the welding workers had to pay great physical labor. After the use of welding robots, the quality of welding has been greatly improved, and the cleaning of welded seams has been reduced to a minimum. The benefits of robot welding can be expressed by the following figures: the welding man hour is reduced from 114h to 80h. The workload of post weld cleaning is reduced by 10%

according to the CAD part data of Siemens, CLOOS developed and designed the control program of the welding robot in the offline mode

moving on the C-shaped support

in order to obtain the best welding effect for the gas turbine parts with a diameter of 4m and a height of 2m, CLOOS installed the Roman 350 robot on the C-shaped support with a height of about 10m. Under the joint action of the foundation, the lifting mechanism, the lateral motion mechanism and the rotary reverse workbench, the crank arm robot can complete 80% of the welding task of 30t parts. The Romat welding robot arm adopts an articulated head structural design, and scaled carries a unique new aircraft for the first time every year, with six axes of motion freedom. The third coordinate axis of model 350 has also been further extended, and the working range has been expanded to 2200mm, which has the best accessibility in the processing of large workpieces. The dynamic servo drive system enables this welding robot to bear a 15kg welding manipulator, and the precision integrated drive device provides a repeated positioning accuracy of 0.1mm. The rotrol II robot control system controls the movement of the robot with six basic coordinates and 12 assigned coordinates, such as the movement of the torch positioning system

the six coordinate motion control of the robot enables it to approach those welding parts that are difficult to access. Only 20% of the welding workload of the whole part needs manual welding

according to the CAD data of the welded parts, CLOOS company has simulated the position of the weld and the quality control program when developing and manufacturing the welding robot, which greatly reduces the parameters that need to be changed when debugging according to the actual workpiece. Therefore, this measure significantly reduces the time of equipment debugging. For example, in the field debugging of different welding accessories, with the help of robots and positioning control systems, only 20% of the welding tasks of the whole part need to be manually welded. In order to facilitate the manual welding of welding workers, Siemens also specially designed a lifting platform, which can bring the welder to the air with a height of 6.5m for welding

beneficial help of active gas

fillet weld and v-weld welding of welding robot in most cases, MAG active gas shielded welding of three-layer weld is used, and then the surface cleaning process is applied to the experimental machine. In order to ensure the best welding effect of this welding process, according to the form of the weld and the welding depth, the duo drive duplex wire feeding mechanism can continuously output the molten welding wire solution according to the changing welding depth. In addition, the shielding gas used in welding is also mixed with a certain amount of active gas, which has a beneficial impact on the welding quality. The mixed shielding gas used by Siemens is composed of 78% AR, 20% CO2 and 2% he, which ensures the reliable welding of thick wall stainless steel parts. At the same time, the tactile sensor can reliably find the starting point of the weld. The arc sensor is responsible for tracking the weld and controlling the welding head for welding, thus reducing the requirements of Siemens for weld preparation and weld width

the welding power supply with a large number of sensors and dual drive drahtzufuhr technology and 600A welding current ensures high welding quality

microprocessor controlled welding power supply

Quinto GLC 603 welding power supply can provide a maximum welding current of 600A and has sufficient power reserve. The extremely fast welding characteristic control program adjustment and microprocessor control system structure become the basis for the best welding of welding equipment according to the weld and the material to be welded when the stress reaches the highest point. In a large LC display screen, the operator can see all the text information about the welding operation. The remote control guarantee can be divided into simple beam zigzag experiment and pure zigzag experiment. The operator can input 20000 working parameters quickly and easily. Thus, the quality control parameters entered at one time can be called at any time. In addition, in order to enable Siemens' employees to be familiar with and master this new welding robot, CLOOS' Berlin office has provided an internship robot for gas turbine manufacturers. Thus, the production plant can use this practice robot to teach, practice and optimize the working parameters. At present, Siemens is still using this internship robot to carry out various welding tests and research and development of welding technology

15min later, it can work at full load

Figure 5 Siemens sgtf gas turbine

the power range of the gas turbine produced by Siemens is 68 ~ 340mw. The 440t 340mw gas turbine is 13m long and 5m high. Compared with thermal power generation and nuclear power generation, gas turbine has the advantage of high efficiency and good possibility of regulation and control. It only takes 15min for the turbine to work at full load after startup. When starting, the generator is first used as a motor to drive the main shaft of the turbine to rotate. The precision impeller of the multi-stage compressor produces a certain amount of compressed air. After igniting the gas, the turbine continues to rotate until it stabilizes at its maximum speed and drives the generator to generate electricity. The exhaust gas with temperature up to 600 ℃ will be recycled: steam is produced by the heat exchanger and sent to the steam turbine at the back end of the gas turbine for power generation. The efficiency of the gas turbine, which is already very high and almost 40%, has been further improved: the total efficiency of the whole generator set is as high as 60%. In addition, Siemens' gas turbine can also adapt to the energy carrier used in the primary end. Gas and fuel oil of different quality can be used as the energy carrier for power generation. In the future, it is possible to use the combustible gas produced by coal to generate electricity

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