DE102009022927A1 - Welding arrangement for the production of straight and long welding workpieces, comprises four seams welded in defined position or two seams present in a plain, where a radio- or light beam system is installed on the welding device - Google Patents

Abstract

The welding arrangement for the production of straight and long welding workpieces, comprises four seams (20) welded in defined position or two seams present in a plain. The welding arrangement vertically or almost vertically guides towards top or bottom on the workpiece and moves itself along in horizontal direction at the workpiece. The welding arrangement is program-controllable or manually controllable. A radio beam system or light beam system is installed on the welding device or on the front side of the workpiece. Independent claims are included for (1) a workpiece; (2) a welding electrode; (3) a measuring device; (4) a program; and (5) a plant for producing straight and long welding workpieces.

Description

Carrier and Support with non-standard geometries and / or non-standard materials made of individual parts. This is especially true for support structures made of aluminum, stainless steel and special materials.

When Example and for explanation the production of a wide flange carrier made of stainless steel is shown.

The usually occurs and according to the state of the art from material blanks, mostly band blanks with defined lengths, widths and thicknesses.

• – Obergurt
• – Steg (Mittelsteg)
• – Untergurt

A carrier usually consists of three basic parts.

• - upper strap
• - Footbridge (middle bridge)
• - lower chord

upper chord and lower chord usually run parallel to each other at a fixed distance from each other. The bridge is vertical and usually centered on the upper and lower chords, connects both positively and non-positively by welding seams together.

State of the art:

On expensive special welding tables or mounts, the big one personnel can absorb the lower flange placed flat and thereon usually vertical and mostly in the middle of the so-called bridge launched and both very firm clamped to the pad. Optimal two welders staple bridge and bottom strap together. These welders have to work very synchronously, so that the resulting distortion manageable remains. Due to the non-symmetrical design and manufacturing due to heat input and seam shrinkage caused in the weld large tensions. After unclamping the workpiece warps such that with considerable effort usually has to be addressed after stapling. The same Repeats when welding the Upper belt. For the straightening of these usually very large and heavy workpieces is often the time required for judging greater than the for the welding. Because mostly multi-layered welded can, the straightening process can be multiple to repeat.

Extreme The production is difficult with the practiced technology of carriers with defined curvature.

The invention:

investment and method for automatically welding individual parts to supports which latter Straightening the workpiece usually unnecessary

Of the Carrier, respectively its individual parts, is located in its longitudinal extent advantageously perpendicular to the floor. The system welds the individual parts the carrier preferably in the so-called process of rising or falling Seam.

The Control of the system is advantageously carried out by means of program control. All manufacturing and quality-related Parameters are sensibly process-controlled. For simple But components is also possible manually controlled movement and meaningful.

there can the welding system relative to the carrier or move its items or the vehicle or its items through the welding system guided vertically or at right angles.

It At least four burners are preferably used simultaneously. The burners are at the same or intentionally different height level about opposite optimal positions. Other burners, downstream of the former, increase efficiency. in principle is a production on this system possible even with horizontal support. Indeed is an elevated one Wear one Part of the welding nozzles due to expect the "overhead seam".

Description and structure of the system

basic structure

• • welding system with burners
• • Sensor technology
• • Control

The Plant is suitable in highest Efficiently high quality special products from individual parts by welding manufacture.

A frame construction ( 15 ), holds and manages the components suitable for this process ( 1 . 2 . 3 ). Preferably within the framework ( 15 ) are burners ( 4 ), Control of burners, guide rollers ( 8th ) or drive rollers ( 8th ), whose control and motor drive installed.

One, the frame ( 15 ) comprehensive coverage protects against high-energy radiation.

The System is only operated by a specialist.

Description of the functions:

The system is suitable for "stapling" parts ( 20 ) and then in further operations, without chucking the workpiece, ready to weld.

With this system, components ( 1 . 2 . 3 ) with or without "stitches" ( 20 ) are welded.

By the system are advantageously at defined intervals on the workpiece "stapling" ( 20 ) set. Necessity or parameters of "stitches" ( 20 ) depend on the requirements of the material and the workpiece construction.

Between the "stitches" ( 20 ) The system runs in the so-called rapid traverse. "Stapling" can also be performed as a rising or falling seam due to the shortness of the seam. This saves travel and production time.

Thereafter, the formation of the root seams ( 20 ) advantageously by means of four burners ( 4 ). Should further suturing be necessary, multiple roots ( 20 ) or so-called cover layers ( 20 ), more burners are usefully arranged at a defined distance in the system. They weld the cover layers ( 20 ). These burners ( 4 ) efficiently use some of the residual heat of the root seams. Each of the burners ( 4 ) can be controlled individually with regard to its welding parameters, such as welding process, current, wire feed and within certain limits of its geometrical position to the workpiece and to the other burners.

These options are of crucial importance in the manufacture of arched beams, for weld together different material thicknesses and to commute the welding torch for the production of cover layers.

On In this plant and in this process the registered heat of the Arc used particularly efficiently, as the seam roots face and heat can not drain off unused. The heat flow from the Welding processes are symmetrical and prevents or reduces stresses or deformations in the workpiece.

On This system is programmatically possible only routes too welding, that means no consistent To perform longitudinal seams.

These Procedure is useful for special customer requirements or just for "stapling".

As a rule, on a front side of a workpiece is a mostly photosensitive sensor surface ( 12 ) attached. From the welding system ( 15 ), at the guide rollers ( 8th ) and burners ( 4 ) is a concentrated directional or light beam ( 13 ) on the sensor surface ( 12 ). The directional or light beam ( 13 ) generally runs parallel to the longitudinal extent of the workpiece ( 1 . 2 . 3 ).

Resulting stresses and distortion direct the system welding system ( 15 ) and sensor surface ( 12 ) against each other. The controller detects the direction and amount of deflection ( 16 ). With a position correction of the welding nozzles ( 4 ) against each other or change other suitable welding parameters during welding, a correction of the deflection takes place. Thus, workpieces are manufactured with extremely low tolerances. The heat thus registered generates a largely symmetrical voltage pattern. Shape-influencing stresses cancel each other out.

1

band material as upper strap of a wearer

2

band material as a lower flange of a wearer

3

band material as a bridge of a carrier

4

welding torch

5

feeder cable for the welding torch

6

drive movement for the Workpiece movement

7

drive movement for the welding system

8th

drive and leadership roles

9

feed motion of the workpiece

10

feed motion of the welding machine

11

attachment of the workpiece

12

photosensitive surface (Sensor)

13

straightening or beam of light

14

position the directional or light beam

15

frame the welding device

16

Deflection of the sensor surface ( 12 )

17

Underground Base

18

coordinate system

19

right Angle, symbol for 4 × right angle

20

presentation of weld and "stapler"

Assignment of pictorial representations:

1 shows in plan view the arrangement of workpieces and welding torches

2 shows in top view the guides for determining the position between the workpiece and welding torches

3 shows in top view the guides for determining the position between the workpiece and welding torches

4 shows in the side view positions of burners and guides

5 shows in the side view the positio NEN welder with light beam and photosensitive plate on a hanging support

6 shows in the perspective view a possibility of the position of workpiece and horizontal base surface with coordinate system

Claims (22)

The welding device welded four seams in defined positions to each other at the same time The welding device welded at least two seams in one plane The welding device moves on the workpiece vertical or nearly vertical The welding device moves on the workpiece perpendicular or nearly vertical up or down The workpiece moves between the welding device perpendicular or nearly vertical up or down The workpiece moves between the welding device vertical or nearly vertical The welding device moves in a horizontal direction along the workpiece The workpiece moves between the welder in horizontal direction The welding electrodes are in intentionally differentiated position to each other not straight To produce components welding electrodes are in intentionally differentiated position to each other by deviations resulting from different alloys or different ones Compensate for material thicknesses The welding device is programmatically The welding device is controlled manually The welding electrodes are almost moving at right angles to the welding feed movement to Generation of given seam geometries. The lateral electrode movement is program-controlled At the front end of the workpiece or at the welding machine is a measuring device Installed The measuring device registers the position of an incident directional or light beam At the welding device or at the front of the workpiece is a directional or light beam system Installed The directional or light beam points towards the measuring device A program evaluates the position of the directional or light beam out The program controls the positions and movements of the welding electrodes The system produces straight or almost straight long welding workpieces The system is operated by only one welder