60吨焊接变位机设计开题报告

欢迎下载本文档参考使用，如果有疑问或者需要CAD图纸的请联系q1484406321编号无锡太湖学院毕业设计（论文）相关资料题目： 60吨焊接变位机设计 信机 系 机械工程及自动化专业学 号： 0923237学生姓名： 朱 斌 指导教师： 尤丽华 （职称：副教授 ） （职称： ）2013年5月25日目 录一、毕业设计（论文）开题报告二、毕业设计（论文）外文资料翻译及原文三、学生“毕业论文（论文）计划、进度、检查及落实表”四、实习鉴定表无锡太湖学院毕业设计（论文）开题报告题目： 60吨焊接变位机设计 信机 系 机械工程及自动化 专业学 号： 0923237 学生姓名： 朱 斌 指导教师： 尤丽华 （职称：教授 ） （职称： ）2012年11月25日 课题来源 本课题来自无锡华联精工机械有限公司的生产实际。目前机械行业，特别是锅炉行业有大量的管和板的焊接，管子和板的接合处为环缝焊接，为适应自动焊接，管与板要自转，同时要倾斜45度，满足船形焊接，要求设计该设备。科学依据（包括课题的科学意义；国内外研究概况、水平和发展趋势；应用前景等） 在焊接过程中，我们经常会遇到焊接变位以及选择合适的焊接位置的情况，为了解决这一问题，焊接变位机就理所应当的出现。它可以通过工作台的回转和翻转，使待焊处置于合适位置，很好的和焊接设备结合使用，实现焊接的自动化，机械化，提高生产效率和焊接质量。概括来讲，焊接变位机就是移动工件，使之待焊部位处于合适的位置的焊接辅助设备。现在我国生产变焊接的厂家已经不少，但都不成规模。以变位机为主导产品发展起来的企业，尚未形成。天津鼎盛公司工程机械有限公司、无锡市阳通机械设备有限公司、长沙海普公司、威达自动化设备有限公司等单位生产的变位机在国内占有较大市场。到2010年，国内已开发的变位机产品约130余种规格。然而在国际上，包括各种功能的产品在内，有百余种系列。在技术上有普通型的，有无隙传动伺服控制型的；产品的额定负荷范围达到0.1KN18000KN。在先进工业国家，焊接变位机已标准化、系列化，并由专门厂家生产，技术指标先进，品种规格齐全，不仅有各种结构形式的通用焊接变位机，也有配合焊接机器人使用的高精度变位机。比较有名的国外公司有：瑞典的ESAB、意大利的ANSALDO、德国的CL00S、奥地利的IGM、美国的LINCOLN和日本的 机械株式会社 。他们的产品，我国都有引进，其中以引进ESAB公司的较多，兰州石油化工机器厂在1991年就引进了该公司生产的30t焊接变位机；四川东方锅炉厂为了核电站反应容器的生产，1997年也从该公司引进了100t的焊接变位机，长春焊机厂还从日本引进了生产焊接变位机的技术。配合焊接机器人使用的焊接变位机，在我国几乎都是作为焊接柔性加工单元(FMC)和柔性加工系统(FMS)的组成部分一并引进的。据1995年的不完全统计，已引进约200多台，主要用于汽车、工程机械等有关结构的焊接。 我国引进的焊机器人柔性加工单元中的变位机，也是针对特定产品研制的，因此价格较昂贵，而技术培训及售后服务却不理想。在技术方面，我国许多工厂引进的弧焊机器人系统己具有机器人与变位机协调运动的功能。这对一些空间曲线或较复杂的焊缝可以始终保持在最佳位置下进行焊接，以提高焊接质量，并能一次起弧就焊完整条焊缝，以提高效率。但是有关技术却往往为外方厂家所垄断，我们并不掌握。从提高我国焊接生产机械化与自动化水平的角度出发，必须加大科研投入，研制高性能的焊接机器人与配套变位设备，力求在自动化焊接领域在国际上占有一席之地。研究内容 本焊接变位机由工作平台、回转机构、翻转机构、机座、控制装置和焊接导电装置组成。工作台 它用于工件的停放和固定。在台面上开沟槽，表面经网络状处理后增大了摩擦，一方面配合夹具固定工件，一方面也增大了表面的摩擦。 工作盘为直径3000的圆盘 用优质钢板焊接而成，在受力部位作了加强处理；退火处理，消除应力后加工。 工作盘固定在专业回转体上，保证稳定地承载和回转。回转机构 工作台固定在大型回转支承上，保证额定载荷下的承载及回转平衡；回转机构用于带动工件旋转，便于焊头对工件进行环形焊接。 工作台底部采用型材焊接成形，在受力部位作加强处理，工作台焊后进行去应力处理，变形小。 工作台固定在回转支承上，从而保证稳定回转。采用回转支承承载，固有承载能力大，回转精度高的特点。 转支承采用“单排四点接触球式回转支承”（型号为012. 60. 2000 . ）由专业厂家生产。具有结构合理、刚性好、自重轻、寿命长等优点。 工作台的回转由交流电机通过双级摆线针轮减速器驱动，减速器输出小齿轮与回转啮合，从而驱动工作台回转。 驱动小齿轮采用40Cr材质，并经调质，齿面淬火处理，从而满足高强度的传递使用。 驱动采用交流变频无极调速，范围广，以保证在较宽调速范围内的恒扭矩输出。 整个回转机构安装在箱型结构的横梁翻转框上，横梁对工件进行支撑承载，并将工件的重量通过横梁传递到两边立柱支架上，能承受大的冲击载荷和扭曲力。采用箱型机构可以有效承载和抗扭能力。翻转机构 翻转机构可使工件产生俯仰运动，改变工件的位置便于焊接； 采用圆弧硬齿面蜗轮蜗杆减速器具有承载能力大，看冲击能力强的特点，但成本是普通蜗轮蜗杆减速器的2-3倍。 翻转工作原理：电磁制动电机-减速器-齿轮-大齿盘-工件，由大直径和大模数的双齿盘才实现工件的翻转，平稳可靠、承载效果好。 翻转驱动装置的小齿轮与伞齿啮合，驱动机构翻转；底座 机架采用型材焊接而成结构牢固可靠，是整个设备的支撑结构 为了保证强度，我们将底座联接为整体，内部行腔根据受力的情况焊接加强筋； 底座的延伸支架腿长度应该达到超过其最大重心距的要求工作机需要电动机输入功率才能工作 一般原动机与工作机不直接相连，而是通过在两者之间设置一个中间装置，称这个中间装置为传动装置简称传动；在机械中，传动装置的功用是根据工作机的工作提要实现某种减速、增速、变速、或改变运动形式的功能。工程实践表明，传动装置是机械中重要的组成部分，在整机的成本和重量中占有很大的比重，并在很大程度上决定整机的技术性能和运转费用。因此，正确设计传动装置对保证整机的技术性能和质量指标都具有相当重要的意义。根据工作原理的不同，传动分为两类：机械传动和电传动。选择传动形式时，应当考虑的主要指标 功率、效率、运动性能、外形尺寸、重量、生产率和成本等。现分别阐述如下：功率 每种传动所传递的功率大小与该传动的工作原理、承载能力 、工作速度、效率 、材料和制造精度等因素有关。一般来说，啮合传动传递的功率高于摩擦传动传递的功率，但是啮合传动中蜗杆传动则因材料关系也不能传递大的功率。效率 效率是评定传动质量指标的一个重要参数。高的效率意味着节约动力。传动效率低，一般不宜传递大的功率。通常啮合传动的效率高于摩擦传动，但普通圆柱蜗杆的传动可能低于摩擦传动。速度 速度是传动装置的一个主要运动特性。提高传动的速度是机械的主要发展方向之一。影响速度的因素有动载荷和制造精度等。传动比 传动比是传动装置的又一种运动特性。每种传动因受外形尺寸或承载能力的影响限制，均有各自适用的最大传动比值。此外，还应考虑传动比值的准确性问题。对于要求精确传动比的机械，不用摩擦传动而采用啮合传动。外廓尺寸、重量及成本 传动装置的外廓尺寸和重量与传动零件材料的机械性和容许传递速度、容许传递功率密切相关。在上述条件确定下，单极传动的外廓尺寸和重量主要取决于传动形式。一般来说啮合传动比摩擦传动轻巧，但成本高。啮合传动中，蜗杆程度和一些内啮合行星传动的尺寸和重量通常小。机构预期寿命 机构预期使用寿命为10年，每天两班制，全年工作300个工作日记则其使用寿命为10*300*2*8=4800小时。 总之，综合考虑各种情况，得出一个最优设计方案，设计一个符合实际情况的焊接变位机。拟采取的研究方法、技术路线、实验方案及可行性分析通过对输煤系统的实地考察，总结得出输60吨焊接变位机的基本结构，工作方式与原理。然后根据考察的结果，再查阅相关书籍，确定基本的设计参数，进行初步的三维建模。交由指导老师检查，修改。完成后，再对主要载荷部件进行校核。最后出主要零件的零件图，编写设计说明书。可行性分析：我国焊接辅助设备与器具制造行业前景分析我国焊接工艺装备制造行业起步较晚，直到二十世纪70年代初才在上海、成都、长春等地陆续建成一批专门生产焊接工艺设备的制造厂。进入80年代，随着国内焊接工艺装备需用量的日益增长，各地又相继成立多家中小型焊接装备生产厂。近期又新建成或改建具有一定规模的焊接装备生产企业。迄今，我国已有24加焊接装备生产企业，年产量2000万元以上的已有10多家。有些企业发展速度较快，并已具有较大的规模，有些焊接设备已实现批量生产。研究计划及预期成果 本焊接变位机由工作平台、回转机构、翻转机构、机座、控制装置和焊接导电装置组成。此焊接变位机可解决锅炉行业有大量的管和板的焊接，管子和板的焊接问题，主要体现在下面几个方面： 稳定和提高焊接质量，保证其均一性 焊接参数如焊接电流、电压、焊接速度等对焊接结果起决定行作用。采用焊接变位机焊接时对于每条焊接的焊缝的焊接参数都是恒定的，焊接质量受人的因素影响较小，降低了工人操作技术的要求，因此焊接质量是稳定的。而人工焊接时，焊接速度、干伸长等都是变化的，因此很难做到质量的均一性。 改善了工人的劳动条件 采用焊接变位机焊接工人只是用来装卸工件，远离了焊接弧光、烟雾和飞溅等，对于点焊来说工人不再搬运笨重的手工焊钳，使工人从大强度的体力劳动中解脱出来。 提高劳动生产率 焊接变位机没有疲劳，一天可24小时连续生产，另外随着高速高效焊接技术的应用，使用焊接变位机焊接，效率提高的更加明显。 今年来我国对于焊接技术有很大的提高，有效提高生产效率，减轻了工人的劳动强度。焊接变位机件大量应用于焊接生产中。特色或创新之处 近年来我国焊接变位机行业占整个行业的40%以上，与焊接这个特殊的行业有关，焊接作为工业“裁缝”，是工业生产中非常重要的加工手段。 焊接变位机应具有以下技术要求：回转驱动实现无极调速，并可逆转。在回转速度范围内，承受最大载荷时转速波动不超过5%。倾斜驱动应平稳，在最大负荷下不抖动，整机不得倾覆。最大负荷Q超过25kg的，应具有动力驱动功能。应设有限位装置，控制倾斜角度，并有角度指示标志。倾斜机构要具有自锁功能，在最大负荷下不滑动，安全可靠。变位机控制部分应设有供自动焊接的联动接口。 我设计的焊接变位机也会按照以上要求设计，即注重实用性和安全性；同时性价比高，成本低。已具备的条件和尚需解决的问题已具备的条件：设计过程中所需要的各种软硬件资源和相关产品实物照片。尚需解决的问题：相关文献资料的缺乏，对一些结构设计部分的具体设计指导，以及三维软件的高级运用技巧。指导教师意见 指导教师（签名）： 年 月 日教研室（学科组、研究所）意见 教研室主任签名： 年 月 日系意见 主管领导签名： 年 月 日 Use of Voice Recognition for Control of a Robotic Welding WorkcellABSTRACT: This paper describes work underway to evaluate the effectiveness of voice recognition systems as an element in the control of a robotic welding workcell. Factors being considered for control include program editor access security,Preoperation checklist requirements, welding process variable control,and robot manipulator motion overrides. In the latter two categories, manual vocal control is being compared against manual tactile control and fully automatic control in terms of speed of response, accuracy, stability, reliability. And safety.Introduction Voice recognition technology is now recognized as a potential means for easing theworkload of operators of complex systems. Numerous applications have already been implemented, are in various stages of development, or are under consideration. These include data entry,control of aircraft systems, and voice identification and verification for security purposes.Voice control has also been proposed for use aboard the space station. One prime area for application would be control of some functions of robots used for intraand extravehicular inspection, assembly, repair,satellite retrieval, and satellite maintenance when a crewmember is serving in a supervisory capacity or the system is operating in a teleoperation mode. Voice control of sensors and process variables would free the crewmembers hands for other tasks, such as direct control or override of the manipulator motion. Similarly, the workload associated with control of many onboard experiments could be eased through the use of this technology.This paper describes the application of voice recognition for control of a robotic welding workcell. This is a complex system involving inputs from multiple sensors and control of a wide variety of robot manipulator motions and process variables. While many functions are automated, a human operator serves in a supervisory capacity, ready to override functions when necessary. In the present investigation, a commercially available voice recognition system is being integrated with a robotic welding workcell at NASA Marshall Space Flight Center, which is used as a test bed for evaluation and development of advanced technologies for use in fabrication of the Space Shuttle Main Engine. In the system under development, some functions do not yet have automatic closedloop control, thus requiring continuous monitoring and real-time adjustment by the human operator. Presently, these ovemdes are input to the system through tactile commands (;.e. pushing buttons. turning knobs for potentiometers, or adjusting mechanical devices). Since the operator monitors the process primarily visually, he must either look away from the process to find the proper button or knob or rely on“muscular memory”much as a touch-typist does. In the first case, the time of response to a deviant condition may be excessive. In the second case, there is an increased probability of a secondary error being introduced by the operator.A voice recognition system could reduce the response time required from the operator.The probability of pushing the wrong button should similarly be reduced. Also, operator fatigue should be minimized.Since the operator can continuously monitor the process during override input, the effect of the change can be observed more quickly. Thus, if the desired value is exceeded and reverse correction is required, it should be accomplished more quickly, allowing less overshoot. This reduction in oscillation about the desired value makes the system more stable.Another factor that can be improved is operator safety. In a safety-critical situation,the robots operation can be halted immediately by use of the “emergency stop, or E-stop, mode, which is initiated, conventionally, by depressing a large button. If an operator inadvertently finds himself in a hazardous situation, it may be necessary for him to initiate the E-stop sequence. Should the operator not be within reach of the button,however, he may be unable to take the necessary action, and, as a result, could suffer serious injury. Having the capability of stopping the robot by issuing a voice command could significantly improve the operators safety by enabling him to stop the robot even when not within reach of the E-stop button. Manual corrections are occasionally required to adjust the location at which the weld filler wire enters the weld pool. Proper entry location is absolutely critical to sound weld quality. Adjustments are made either by manually adjusting mechanisms that hold the wirefeed guide tube or by issuing tactile commands to a servomechanism. Use of a voice recognition system could eliminate the need for the operator to place his hand within the working envelope of the robot end effector or, if servomechanisms are employed,could improve speed of response and stability. Another aspect of robot operation in an industrial environment that is very important is the security of a program editing capability of the system. Under no circumstances should any unauthorized person be able to enter this programming mode and alter the robots program. A voice recognition system can provide the necessary security by allowing access only for individuals who are authorized and whose voices can be identified by the system. BackgroundRobotic welding is under development by NASA and Rocketdyne for the automation of welds on the Space Shuttle Main Engine that are presently made manually. The programmability of a robot can reduce the percentage of welding defects through a combination of consistency and repeatability unattainable by its human counterparts. To do this, the robot is programmed to a nominal weld path and level of weld process parameters (i.e., current, travel speed. voltage,wire addition rate). Some adjustment of these values is often necessary due to conditions changing during the weld. A human making a manual weld accomplishes this adjustment readily, while a robot must rely on the limited talents of sensors and the ability of the operator to override functions when necessary. System IntegrationThe basic elements of the workcell system are shown diagrammatically in the illustration.The ultimate goal of the system development work in progress is to generate robot manipulator programs and weld process programs off line, download them to the workcell supervisory computer, then use sensor subsystems to make closed-loop corrections to the robot path and process variables. Offline programming is being done with an Intergraph modified VAX 780/785-205 computer system with Interact color graphics workstations. Deviations between the programmed robot path and the actual required path are observed and corrected by a sophisticated vision-based sensor developed for this application by Ohio State University.This sensor system is also designed to permit measurement of the molten weld pool surface dimensions and correct welding current level to maintain the weld pool dimensions within desired limits. Presently, a number of functions are still controlled manually, and manual overrides capability is required for all functions. As stated in the Introduction, use of voice recognition may improve the accuracy and speed of response of these manual overrides. To explore this technology, a Votan VRT 6050 stand-alone voice recognition terminal has been integrated into the workcell. This system provides continuous speech recognition of up to 10 sets of words with 75-150 words per set.The integration of the voice recognition system is broken into analog and discrete signals for control. The voice recognition system connects to the control computer through a standard RS232-C communications link.Discrete Control SignalsIn this project, most of the control circuitry is based on discrete digital signals.This is due to the on/off state nature of the circuits to be controlled in the robot controller.The circuits of the system to be controlled by the voice recognition control computer (VRCC) by discrete signals are the emergency stop circuit and the positive jog and negative jog circuits for motion control. Since the safety of the operator is paramount in any automated workcell, the voice recognition system should be incorporated as a safety feature. To accomplish this, the VRCC has been interfaced into the workcell emergency stop circuit. The emergency stop circuit in the robotic workcell will shut down the welding process and the mechanical motion of the manipulators. Through the use of a digital signal from the VRCC, a relay is energized that interrupts the necessary circuits in the weld power supply and robot controller. With the use of the voice recognition system as a safety control for this workcell, we have added a third level of redundancy into the emergency stopping ability of the operator (in addition to the present emergency stop buttons).Manipulator motions are controlled through an axis select button in conjunction with a positive or negative jog button that is depressed by the operator. Once the operator has selected an axis, he depresses one of the jog buttons for the desired travel distance.This function was selected to be controlled by the VRCC because of its utilization during automatic operation of the manipulator to correct trajectory errors. The circuitry necessary to control this operation draws the signal to ground through the activation of relays for the positive or negative jog motion. Because motion is achieved only as long as these signals are active low. they can be controlled by discrete digital signals from the VRCC.Analog Control SignalsThere are many variables that affect the quality of weld during the welding process. but the welding current has the greatest effect over a small range of values. It was for this reason, that the welding current was chosen to be controlled by the voice recognition system.The welding power supply controls the current level through a voltage circuit that uses a range of 0-10 V DC. These voltage values are converted to current levels from 0 to 300 A for welding. A digital-to-analog converter is used in conjunction with a multiplying circuit. The converter allows the VRCC to control a voltage level that is used by the weld power supply to achieve the proper welding current. The multiplier circuit is necessary to allow the weld power supply to be controlled by the other subcontroller used in the workcell.Experimental InvestigationThe accuracy and speed of response of corrections to robot manipulator motion and welding process variables made with the VRCC are being compared with those made with the original control system. Step input errors to robot motion and welding current are introduced randomly into the robot program. By graphically recording relevant system output signals,the time required for the operator to detect the change and initiate corrective action may be measured. Response accuracy and stability may also be gaged through similar analysis of the relevant recorded system output signals.ConclusionsFuture work will investigate voice control of welding filler wirefeed speed and location of wire entry into the weld pool. Also to be investigated is voice control of welding arc voltage override. Later, restriction of access to the robot program editor by voice recognition may be implemented.The use of voice recognition technology for manual supervisory control of industrial robot systems is very promising. This technology has application for aerospace welding due to the need to have constant human supervision over a multitude of process parameters in real time. Future development of this technology will permit rapid expansion of its application to both robotic and nonrobotic processes. AcknowledgmentSpecial thanks to Mr. Jeff Hudson of Martin Marietta Corporation for assistance in the preparation of the illustration presented in this article.References 1 C. A . Simpson. hl. E. McCauley. E. F. Rolland. J . C. Ruth. and B. H. Williges. System Design for Speech Recognition and Generation. Hutnnn Factors. vol. 27. no. 2. pp.115-1-11. 1985.2 National Research Council. Committee on Computerized Speech Recognition Technologies.Automatic Speech Rerop1irior1 in severe Environme