立式环缝自动焊接机虚拟设计开题报告

编号无锡太湖学院毕业设计（论文）相关资料题目： 立式环缝自动焊接机 虚拟设计 信机 系 机械工程及自动化专业学 号： 0923162学生姓名： 祝 灏 指导教师： 范圣耀 （职称：副教授） 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： 立式环缝自动焊接机 虚拟设计 信机 系 机电一体化 专业学 号： 0923162 学生姓名： 祝 灏 指导教师： 范圣耀（职称：副教授 ） 2012年11月25日课题来源气电立焊是80年代发展起来的一种熔化极气体保护电弧垂直对接焊方法，采用药芯焊丝作熔化极，用能自动控制的上升系统带动焊枪进行连续焊接，在水冷滑块的强制成型作用下以CO2气体保护实现单面焊双面一次成型。过去我国对气电立焊的设备主要依赖进口，并被广泛应用于石油天然气的储油罐建设这些设备，虽然性能良好但价格昂贵，国内一些中小企业无力购买，受进口设备和国内药芯焊丝技术不过关的制约，其应用范围和发展受到限制。所以，开发拥有我国自主知识产权的气电立焊设备，以解决困扰我国众多企业的焊接问题，成为当务之急。 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）气电立焊是由普通熔化极气体保护焊和电渣焊发展而形成的一种熔化极气体保护电弧焊方法。目前气电立焊焊接材料主要采用(金属芯)药芯焊丝，其特点是生产效率高、成本低。气电立焊属于窄间隙焊，与其它窄间隙焊的主要区别是焊缝一次成型，而不是多道多层焊。所以其焊接效率及焊接质量均较高，主要应用于船舶的外壳板的中厚板焊接，也可应用于相应尺寸的桥梁箱式梁腹板及大型储罐侧板的中厚板的焊接。目前通过船级社认可的气电立焊药芯焊丝全部为国外厂商，而国内研究生产的焊丝常常出现焊接力学性能不稳定的情况，不能满足国内客户的需求。所有气电立焊药芯焊丝的使用全都依赖进口，而国内目前应用最多的是日本神钢生产的DWS-43G和DWS-1LG两种气电立焊药芯焊丝。过去我国对气电立焊的设备主要依赖进口，并被广泛应用于石油天然气的储油罐建设这些设备，虽然性能良好但价格昂贵，国内一些中小企业无力购买，受进口设备和国内药芯焊丝技术不过关的制约，其应用范围和发展受到限制。所以，开发拥有我国自主知识产权的气电立焊设备，以解决困扰我国众多企业的焊接问题，成为当务之急。为了提高快速响应能力，气电立焊企业首先应能迅速捕捉复杂多变的市场动态信息，并及时作出正确的预测和决策，以决定新产品的功能特征和上市时间。明确了新产品的开发项目以后，实现快速虚拟设计就成为重要的一环。工程设计的重要性是不言而喻的。据统计，工程设计的费用虽然只占产品最终成本的一小部分(不到10)，但往往决定了它的80以上的制造成本，而且还决定性地影响产品的性能和交货期。现代机械产品由于用户的要求越来越高，产品结构日益复杂，科技含量愈来愈高，从而使得产品的开发周期同趋延长。如何解决好产品市场寿命缩短和新产品开发周期长的尖锐矛盾，已经成为决定企业成败兴衰的生死攸关问题。产品开发周期包括设计、试制、试验和修改等一系列环节，除了设计以外的后几个环节可以统称为试制定型阶段。由此可知，实施虚拟快速设计，至少有如下优点：及时交货，争先抢占市场，因缩短制造时间和消除各种浪费而降低制造成本，因加快产品更新换代而向市场大量提供质量更高、价格更低的高性能产品。其结果就大大提高了企业的综合竞争力和持续发展的生命力。研究内容 了解气电立焊的工作原理，国内外的研究发展现状； 完成焊接机的总体方案设计； 完成有关零部件的选型、建模，虚拟装配； 熟练掌握有关计算机绘图软件，并绘制装配图和零件图纸； 完成设计说明书的撰写，并翻译外文资料1篇。拟采取的研究方法、技术路线、实验方案及可行性分析 本文主要采用PRO/ENGINEER软件对气电立焊及进行快速虚拟设计，该软件有如下特点：全相关：Pro/ENGINEER的所有模块都是全相关的。这就意味着在产品开发过程中某一处进行的修改，能够扩展到整个设计中，同时自动更新所有的工程文档，包括装配体、设计图纸，以及制造数据。全相关性鼓励在开发周期的任一点进行修改，却没有任何损失，并使并行工程成为可能，所以能够使开发后期的一些功能提前发挥其作用。 基于特征的参数化造型：Pro/ENGINEER使用用户熟悉的特征作为产品几何模型的构造要素。这些特征是一些普通的机械对象，并且可以按预先设置很容易的进行修改。例如：设计特征有弧、圆角、倒角等等，它们对工程人员来说是很熟悉的，因而易于使用。装配、加工、制造以及其它学科都使用这些领域独特的特征。通过给这些特征设置参数（不但包括几何尺寸，还包括非几何属性），然后修改参数很容易的进行多次设计叠代，实现产品开发。数据管理：加速投放市场，需要在较短的时间内开发更多的产品。为了实现这种效率，必须允许多个学科的工程师同时对同一产品进行开发。数据管理模块的开发研制，正是专门用于管理并行工程中同时进行的各项工作，由于使用了Pro/ENGINEER独特的全相关功能，因而使之成为可能。 装配管理：Pro/ENGINEER的基本结构能够使您利用一些直观的命令，例如“啮合”、“插入”、“对齐”等很容易的把零件装配起来，同时保持设计意图。高级的功能支持大型复杂装配体的构造和管理，这些装配体中零件的数量不受限制。 易于使用：菜单以直观的方式联级出现，提供了逻辑选项和预先选取的最普通选项，同时还提供了简短的菜单描述和完整的在线帮助，这种形式使得容易学习和使用。 我们最终选择PRO/ENGINEER作为虚拟设计软件,主要是由于其在机构运动仿真功能方面强大的功能、易操作性和直观性。同时，在大型组件的创建过程中，PRO/ENGINEER的单一数据库、参数化建模和全相关性将使零部件的创建和修改变得非常容易，这对缩短建模周期将起到显著的作用。研究计划及预期成果研究计划：2012年11月12日-2013年1月20日：按照任务书要求查阅论文相关参考资料，填写毕业设计开题报告书。2013年1月21日-2013年3月15日：填写毕业实习报告,学习并翻译一篇与毕业设计相关的英文材料。2013年3月16日-2013年3月22日：立式环缝自动焊接机初步虚拟设计。2013年3月23日-2013年4月20日：绘制装配图校核后并进行修改。2013年4月21日-2013年5月 3 日：绘制相关零件图。2013年5月 4 日-2013年5月10日：毕业论文撰写。2013年5月 6日-2013年 5月20日：毕业论文修改工作。成果： 开发拥有我国自主知识产权的气电立焊设备，以解决困扰我国众多企业的焊接问题，解燃眉之急。特色或创新之处（1）虚拟快速设计，至少有如下优点：及时交货，争先抢占市场，因缩短制造时间和消除各种浪费而降低制造成本，因加快产品更新换代而向市场大量提供质量更高、价格更低的高性能产品。（2）大大提高了企业的综合竞争力和持续发展的生命力。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 系主任（签名）： 年 月 日系意见主管领导签名： 年 月 日 英文原文Automatic girth welding machineAutomatic girth welding machine is a complete general all kinds of circular, annular weld automatic welding equipment. Can be used for high quality welding of carbon steel, low alloy steel, stainless steel, aluminum and its alloys and other materials, and can choose welding (filler wire or without filler wire), gas metal arc welding, the power to form a automatic girth welding system of plasma welding welding. Can be widely used in the hydraulic cylinder, the direction of the vehicle frame, a transmission shaft, air storage tank, chemical and medical containers, liquefied gas tank, fire equipment, mining and production line with roller and the liquid storage tube welding products.CharacteristicThe kind of welding machine is suitable for what kind of welding parts, main structure characteristics are as followsThe a vertical automatic girth welding machine representation method: HF (L) and its meaning for girth (vertical), here is a welding ring diameter below for a type of technical parameters of 200mmThe control power supply: single-phase 220V, 50HZ structural forms: single column tiltingTilt adjusting method: stepless regulation, wormTilt angle range: 0- 90 degreesWelding workpiece diameter (mm): 0200Spindle speed: 07rmp or 0.514rmpGirth welding range: 01080The torch pneumatic stroke: 100Welding manual fine-tuning distance: X, y, Z to 60mmThe collector ring the maximum current 300AVertical automatic girth welding machine is a small, cheap, simple and convenient operation, can complete the general small circular, annular welding seam automatic welding equipment. Its biggest characteristic is applicable to some small workpiece circular seam welding, and the workpiece is too, as long as the finger length is suitable for welding.Main controller uses the motion controller programmable controller as the core control unit, according to the requirements of users, through the program and parameters to modify the control software to adjust the equipment function, to achieve circular, semicircular, welding section multisect circle, circular weld, so that the whole device is highly intelligent and flexible, is a a higher grade, higher cost performance and reliability of the controller. The controller has a manual control and automatic welding control function; rotary mechanism driven by DC servo motor, stepless adjustment of welding speed, welding speed displayed by the digital display control panel; the control circuit of independent, lap weld can advance digital setting, after welding, welding speed reduction; the controller according to the requirements of a variety of control output signal and output interface of welding process, with strong anti-interference, high reliability, stable speed regulation, convenient operation, high automation degree, welding control widely used circular weld workpieceSeam automatic welding ring horizontalSeam automatic welding machine and vertical automatic girth welding horizontal welding compared to ring, the length of not too many restrictions. Long three or four meters can easily welding. The device can be widely used in the hydraulic cylinder, the direction of the vehicle frame, a transmission shaft, air storage tank, chemical and medical containers, liquefied gas tank, fire equipment, mining and production line with roller and the liquid storage tube welding products.Performance characteristics:The bed is horizontal structure, by welding pieces of the structure after annealing and refined processing, ensure no deformation of rail bed;Rotary head is driven by DC motor or AC variable frequency motor speed, stable and reliable;Welding fixture or three claw chuck spindle installed, used for clamping workpiece position;The tailstock can adopt pneumatic or manual tightening mode, end of welding fixture or top selected according to different workpiece of different forms;The rear seat can slide on the guide rail of the bed, can adjust the machine tail seat distance in order to adapt to the workpiece with different length;According to the welding torch in different position, the direction to guide the appropriate position.The welding positioner1, HB series welding positioner is the workpiece in convenient welding equipment position by tilting and turning, mainly used for complex workpiece (such as frame, frame, flange, spherical vessel, head, three links and a top cover) of TIG, MIG/MAG or PLASMA automatic welding, PLASMA can also be used for cutting2, HB series welding positioner is mainly composed of a working table, a turnover mechanism, gear box, frame.3, can be set according to needs of different welding speed of welding speed, the ellipse workpiece can weld programming through partition, meet the welding requirements of each section4, exquisite design, high accuracy of rotation, small inertia, braking performance and stability of the good, the precision is high5, HB series positioner with TIG, MIG/MAG or PLASMA composition automatic welding system, power supply and control system of welding, also can with operation machine or the use of welding robot linkage, automatic welding system is complexWelding torch manual 3D adjusting mechanism and the rotary mechanism can satisfy the welding torch accurate alignment of micro adjust position need;The torch pneumatic lifting mechanism and a tailstock pneumatic pushing mechanism of automatic welding and can satisfy the requirement of automatic clamping, improve production efficiency;According to the welding requirements, optional pneumatic lifting bracket, seam tracking device, welding oscillator;The motion controller programmable controller as the main control unit, touch screen operation interface with industry, high degree of automation, welding quality is stable and reliable;Through the program and parameters to modify the control software to adjust the equipment function, to achieve circular, semicircular, welding arc, the segmented circular weldThe welding operation frameWelding operation machine is generally composed of columns, beams, slewing mechanism, car and other components. Each component is the modular structure, the general column, beam as its basic components, the rest components according to user request. Generally applicable to the boiler and pressure vessel of the steam drum, and petrochemical container cylindrical workpiece seam welding of longitudinal seam and ring seam welding.Unique beam and column section design, guide rail for the 45 steel, welding stress, plane grinding. Light weight, high strength, good stability. Design of telescopic arm beam, which can effectively increase the horizontal expansion distance.Lifting beams with constant speed AC motor, smooth, uniform, high safety coefficient. With safety anti-falling device.The beam expansion, column electric rotary, electric vehicles are driven by AC motor variable frequency variable speed, constant torque output, stable speed (especially at low speed), start or stop the fast speed of digital display, and can be preset.The column turning into manual, electric two, slewing bearing using domestic brand-name manufacturers of products, with high precision gear, flexible rotation, and pneumatic locking, safe and reliable.Trolley with standard railway track for walking track, divided into manual and electric two. Operation manual for light and smaller, electric apply operation machine for heavy or larger moving range.Manned operation machine is provided with a manned platform, move along the transverse arm.The hand control box, the control box (welding control box) constitute nearly control and remote control mode, the operation is flexible and convenient, and reserved the linkage interface in the electrical box, with the company or other manufacturers at home and abroad welding machine, roller frame, positioner, a circular rotary table to realize the synchronous linkage.Automatic welding seam of profile ringNew welding equipment profile circular seam welder is oval saddle-shaped seam weld my company and the formation of the welding process of a vertical cross tube and tube plate tilt angle and the development, suitable for car storage tank of the cylinder body and the nut, automobile oil box, oil cylinder and a water heater water faucet, water heater heating pipe and the fixed mounting plate, hydraulic oil, air conditioning compressor nut and other parts of the welding. Welding machine by the pressurized positioning mechanism, bed, profiling mechanism, a welding torch adjusting mechanism, control system etc. Can adapt to the saddle type joints of different sizes or welding tube sheet joint. Welding power can be gas metal arc welding power supply or TIG welding power source.Vertical lathe adopts a welding structure, wire feeding machine arranged in columns, mounted gun turn head plate is arranged upright front end.Main features:The torch rotary machine head adopts DC gear motor drive, the rotation speed to realize stepless speed regulation, welding lap through digital preset.Numerical control mechanism for single or multi-axis NC, the driven by stepping motor or AC servo motor, the welding torch do girth welding numerical control mechanism to drive the welding torch do do copying motion.Welding fixture to ensure the axial and radial positioning, positioning clamp and replace the centring by adjusting welding, can achieve different workpiece automatic welding nut.Head: head swinging device can realize the swing, increase the weld width, the oscillation frequency, oscillation amplitude stepless adjustable;The torch pneumatic lifting mechanism adopts the cylinder drive, to ensure the repeatability.Welding torch three-dimensional adjustment mechanism for fine-tuning of initial welding position.The main control cabinet adopts motion controller programmable control, the main control box are independent components, all action adjustment and welding operation can be completed.Girth welding heat source introduction of automatic welding machineAutomatic girth welding machine forms, it should be according to the different work piece shape and size, material, thickness and welding requirements of different welding power source.(1) submerged arc weldingSubmerged arc welding is a continuous wire feeding wire as an electrode and filler metal. Covered with a layer of granular flux in the region when welding, arc burning in the flux layer, the wire end and the local fusion, the formation of weld.Under the action of the arc heat flux, a part of melting slag and metallurgical reaction in the liquid metal, slag floating on the surface of the molten pool, on the one hand can protect the weld metal, to prevent air pollution, on the other hand can make the weld metal slow cooling.(2) gas tungsten arc weldingThis is a non - gas metal arc welding, tungsten electrode and the workpiece is the use of electric arc between the metal melting and the formation of the weld, tungsten welding process does not melt, only play the role of the electrode. By the welding torch nozzle out of argon and helium as protective gas, in addition to require the addition of filler metal (Division I production of wire feeding machine professional). Tungsten as well to control the heat input, so it is an excellent method of continuous welding sheet metal and backing welding, welding current with pulse form, so often used for welding of pipeline bottom, so as to achieve the purpose of one-side welding with back formation, this method can be used for welding almost, all metal, especially for in the aluminum magnesium can form refractory oxides and welding of titanium and zirconium metal like the lively, the welding method of welding quality is high, but compared with other electric arc welding, the welding speed is slow.(3) plasma arc weldingPlasma arc welding is a kind of no gas metal arc welding, it is to use compressed arc between the electrode and the workpiece to welding, the electrode is usually tungsten. The plasma gas plasma arc available argon, nitrogen, helium or mixture of both. At the same time also by inert gas protection welding tail nozzle, can choose whether the filler metal (wire).Plasma arc welding, arc straight, high energy density, and thus arc penetration ability. Plasma welding can produce the keyhole effect, so for most metals within a certain range of thickness not open groove welding, and can guarantee the penetration and weld uniform. Therefore, plasma arc welding of high production efficiency, good welding quality, but more complex plasma arc welding equipment, welding process and parameter control requirements higher (our own core expertise in this area), for steel sheet 1mm welding, using microbeam plasma welding is easy.(4) gas metal-arc weldingThis welding method is the use of electric arc burning between the continuous feeding wire and workpiece as heat source, the gas welding torch nozzle to arc welding.Gas gas metal arc normally used with argon, helium, CO2, mixed gas of oxygen or the gas. In argon and helium as shielding gas called MIG welding, active gas (CO2, oxygen) or reactive gas and inert gas mixture for the protection of gas called MAG weldingThe main advantages of gas metal arc welding are welding to position, also have higher welding speed, higher deposition rate.(5) flux-cored wire weldingCored wire arc welding is the use of electric arc burning between the continuous feeding wire and workpiece as heat source for welding, can be considered as a kind of gas metal arc welding, so the use of the wire is a core part of the flux-cored wire, wire has a different part of the powder, welding and gas shielded, medicinal powder heat decomposition or melting, gasification slagging protection, playing pool, alloying and arc stability.(6) resistance weldingIs a kind of welding method, the resistance of the heat energy, including the slag resistance of heat energy electroslag welding and solid resistance heat energy resistance weld