Production line for logitudinal welding of hatch gondola car center sill

The system allows to perform welding of workpieces in “normal” position as well as in “reverse” position ensuring reverse deflection during welding in order to prevent welding deformations.

Robots application allows to perform fast and flexible changeover to different items. In this case the robot is programmed for welding start and ending, overcoming of obstacles during the process of welding when the item has inner population of reinforcement elements.

One of the equipment peculiarities is the ability to weld on v-shaped gap from 0 to 12 mm by means of META laser welding seam tracking system (UK). The tracking system traces the size of the gap in the butt joint and transfers data to the robot controller.

After analyzing the received information the robot controller gives a command to the power sources and feeding mechanizms to change parameters of welding without interruption of welding process.

Flux recirculation system allows to feed the flux to the welding zone and to collect unused flux and slag crust after welding without operator in automatic mode.

Specifications:

1.Overall dimensions of the detail, mm12960х610х500
2.Welding stand:
Center sill longitudinal positioning unitfolding catches
Center sill transversal positioning unitpneumatic
Center sill deflection unitpneumatic
Deflection total force, kgf24000
Deflection, mm100
Center sill vertical catch unitpneumatic
Support drive systempneumatic
Support typeadjustable
Support turning angle, degrees90
3.Transportation system:
Platform motion driveelectromechanical
Number of platforms, pcs2
Drive power, kWt1
Cruising speed, m/min7,5
Welding speed, m/min0,3…2
Welding speed control typefrequency
Seam typebutt seam
Welding typeRobotic, flux welding
RobotFanuc
Number of robots, pcs.2
Seam tracking systemlaser, SmartLazerPilot
Welding source type Lincoln Electric
4.Installed capacity, kWt3
5.Working air pressure, mPa0,7 … 0,8
6.Air consumption, m3/h20
7.Overall dimenstions, mm40040х5020х1900
8.Weight, kg23000