Engine fuel injection pipe robot laser spot welding station

TEL: 0086-0571-82685351

Description

Engine fuel injection pipe robot laser spot welding station introduction.This laser spot welding station is used to conduct spot welding of fuel injection pipe, to prepare for brazing, the following process.
FANUC M20iA carrying PFO 20 laser welding head from TRUMPF is used in this station, for laser spot welding. Laser adopts Trudisk 2002 from German company TRUMPF. Single- working position-indexing table form. 2 sets of welding tooling equipped in each working position. The fixture is automatic pneumatic tightening. Manual loading and unloading of work piece. See equipment layout for details.
2.Engine fuel injection pipe robot laser spot welding station Design Basis

The design is based on full technical communication of NGC product welding spots and welding cycle time analysis. The following is GM NGC welding position diagram.

3.Engine fuel injection pipe robot laser spot welding Process Analysis

3.1 Engine fuel injection pipe robot laser spot welding Process Flow

According to the external form characteristics of the engine fuel injection pipes, the whole laser spot welding process is conducted automatically in one time, which requires the coordinated movement of multiple pneumatic cylinders and the positioner.
Welding process: laser spot welding.
Welding spot number: 28.
3.2 Cycle Time Analysis
Cycle time for the welding of each work piece is less than 30s.
4． TOTAL LAYOUT AND THE CONFIGURATION OF ROBOT LASER SPOT WELDING STATION (CELL)

4.1 ROBOT LASER SPOT WELDING STATION (CELL) Layout (length3000mm×width2000mm×height2700mm)

4.2 ROBOT LASER SPOT WELDING STATION (CELL) l Configuration

No.	Name	Remarks	Brand	Unit	Qty
1	ROBOT SYSTEM	used in robot laser welding		SET	1
	ROBOT ARM	M20iA ROBOT, standard load is 20KG	FANUC	SET	1
	ROBOT CONTROL BOX	R30iA	FANUC	SET	1
	robot teach Pendant		FANUC	SET	1
	Accessory	Cable between the robot and control cabinet (7m), input/output module, robot operating system , anti-crash software, robot software, Device Net channel connector, Profibus adaptor, internet web card	FANUC	SET	1
2	LASER SYSTEM			SET	1
	Trudisk 2002		TRUMPF	SET	1
	2 Channel		TRUMPF	set	1
	Operating Laser cable 20m, 200um		TRUMPF	SET	1
	Water Cooling Machine	MCWL-100DTRW-01BES7-3385	TONGFEI	SET	1
3	Laser Welding Head	PFO 20	TRUMPF	SET	1
4	2 stops range indexer	2 stops range	FIBRO	SET	1
5	Sing axis servo positioner	Used in positioning for welding	JINGGONG	SET	2
6	GM NGC welding fixture	cylinders + servo positioner	JINGGONG	set	2
7	PLC Electrical Control System	SIEMENS PLC, 12inch HMI+Control Cabinet+OMORON Light Curtain+ 3-color Light Tower+Control Button+Low voltage aparatus+PHILIPS Lighting + Safety Components	SIEMENS&OMRON&Schinder	SET	1
8	Welding Room	Squre tubes welded to form the frame, fixed with steel plates to form a sealed space for robot working area, to prevent danger caused by undesired intrusion.	JINGGONG	SET	1
9	Robot base	Steel welded structure.	JINGGONG	SET	1
10	Safety Protecting instruments	Safety door switch and protecting Glass	JINGGONG	SET	1
11	Voltage regulator	Used to provide stable voltage	SHANGWEN	SET	1
11	Fume & dust exhausting system	Used to clean the fume and dust	DONALDSON	SET	1
12	Weld monitoring system	camera, screen and install base	JINGGONG	SET	1
13	Other	Spare parts	JINGGONG	SET	1

5. ROBOT LASER SPOT WELDING STATION (CELL) Main equipment Description
5.1 Robotics System

In this project, one FANUC M20iA 6-axis-robot and its control box R30iB are used to conduct laser spot welding. Robot load capacity 20kg, max motion radius 1811mm, repositioning accuracy ±0.07mm, see pictures below.

FANUC M20iA 6-axis-robot

5.2 Engine fuel injection pipe robot laser spot welding station Laser Power and Welding Head

Laser power system used here is Trudisk 2002 from TRUMPF, as the following picture.

robot laser spot welding station Laser Power

Laser head is PFO 20 model from TRUMPF, as in the following picture.

robot laser spot welding station Laser head

This welding laser galvanometer lens can perfectly finish high speed laser welding within the working area. The switching between point to point and track to track is less than 30ms, which improves greatly the welding cycle time. Using relative TRUMPF specialized software, various welding process parameter can be set or changed, welding track (welding spots) can be edited. The coordinated robot movement can be fitting programmed to realize laser scanner welding (LSW).

5.3 Two Stops Range Indexer

Two stops two work position indexer from German company FIBRO is used. Motor from SEW. Driven by SEW inverter. Motor is with band brake. Indexer rotates anti-clockwise ( rotation direction can be switched to clockwise too). Re-positioning accuracy ±30”.

5.4 Fuel Injection Pipe Welding Fixture
Fixture is designed based on GM NGC product and uses pneumatic cylinders group to realize pressing tight on the work piece. Welding pressing pneumatic cylinder, regular pneumatic cylinder and rotation press tight cylinder coordinate with laser head to conduct laser spot welding. The diagram underneath illustrate the concept design of this fixture. All components and parts of the work piece are detected by proximity detector to determine if they are in position as well as their respective model number. Fixture is equipped with pneumatic/electric aerial plugs and can be quick-changed using 2-pins and 2 bolts.

Fuel Injection Pipe Welding Fixture

5.6 single-axis servo positioner
Head and tail seated structure single-axis servo positioner is used. Rotation encoder is mounted on the non-drive end to control the angle change precisely. 2 electrical fast aerial plugs and FESTO pneumatic fast aerial plugs are equipped on the positioner frame. The positioner has zero point marker and feeding point marker. The tail seat uses a self-aligning bearing with a centre hole. All key position linkages adopt pin/key for position fixing. The following picture illustrate a posistioner equipped with jig/fixture.

single-axis servo positioner