Pump body laser welding station

TEL: 0086-0571-82685351

Description

This pump body laser welding station laser welding station is used in welding the inner and outer casing of the pump body.

This laser welding station uses FANUC M-20iA robot which is carrying D70 laser welding head from TRUMPF for the laser welding. The laser model is Trudisk 2002 from a German company TRUMPF.

Feeding mode: conveyor coordinates with v-shape fixture which is adjustable in length direction. Manual change/adjustment.

Fixture mode: when the tooling reaches the stop position, rotation positioner reaches designated position automatically and locates and grabs the work piece using centre-aligning method and rises to welding position for welding.

Welding mode: the robot carries the laser welder to weld the outer casing and inner casing of the pump body respectively. When the work piece model is changed, the robot changes to different optimal welding postures according to different programmed control.

2. design basis

Based on the physical pictures and 3d models provided by party A, we marked the welding position using blue arrows.

physical pictures of the products

In the welding process of each welding seam, the robot and the laser welding head remain still, the rotation positioner rotates carrying the work piece. The rotation parameter such as angle & speed should be fixed based on practical process testing

Exact process as follows:

1、 After the preceding process, pump body is laid down manually on V-shape fixture, on which there’re grooved lines to make sure it’s placed within correct range.
2、Conveyor with v-shape fixture carries the work piece to stop position.
3、Inner support fixture grabs the work piece driving by electric cylinder using center aligning method. Because the length dimensional allowance is quite big, there needs to be module position compensation after each grabbing to achieve precise welding.
4、Electric cylinder module rise the work piece to welding position, waiting for welding.
5、Robot carrying laser welding head reaches designated position, ready for welding.
6、Rotation positioner rotates, at the same time laser welding head generates laser beam for welding.
7、Repeat step 5 & 6 until 4 weld seams are finished.
8、Robot returns to safe position.
9、Electric cylinder module drives the welded finished product to return to v-shape fixture.
10、Stopping mechanism returns to original position allowing the finished product being carried to next work position by conveyor.
4．Robot laser welding station layout and configuration
4.1 station layout
Main machine size: 3650mm×3000mm×4500mm

4.2 station configuration

No.	name	description	brand	unit	q’ty
1	Robot system	Used in robot laser welding		set	1
	Robot arm	M-20iA load capacity20KG	FANUC	set	1
	Robot control box	R30iB	FANUC	set	1
	robot teach Pendant		FANUC	set	1
	Accessory	The cable between the robot and control cabinet (7m), input/output module, robot operating system , anti-crash software, robot software, Profibus adaptor, internet web card	FANUC	set	1
2	Laser system			set	1
	TruDisk 2002		TRUMPF	set	1
	Single channel		TRUMPF	set	1
	Operating Laser cable 20m, 200um		TRUMPF	set	1
	Water cooler		TONGFEI	set	1
	Laser welding head	BEO D70	TRUMPF	set	1
	Assisting gas device	Welding seam assisting gas flow	JINGGONG	set	1
3	Rotation positioner	Used to rotates the work piece for welding	JINGGONG	set	1
4	Loading/unloading conveyor	Used to convey pump body	JINGGONG	set	1
5	Welding inner support fixture	Welding fixture	JINGGONG	set	1
6	PLC Electrical Control System	SIEMENS PLC, 12inch HMI + Control Cabinet+BANNER Light Curtain+3-color Light Tower + BANNER Control Button+Cables+Low voltage apparatus+ PHILIPS Lighting + Safety Components	SIEMENS+OTHERS	set	1
7	Robot and positioner base	used to integrate the robot with the fixture	JINGGONG	set	1
8	Welding room	Double layer welding room type. The bottom layer conducts robot welding. The upper layer houses peripheral equipment such as the laser system, water cooler, electric control cabinet, voltage regulator etc.	JINGGONG	set	1
9	Safety Protecting instruments	Safety door switch and specialized protection Glass	JINGGONG	set	1
10	Fume & dust exhausting system	Used to clean the fume and dust	DONALDSON	set	1
11	Weld monitoring system	Camera, screen and install base	JINGGONG	set	1
12	voltage regulator	Ensure stable voltage supply for laser and robot		set	1
13	Constant temperature & humidity room	境 provide a constant temperature and humidity environment for laser	JINGGONG	set	1
14	Others	Spare parts	JINGGONG	set	1

5. MAIN EQUIPMENT INTRODUCTION
5.1 Robot system
In this project, one FANUC M20iA 6-axis-robot and its control box R30iB are used to conduct laser welding. Robot load capacity 20kg, max motion radius 1811mm, re-positioning accuracy ±0.08mm, see pictures below.

5.2 Laser Power and Welding Head

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

Laser welding head is BEO D70 from TRUMPF. The following pictures are examples of the laser welding head.

5.3 rotation positioner

The whole rotation positioner includes servo module, inner support mechanism and rotation positioning mechanism.

5.3.1 servo module

This servo module consists of 2 set XY axis electric cylinder which are controlled by PLC to achieve simultaneous motion and can grab the products on v-shape fixture using centre-aligning method and carry it to welding position waiting for welding.

5.3.2 inner support mechanism

Inner support mechanism can realize 2 functions as follows.

1、 Provide certain support when welding inside weld seam of the pump body to reduce welding deformation.

2、The custom-designed inner support fixture allows laser beam to enter the inner casing and conduct welding.

inner support fixture schematic diagram

5.3.3 rotation positioning mechanism

Servo motor drives the pump body to rotate through belt pulley. Laser head generates laser beam and the laser beam radiating position remains still.