I. Summary and features:
1. Summary:
1.1、This trolley is used for all-position fillet weld workpieces. The welding torch is dragged along the weld direction by gear transmission and crank swing mechanism, so that the relative movement between the welding torch and the trolley body can be realized, and the "welding blind area" caused by the fixed installation of the welding torch and the width of the welding machine body of the traditional trolley can be overcome. Especially suitable for square, narrow space and all-position fillet welding;
1.2、The adsorption force of trolley is ≥36Kg, and it can weld workpieces in parallel, vertical and upward corner joints. The welding gun clamping mechanism has swing function, which is suitable for welding wide and thick welds.
The clamping angle of welding gun is 35-45, which is suitable for the overlapping mode and angle adjustment of T-joint and corner joint workpieces.
1.4、Built-in high-performance permanent magnets cooperate with guide wheels to trace the welding seam along the edge of the workpiece to complete welding.
1.5、The battery is used for power supply, which is especially suitable for outdoor and welding occasions where it is not convenient to provide power for the trolley. The trolley is light in weight, and the magnetic adsorption has the function of lifting the handle and automatically engaging and disengaging, which is convenient for operators to work on site.
1.6、Simple operation, even operators without professional skills can use it after simple training, and can also get good welding effect, and it has the function of automatic limit stop. The degree of welding automation is high, and one operator can control multiple welding machines at the same time to improve the productivity.
2. Features:
2.1、A clutch device is installed on the car body, which can manually move the car body quickly.Digital display of digital tube is convenient for adjusting various parameters.
2.2、The walking speed, swing speed, swing angle, left and right residence time, etc. are precisely controlled by program.The swinging device is controlled by the program, and the swinging device has the functions of left stop and right stop, so as to prevent the phenomenon of insufficient molten pool during swinging welding; At the same time, the weld center can be adjusted during welding to prevent partial welding.
2.3、The adjustment of welding torch magnification is controlled by program, which can adjust the welding speed of starting and closing arc. Arc starting and closing have 2S extension time, respectively, to remove welding arc pits.
2.4、The swing mechanism of welding gun has reasonable structure, stable and reliable mechanical transmission, realizes blind spot welding, does not need workers to carry out secondary repair welding, and the car body occupies little space;
2.5、And 24V-4AH lithium battery pack, which provide power for the trolley and reduce its dependence on external power supply.
II. Scope of application:
2.1 description of applicable materials
2.1.1 The automatic welding machine shall meet all kinds of parallel, vertical and upward T-joints and fillet welds, and the height of the top wheel abutment plate shall be greater than 75mm so that the top wheel abuts. The surface of the workpiece is a plane or an arc surface with a radius greater than 1.2m;
2.1.2 The walking width of the welding trolley should be greater than 360mm, and the workpiece spacing should be ≧320mm to ensure the normal operation space of the welding mechanism; The gap between the base metal of weld should be consistent, otherwise the welding effect will be affected;
2.1.3 The trolley adopts the improved magnetic adsorption system, which can meet the requirements of adsorption and copying of bidirectional stainless steel with certain magnetic adsorption performance (its magnetic adsorption performance should be no less than 40% of that of conventional iron materials).
2.2 applicable welding materials
Applicable to common welding wires and flux-cored wires with φ Φ1.6mm and below.
III. Specifications and technical parameters:
Serial number |
Item |
Parameter internal capacity |
|
1 |
Applicable workpiece |
Iron, all-position fillet weld with walking blind area |
|
2 |
Walking mode |
Through the mechanical top wheel propping against the base metal vertical plate and the magnetic adsorption of the adsorption device to the base metal bottom plate, the welding machine can run straight along the weld line. |
|
3 |
type of drive |
Four-wheel drive (rubber wheel) |
|
4 |
adsorption capacity |
≥32KG (steel plate test) |
|
5 |
Walking speed |
0、3.5 — 93.0 (cm/min) |
|
6 |
Welding mode |
After the welding torch swings from the initial position to the midpoint, the welding machine starts to walk. After the limit switch is touched, the welding torch swings from the midpoint to the end position to finish welding. Press the return key to automatically return to the initial position for the next start. |
|
7 |
Swing speed |
0-40 cycles/min |
|
8 |
Left/right dwell time |
0—2.5S |
|
9 |
Arc starting and closing speed |
(0.8-1.2 magnification) The automatic time delay of arc starting and closing is 2.0S, |
|
10 |
Travel limit switch |
Touch walking stop |
|
11 |
Swing angle |
0—±8° |
|
12 |
Welding torch adjustment range |
crosswise |
30mm |
be on the perpendicular |
30mm |
||
13 |
Welding torch limit switch |
The swinging mechanism welds the arc closing position along the weld line direction, and the touch delay is 2.0S Stop welding |
|
14 |
Material |
aluminium alloy |
|
15 |
Input power supply |
24V-4AH lithium battery |
|
16 |
Trolley size |
Length× width× height: 270×330×242 |
|
17 |
Weight |
13kg |
|
IV. Operating instructions of the control panel:
Serial number |
Naming |
function |
one |
Welding torch magnification adjusting potentiometer |
The potentiometer has the function of pressing the shaft, which is used to display the switch of parameter marks. The clockwise parameter increases and the counterclockwise parameter decreases. |
two |
Welding process time Display nixie tube |
The format is X Y.Y To display the mark X, you can switch between L-R-D by pressing the rotary shaft of the time adjusting potentiometer. L represents the residence time of the left extreme position of the wiggler; R represents the dwell time of the right limit position of the swinger; D represents the welding gun magnification, welding speed and walking speed ratio from both ends of arc starting and closing. |
three |
Welding process time Adjusting potentiometer |
The potentiometer has a pressing function, which is used to display the switch of parameter marks; Rotate the potentiometer shaft to adjust the time parameter corresponding to the displayed parameter mark, and the clockwise parameter increases and the counterclockwise parameter decreases; |
four |
Medium potentiometer |
Used to adjust the swing center position of the swinger, clockwise to the right and counterclockwise to the left; |
five |
Swing speed Display nixie tube |
The display format is XX, which is used to proportionally display the swinging speed of the swinger; |
six |
Swing speed Adjusting potentiometer |
Rotate the potentiometer shaft to adjust the swing speed. The clockwise value increases and the counterclockwise value decreases. |
seven |
Swing angle Display nixie tube |
The format is XX, which is used to display the swing angle proportionally. |
eight |
Swing angle Adjusting potentiometer |
Rotate the potentiometer shaft to adjust the swing angle, increasing clockwise and decreasing counterclockwise; |
nine |
Start-stop switch |
Used to switch the start-stop state of the car. Every time the switch is pressed, the car switches between the start-stop states once; |
ten |
Welding/non-welding control switch |
It is used to control the welding state. When the switch is set to "Welding", the welding will be synchronized with the trolley, and the welding power supply will act synchronously when the trolley is started (the arc starting delay time is still valid, and the welding gun port of the trolley needs to be correctly connected with the power feeder). |
eleven |
electric outlet |
|
twelve |
Walking speed Display nixie tube |
The format is XX.X, which is used to actually display the walking speed; |
thireen |
Walking speed Adjusting potentiometer |
Rotate the potentiometer shaft to adjust the walking speed value. The clockwise rotation value increases and the counterclockwise rotation value decreases. |
V. Installation and use:
1.1 electrical connection inspection
Battery, swinging device butt plug and welding gun control plug shall be installed correctly without looseness;
1.2 car placement
Clean up the path of the trolley and the sundries and scrap iron on the underside of the trolley, and then install the trolley on the workpiece to be welded, with both top wheels propped against the vertical plate.
1.3 welding torch position adjustment
Before the trial operation, please turn the welding switch to the "non-welding" position, press the trial welding mode key, and the crank rocker mechanism will take the welding torch to run on the welding mold to verify the walking and swinging track of the welding torch. The welding gun clamping mechanism automatically returns to the midpoint, clamping the welding gun on the welding gun fixture and fastening it (welding gun butt welding can be performed by using the trolley centering function and the cross adjusting frame).
1.4 welding operation
Set the welding control switch to "Welding" for trial operation, press the start key, and the crank rocker mechanism will drive the welding gun to automatically weld from the arc starting position and delay for 2S (arc pit cutting)-Figure 1. After the welding gun swings from the initial position to the midpoint, the welding machine starts to walk-Figure 2. After the limit switch is touched, the welding torch swings from the midpoint to the end position, and the welding arc closing time is delayed for 2S (arc pit cutting)-Figure 3. According to the welding effect, the trolley walking parameters, welding torch height and welding parameters can be fine-tuned.
1.5 start/stop welding
After welding, lift the trolley, and after leaving the workpiece, press the return key, and the welding gun will automatically return to the initial position for the next start (the fillet weld of the same specification will be centered once in the "non-welding" mode, and continuous operation can be done according to 5.4 Welding Operation.
1.6 parameter preset
According to the specific process requirements (compiled by users themselves), preliminarily preset the trolley parameters (welding process time, swing speed, swing angle, walking speed, arc starting and closing speed);
VI. Inspection and Maintenance:
In order to use the automatic welding trolley safely and for a long time, the equipment should be maintained regularly.
1. Remove the splash from the control box panel and welding torch adjustment position: always clean the splash from the control box panel and welding torch adjustment position to prevent the circuit board from being damaged and the welding torch from being unable to be adjusted.
2. Removal of welding slag: Always remove welding slag and foreign matter from the guide wheel, driving wheel, track, magnet and slider.
3. Fasten the screws of the welding gun fixture and the guide wheel: if they are loose, they will cause unstable walking and poor welding.
4. Often check whether the plug, welding torch control line is damaged, whether the battery can charge and discharge normally.
5. Regularly check the running status of the traveling motor, swing motor, traveling mechanism, etc. to confirm whether there is abnormal heat or noise.
