Welding device

Patent metadata

Field	Value
Publication number	US-10843286-B2
Application number	US-201716319858-A
Country	US
Kind code	B2
Filing date	Jul 18, 2017
Priority date	Jul 27, 2016
Publication date	Nov 24, 2020
Grant date	Nov 24, 2020

Abstract

A welding device for automatically welding a workpiece by a welding robot using a welding wire includes a welding control device that controls operation and welding work of the welding robot. The welding control device includes a sensing unit configured to detect a position of the workpiece, a root gap calculating unit configured to determine a root gap, and a storage unit including wire melting information as a database of a proper welding current corresponding to a feeding rate for each of the welding wire. A lamination pattern and a welding condition are provided in accordance with the root gap determined by the root gap calculating unit and the wire melting information so that an amount of heat input is equal to or less than a predetermined amount of heat input.

First claim

The invention claimed is:

1. A welding device for automatically welding a workpiece by a welding robot using a welding wire, comprising
a welding control device that controls operation and welding work of the welding robot, the welding control device including:
a sensing unit configured to detect a position of the workpiece; and
a storage unit including wire melting information as a database of a proper welding current corresponding to a feeding rate for each of the welding wire,

wherein the welding control device is configured to calculate a root gap based on data of detected positions of both groove faces in a groove width direction from a detection position of a predetermined depth relative to a set groove depth from at least one surface of the workpiece, the data of detected positions of the both groove faces being detected by the sensing unit, a difference between the set groove depth and a detection start position, and preset angles of both of the groove faces,
wherein a lamination pattern and a welding condition are provided in accordance with the root gap and the wire melting information so that an amount of heat input is equal to or less than a predetermined amount of heat input,
wherein the wire melting information includes information about a diameter of the welding wire, information about a wire extension, gas information about a shielding gas, and the wire melting information includes a database of a proper welding current corresponding to a feeding rate for each of the welding wire within a welding wire diameter range of 1.0 to 2.0 mm and a wire extension range of 10 to 35 mm, and
wherein the sensing unit detects the position of the workpiece with a laser sensor, or detects the position of the workpiece by applying a sensing voltage between a welding torch supporting the welding wire set to have the predetermined extension and the workpiece, and detecting a current conduction state caused by contact between the welding wire and the workpiece.

2. The welding device according to claim 1 ,
wherein the wire melting information is set within a range of “12≤{proper welding current (A)/feeding rate (m/min)}≤125” for each of the welding wire.

3. The welding device according to claim 1 ,
wherein the wire melting information includes information of a composition of the welding wire,
the welding wire containing, based on total weight of the welding wire,
C: 0.50 mass % or less (including 0%),
Si: 0.10 to 2.00 mass %,
Mn: 0.10 to 3.00 mass %,
S: 0.0001 to 0.0500 mass %,
Ti: 0.80 mass % or less (including 0%),
Al: 0.80 mass % or less (including 0%),
Mo: 5.0 mass % or less (including 0%),
Cr: 30.0 mass % or less (including 0%),
Ni: 20.0 mass % or less (including 0%),
Cu: 1.0 mass % or less (including 0%),
B: 0.0100 mass % or less (including 0%).

4. The welding device according to claim 3 ,
wherein a ratio between Si, Al and Ti which are contained in the welding wire satisfies the following relationship of “0.10≤Si/{1+(Al+Ti)}”.

5. The welding device according to claim 1 , further comprising:
a pair of rotary positioners that is provided movably in a longitudinal direction of the workpiece and holds and rotates the workpiece;
a carriage or a plurality of carriages, provided movably in a parallel direction to the direction in which the pair of the rotary positioners move;
the welding robot, provided on the carriage movably in a perpendicular direction to the direction in which the rotary positioners move; and
a welding torch, provided at an end of the welding robot, wherein:
the pair of rotary positioners includes:
a pair of annular holding members that receive the workpiece internally and hold the workpiece with a plurality of fixing jigs; and
a driving member that rotates one or both of the pair of annular holding members; and
each of the annular holding members is divided at a predetermined position of an annular portion to form a part of the annular portion to be open, so that the workpiece can be received in the annular holding members.

6. The welding device according to claim 5 ,
wherein when a plurality of welding joints having different volumes to be welded due to different sectional areas of the workpiece or different welding lengths of the workpiece or both of them are welded concurrently by a plurality of the welding robot, a feeding amount of the welding wire is controlled to be changed to compensate the difference in the volume to be welded in order to equalize a welding time from a base point to a next base point.

7. The welding device according to claim 6 ,
wherein when welding cannot be performed within a range of a welding current with which welding can be performed in each of passes, the welding control device makes control to weld the welding joints individually in at least one of the passes so that a total error in thickness is compensated.

8. The welding device according to claim 6 ,
wherein the welding control device sets a range of a welding current with which welding can be performed in each of passes, performs welding within the range in the pass, and makes control to compensate a difference in amount of deposition generated as a result of the welding in another following pass, so that a total amount of deposition is within a desired range.

9. The welding device according to claim 8 ,
wherein when welding cannot be performed within a range of a welding current with which welding can be performed in each of passes, the welding control device makes control to increase a difference in wire feeding amount and to change an extension of the welding wire so that a welding current being out of the proper range is set at a desired value.

10. The welding device according to claim 1 , further comprising a slag removing device provided at an end of the welding robot, the slag removing device removing a slag generated in a weld portion of the workpiece.

11. The welding device according to claim 1 , further comprising a nozzle exchanging device that exchanges a nozzle provided at an end of a welding torch, the nozzle exchanging device including:
a coil spring to which the nozzle can be inserted; and
a rotary drive source that rotationally drives the coil spring, to which the nozzle is inserted, around a central axis of the coil spring, so as to remove the nozzle from a torch body of the welding torch.

12. The welding device according to claim 1 ,
wherein when multilayer welding is performed on a plurality of weld portions in the workpiece, welding of each layer is dividedly performed in each of the weld portions in a predetermined order.

13. The welding device according to claim 1 ,
wherein the welding control device includes at least an input unit to which at least one or both of dimensions of the workpiece and a shape of a welding joint, and information about whether welding can be executed or not are inputted through input by a worker or through input of CAD data of the workpiece, and
the welding control device automatically provides a welding robot operation orbit and a welding condition for welding, based on a welding robot orbit and a welding condition prepared in advance in accordance with at least one or both of the dimensions of the workpiece and the shape of the welding, joint, and performs welding.

14. A welding device for automatically welding a workpiece by a welding robot using a welding wire, comprising
a welding control device that controls operation and welding work of the welding robot, the welding control device including:
a sensing unit configured to detect a position of the workpiece; and
a storage unit including wire melting information as a da

Assignees

• Kobe Steel Ltd

Inventors

• Kishikawa hirohisa
• Matsumura Hiroshi
• Takada Shigeto
• Sadahiro Kenji
• Izutani Shun

Classifications

• B23K9/095 Primary

  Monitoring or automatic control of welding parameters · CPC title

• B23K9/00

  Arc welding or cutting · CPC title

• B23K9/12

  Automatic feeding or moving of electrodes or work for spot or seam welding or cutting · CPC title

• B23K37/047

  moving work to adjust its position between soldering, welding or cutting steps (B23K37/053 takes precedence) · CPC title

• B23K37/0452

  Orientable fixtures (B23K37/0461 takes precedence) · CPC title