摘要
针对特种领域多规格小批量精密金属波纹管环缝焊接中,现有自动化设备成本高、简易焊机无法兼容扁波、直壁及扩口等多接口形式的问题,本文研制了一种低成本多功能环缝焊机。该设备以旋转变位装置为核心,通过1/4圆弧条形孔与锁紧杆配合,实现卧式与立式工位90°快速切换,可适配不同接口形式的焊接需求;采用直流电机+齿轮传动替代伺服驱动系统,在降低成本的同时,通过齿轮机构缩小转速调节范围,提升控制精度;配备X-Y向可调焊枪支架与滑动平台-顶尖组合定位系统,确保0.3~0.5 mm级组对精度,避免薄壁多层结构焊接分层缺陷。试验验证显示,焊接组件经荧光渗透、氦质谱漏率及金相检测,均符合JB/T 11620标准要求;设备连续运行5年稳定性良好,综合成本较同类自动化设备降低40%以上。本研究通过“工位可调+低成本驱动+精准定位”的集成设计,突破了传统焊机通用性与经济性难以兼顾的瓶颈,为小批量多规格波纹管焊接提供了高效解决方案,其结构创新对同类非标焊接设备研发具有参考价值。
In view of the high cost of existing automation equipment and the incompatibility of simple welding machines with flat,straight-walled,and expanded port forms in the multi-specification small-batch precision metal bellows seam weld‐ing in special fields,this paper develops a low-cost multifunctional seam welding machine.The equipment,with a rotating position-changing device at its core,realizes 90°quick switching between horizontal and vertical positions through the coop‐eration of a 1/4 arc slot hole and a locking rod,adapting to different port form welding needs;DC motor+gear drive re‐places the servo drive system,reducing costs while increasing control accuracy by narrowing the speed adjustment range through the gear mechanism;equipped with an X-Y adjustable welding torch holder and a sliding platform-top combination positioning system to ensure 0.3-0.5 mm level pairing accuracy,avoiding delamination defects in thin-walled multilayer structure welding.Test verification shows that the welded components meet the JB/T 11620 standard requirements through fluorescent penetrant,helium mass spectrometry leak rate,and metallographic tests;the equipment has good stability after continuous operation for 5 years,and the comprehensive cost is reduced by more than 40%compared to similar automation equipment.This research,through the integrated design of"adjustable position+low-cost drive+precise positioning,"breaks through the bottleneck that traditional welding machines are difficult to balance universality and economy,providing an efficient solution for small-batch multi-specification bellows welding.Its structural innovation has reference value for the research and development of similar non-standard welding equipment.
作者
张全厚
邓艳秋
吕威
于翔麟
刘昕
ZHANG Quanhou;DENG Yanqiu;YU Xianglin;ZHANG Bo;LIU Xin(Shenyang Academy of Instrumentation Sciences Co.,Ltd.,Shenyang 110168,China;China Energy Engineering Group Liaoning Electric Power Survey&Design Institute Co.,Ltd.,Shenyang 110179,China;Beijing Aerospace Propulsion Institute,Beijing 100176,China)
出处
《电焊机》
2025年第8期63-67,共5页
Electric Welding Machine
基金
中国机械工业集团青年科技基金项目(PK2010-112)
沈阳市中青年科技人才项目(RC220513)。
关键词
精密金属波纹管
环缝焊机
旋转变位
低成本设计
多接口焊接
precision metal bellows
ring seam welder
rotational position changing
low-cost design
multi-interface welding
