Machining Automatic Welding
Customized according to drawings and quantities
Technical principles and core advantages
The foundation of automation technology: Through industrial robots (such as KUKA, FANUC), CNC numerical control systems or dedicated welding workstations, integrating visual positioning (such as 3D cameras), sensors (such as arc sensors) and AI algorithms, automatic tracking of weld seam trajectories, dynamic parameter adjustment and real-time quality monitoring are achieved. For instance, the welding of car bodies adopts a "robot + laser welding" system, with a welding speed of 6-10m/min and a weld width accuracy of ±0.1mm.
Core advantages
Efficiency improvement: Compared with manual welding, production efficiency has increased by 3 to 5 times. For instance, the welding line cycle for car body-in-white can be compressed to 40 seconds per vehicle.
Stable quality: High weld consistency (defect rate < 0.1%), reducing defects such as porosity and cracks.
Cost optimization: Reduce labor costs by over 50% and minimize waste of welding materials (for instance, the utilization rate of laser welding materials is over 95%).
Environmentally friendly: Reduces smoke and arc light pollution, suitable for clean workshops (such as semiconductor and medical equipment production).
Customized requirements and process parameters
Material compatibility
Metal materials: 304/316L stainless steel (corrosion-resistant), aluminum alloy (lightweight), titanium alloy (biocompatible), high-strength steel (automotive structural components). The surface treatment needs to match the welding process (for example, the oxide layer of anodized aluminum needs to be removed).
Non-metallic materials: plastics (ultrasonic welding), composite materials (laser welding + filler). The heat input needs to be adjusted to prevent ablation.
Parameter optimization
Laser welding: Power (500W-10kW), welding speed (1-10m/min), focus position (defocus ±1mm), shielding gas (argon/nitrogen).
Arc welding: current (50-500A), voltage (15-30V), wire diameter (0.8-2.0mm), wire feeding speed (2-20m/min).
Robot path: Trajectory planning (straight line/arc/curve), welding torch Angle (forward tilt/backward tilt), dry elongation (wire extension length).
Structural design: Reduce welding deformation through topological optimization. Use "fixture + positioning pin" to ensure the clamping accuracy of parts (repeat positioning accuracy ±0.05mm), and adapt to complex geometries (such as curved surfaces, thin-walled structures).
Process flow and quality control
Process flow
Design stage: CAD/CAM modeling, weld path planning, and optimization of welding sequence (such as symmetrical welding to reduce deformation).
Preparation stage: Material cutting (laser/plasma), surface treatment (rust removal/oxide layer removal), fixture installation (hydraulic/pneumatic clamping).
Welding stage: The robot executes the welding program, monitoring the current/voltage/wire feeding speed in real time and dynamically adjusting the parameters.
Post-treatment: Weld seam cleaning (removal of slag), heat treatment (annealing/aging), surface polishing (mirror-like effect).
Quality control
Online detection: The vision system detects the position/width of the weld seam, the arc sensor monitors the penetration depth, and the laser displacement sensor measures the height of the weld seam.
Offline inspection: X-ray flaw detection (for internal defect detection), ultrasonic testing (weld thickness), hardness testing (HV), metallographic analysis (grain structure).
The standards comply with: ISO 15614 (Welding Procedure Qualification), ASTM E1417 (Non-destructive Testing), ISO 9001 (Quality Management System).
Application scenarios and cases
Automobile manufacturing: Welding of body frames (such as A/B pillars), chassis (subframe), and battery packs (aluminum shells), using robot arc welding combined with laser welding, increases structural strength by more than 30%.
Aerospace: Engine blades (titanium alloy laser welding), fuel pipelines (electron beam welding), satellite structural components (friction stir welding), meeting the requirements of high temperature and high pressure (above 300℃) and lightweight.
Energy equipment: Nuclear power plant pressure vessels (thick plate welding), wind power towers (circumferment seam welding), oil and gas pipelines (automatic welding machine + crawler), compatible with IP68/IP69K protection grades.
Medical equipment: Surgical robot joints (stainless steel laser welding), implants (titanium alloy electron beam welding), certified by ISO 13485 to ensure biocompatibility.
Construction and pipelines: Steel structure Bridges (thick plate welding), urban pipe networks (PE pipe hot melt welding), enhancing construction efficiency and sealing performance.
