发布时间 : 星期二 文章焊接机器人的应用与发展更新完毕开始阅读
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焊接技术的发展方向
焊接技术发明至今已有百余年的历史，工业生产中的大量重要产品，如航空、航天及核能工业中产品的生产制造都离不开焊接技术。当前，新兴工业的发展迫焊接技术不断前进，如微电子工业的发展促进了微型连接工艺和设备的发展；陶瓷材料和复合材料的发展促进了真空钎焊、真空扩散焊、喷涂以及粘接工艺的发展。所以焊接技术将随着科学技术的进步而不断发展，主要体现在能源、计算机在焊接中的应用、焊接机器人和智能化、提高焊接生产率等方面。
1、能源方面
目前，焊接热源已非常丰富，如火焰、电弧、电阻、超声、摩擦、等离子、电子束、激光束、微波等等，但焊接热源的研究与开发并未终止，其新的发展可概括为三个方面：
首先是对现有热源的改善，使它更为有效、方便、经济适用，在这方面，电子束和激光束焊接的发展较显著；其次是开发更好、更有效的热源，采用两种热源叠加以求获得更强的能量密度，例如在电子束焊中加入激光束等；第三是节能技术，由于焊接所消耗的能源很大，所以出现了不少以节能为目标的新技术，如太阳能焊、电阻点焊、螺柱焊机中利用发展电子技术来提高焊机的功率因素等
2、计算机在焊接中的应用
弧焊设备微机控制系统，可对焊接电流、焊接速度、弧长等多项参数进行分析和控制，
对焊接操作程序和参数变化等作出显示和数据保留，从而给出焊接质量的确切信息。目前以计算机为核心建立的各种控制系统包括焊接顺序控制系统、PID调节系统、最佳控制及自适应控制系统等。这些系统均在电弧焊、压焊和钎焊等不同的焊接方法中得到应用。计算机软件技术在焊接中的应用越来越受到人们的重视。目前，计算机模拟技术已用于焊接热过程、焊接冶金过程、焊接应力和变形等的模拟；数据库技术被用于建立焊工档案管理数据库、焊接符号检索数据库、焊接工艺评定数据库、焊接材料检索数据库等；在焊接领域中，CAD/CAM的应用正在处于不断开发阶段，焊接柔性制造系统也已出现。
3、焊接机器人和智能化
焊接机器人是焊接自动化的革命性进步，它突破了焊接钢性自动化的传统方式，开拓了一种柔性自动化新方式，焊接机器人的主要优点是: 稳定和提高焊接质量，保证焊接产品的均一性；提高焊接生产率，一天可24小时连续生产；可在有害环境下长期工作，改善了工人劳动条件；降低了对工人操作技术要求；可实现小批量产品焊接自动化；为焊接柔性生产线提供了技术基础。为提高焊接过程的自动化程度，除了控制电弧对焊缝的自动跟踪外，还应实施控制焊接质量，为此需要在焊接过程中检测焊接破空的状况，如熔宽、熔深和背面焊道成形等，以便能及时的调整焊接参数，保证良好的焊接质量，这就是智能焊接。
智能化焊接的第一个发展重点在视觉系统，它的关键技术是传感器技术。虽然目前智能
化还处在初级阶段，但有着广阔的前景，是一个重要的发展方向。有关焊接工程的专家系统，近年来国内外已有较深入的研究，并已推出或准备推出某些商品化焊接专家系统。焊接专家系统是具有相当于专家的知识和经验水平，以及具有解决焊接专门问题能力范围的计算机软件系统。在此基础上发展起来的焊接质量计算机综合管理系统在焊接中也得到了应用，其内容包括对产品的初始实验资料和数据的分析、产品质量的检验、销售监督等，其软件包括数据库、专家系统等技术的具体应用。
4、提高焊接生产率
提高焊接生产率是推动焊接技术发展的重要驱动力。提高生产率的途径有两个方面： 其一，是提高焊接熔敷率。手工电弧焊中的铁粉焊、重力焊、躺焊等工艺；埋弧中的多丝焊、热丝焊均属此类，其效果显著。例如三丝埋弧焊，其工艺参数分别为2200AX 33V；1400AX 40V；1100AX 45V，采用坡口截面较小，背面采用挡板或衬垫，50-6mm的钢板可一次焊透成形，焊速达到0.4m/min以上，其熔敷率是手工电弧焊的100倍以上。
其二，是减少坡口截面及熔敷金属量，近10年来最突出的成就窄间隙焊接。窄间隙焊接采用气体保护焊为基础，利用单丝、双丝或三丝尽心焊接。无论接头厚度如何，均可采用对接形式。例如，钢板厚度由50-300mm，间隙均可设计为13mm左右，因而所需熔敷金属量成数倍、数十倍地降低，从而大大提高了生产率。
窄间隙焊接的主要技术关键是如何保证两侧熔透和保证电弧中心自动跟踪处于坡口中心线上。为解决这两个问题，世界各国开发出多种不同方案，因而出现了种类多样的窄间隙焊接法。电子束焊、激光束焊及等离子弧焊时，可采用对接接头，且不用开坡口，因此是理想的窄间隙焊接法，这是它们受到广泛重视的重要原因之一。
Addendum:
Development of welding technology
Welding technology has been invented over a hundred years of history, a large number of industrial production in major products, such as aviation, aerospace and nuclear industries manufacturing products that can not be separated from the welding technology . At present, the development of new industries continue to advance welding technology force, such as micro-electronics industry has promoted the development of micro-connection technology and equipment development; ceramic materials and composite materials to promote the development of the vacuum brazing, vacuum diffusion bonding, coating and bonding process development. Therefore, welding technology with the progress of science and technology development, mainly in the following areas:
1) Energy
At present, the welding heat source is very rich, such as flame, arc, resistance, ultrasonic, friction, such as in vitro, electron beam, laser beams, microwave and so on, but the welding heat source in research and development has not been terminate, the development of its new summed up in three aspects:
The first is the improvement of existing sources of heat, making it more effective, convenient and affordable, in this respect, electron beam and laser beam welding of the development of more significant; followed by the development of better, more efficient sources of heat, two heat
superimposed in order to obtain greater energy density, such as electron beam welding, such as adding a laser beam; third is energy-saving technologies. As a result of welding a lot less energy, so there are a lot of energy-saving target for the new technologies, such as solar energy welding, resistance spot welding, stud welding machine, the use of electronic technology to improve power factor, such as welding.
2) Computer Application In Welding
Arc welding equipment, microcomputer control system, can welding current, welding speed, arc length, such as analysis of a number of parameters and control of welding procedures and parameters to make changes in display and data retention in order to give the exact information of welding quality. At present, the establishment of a computer at the core of the various control systems including welding sequence control system, PID-conditioning systems, optimal control and adaptive control systems. These systems are in arc welding, pressure welding and brazing welding different methods are applied. Computer software technology in the welding has been growing attention. At present, the computer simulation technique has been use to heat process, the process of welding metallurgy, welding stress and deformation of the simulation; database technology is used to set up welders file management database, searchable database of welding symbols, welding procedure qualification database, searchable database, such as welding material; in the field of welding, CAD / CAM application development phase is in a continuous welding of flexible manufacturing systems have emerged.
3) Welding Robots And Intelligent
Welding robot is welding of the revolutionary advances in automation, it broke through the automated welding of rigid traditional way to open up a new way of flexible automation, welding robot’s main advantages are: the stability and improve the welding quality to ensure uniformity of welding products; increased productivity, continuous 24-hours a day production; could be harmful to the long-term work environment, improved working conditions of workers; reduce the technical requirements of the workers to operate; can achieve welding automation products in small quantities; flexible production line for welding to provide the technical foundation. In order to enhance the automation of the welding process, in addition to control the arc of the automatic tracking of the weld but also the quality of real-time control of welding, which requires testing in the welding process of welding groove of the situation, such as the weld width, penetration depth and the back of weld shape and so on, in order to adjust the welding parameters in a timely manner to ensure good welding quality, and this is intelligent welding. Intelligent welding of the first focus of development in the visual system, which is the key technology is the sensor technology. Although the intelligence is still in its infancy, but there are broad prospects, is an important direction of development. Welding works on the expert system, both at home and abroad in recent years has been more in-depth studies have been launched or preparing to introduce some of the commercialization of expert system for welding. Welding expert system is equivalent to the expert level of knowledge and experience, as well as the ability to solve the problem of welding the scope of specialized computer software systems. On this basis developed a computer integrated welding quality management system is also in the welding has been applied to its contents, including the initial test of the product information and data analysis, product quality inspection, supervision, such as sales of its software, including databases, expert system technologies such as the specific application.
4) To Improve Welding Productivity
Improve welding productivity is to promote the development of welding technology important driving force. Ways to increase productivity has two aspects: First, is to improve the deposition rate welding. Hand arc welding of iron, gravity welding, welding and other craft lie; the multi-wire submerged arc welding, hot wire welding fall into this category, the results are obvious. For example, three-wire submerged arc welding, the process parameters were 2200AX 33V; 1400AX 40V; 1100AX 45V, the use of smaller cross-section groove, the back of the use of baffles or liner, 50-6mm steel plate can be formed through a welding, welding speed 0.4m/min achieve more than the efficiency of its cladding SMAM over 100 times. Second, is to reduce the cross-section groove and the volume of deposited metal, the past 10 years the most prominent achievement was the narrow gap welding. Narrow Gap welding using gas shielded arc welding based on a single wire, double wire or three wire welding. No matter how the thickness of connector, docking forms can be used. For example, the plate thickness from 50-300mm, space can be designed to be about 13mm, so the required amount of deposited metal into several times, several times to be reduced, thus greatly improving the productivity. Narrow gap welding of the main technical key is how to ensure and guarantee both sides of the penetration of automatic tracking of Arc Center in the center line of groove. To address these two issues ,all countries in the world to develop a variety of different options, resulting in a wide variety of narrow -gap welding method. Electron beam welding , laser beam welding and plasma arc welding, the but joint can be, and I do not have to open wave, it is ideal for narrow gap welding method, it is their extensive attention by one of the important reasons.