Base Plate Welding Machine
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Robot lamp pole base plate welding switch cutting and welding integrated machine
MODEL: RW-DC120/300
Application:
The welding system are applied for light pole base plate welding production. By real time communication between robot and welding power, according to different welding position to gain good quality welding seam,。
This machine has six major applications in the production of street light poles, as follows:
CNC cut flat of the pole bottom
Positioning and assembly of the bottom plate,
Welding the inner and outer seams between the bottom plate and the pole，
Welding the base plate stiffener,
CNC electrical door cutting
Door frame welding
Suitable for conical poles, round poles, octagonal poles, polygonal poles, equal diameter poles
Main parameter:
| NO. | Item | Parameter |
| 1 | Pole min diameter | 120mm |
| 2 | Pole max diameter | 300mm |
| 3 | Pole max.length | 14m |
| 4 | Pole min. thickness | 2.5mm |
| 5 | Pole max. thickness | 12mm |
| 6 | The maximum thickness of the expanded tube that can be deformed | 8mm |
| 7 | Pole max weight | 500kg |
| 8 | Max QTY of base plate stiffener | Note: If the quantity is large and the spacing of the stiffeners is small and the welding torch is affected, half of the stiffeners can be welded |
| 9 | Size of base plate stiffener | Normal street light poles and high mast are suitable(Different sizes of stiffener require different molds, which can be processed and manufactured by the user in accordance with the mold provided in the machine) |
| 10 | Welding speed | 300~500mm/ Reference speed 300~500mm/minDifferent thickness and different welding speed |
| 11 | Base plate shape | Circle, square, octagon, multiple sides of four sides |
| 12 | Min thickness of base plate | 10mm( Recommended value, too thin, difficult to weld inside and outside, easy to burn through) |
| 13 | Max thickness of base plate | Suitable for normal poles |
| 14 | Min size of base plate | 150mm×150mm |
| 15 | Max size of base plate | 700 diameter, or opposite side size 700 |
| 16 | Requirements for the consistency of the size of the stiffener and the base plate | Dimension tolerance is within 1mmIt is recommended to use laser cutting or plasma cutting to ensure the consistency of the size to obtain a better robot welding effect |
| 17 | Requirements for the size consistency of the door frame | Generally, the door frame is purchased from outside, and the size tolerance is more than 1mm.Therefore, it is necessary to manually install the door frame, and after the spot welding is firmly (or after the clamping, the robot will weld again, if the tolerance is relatively small, it can also be directly welded by the robot(Note: If the dimensional tolerance of the door frame is relatively large, it will cause the gap between the door frame and the door to be relatively large, leading to local leakage of welding, and local manual repair welding is required later) |
| 18 | Regarding the position of the switch plasma cutting,The maximum distance from the highest point of the door to the base plate | 1400mm |
| 19 | Cutting shape | Square tube plane cutting + tube cutting (4-axis control) |
| 20 | Door size and shape | There is no limit in the cutting range |
| 21 | Regarding the welding position of the door frame,The maximum distance from the highest point of the door to the base plate | 2000mm |
| 22 | Suitable for pole type | Conical poles, round poles, octagonal poles, polygonal shapes above octagonal, and equal diameter poles are all suitable |
| 23 | Plasma source | Hypertherm Powermax 65(Made in USA) |
| 24 | Max perforation and quality cutting thickness | 12mm( suggested value) |
| 25 | Cutting speed | The cutting time of a door on a normal street light pole is 30~40 seconds |
| 26 | CNC system | Si Dafeng(SF-2100S) |
| 27 | Nesting SOFTWARE | SmartNest |
| 28 | CNC Plasma cutting torch | 1 set |
| 29 | Arc voltage height controller | HEAVTH HP105 |
| 30 | Height device | Plasma Torch height moving device， 1set |
| 31 | Production speed(Including inner and outer welding of base plate, electric door cutting, door frame welding) | Normal street light pole: 12~16 minutes5G pole: 40~45 minutesThe specific time depends on the size of the pole, the size of the stiffener, and the size of the door |
special requirements:
1. The maximum tube diameter is 400 (originally 300) and the bottom is a 250x250 square tube (the maximum can meet the square tube 350x350), the electric chuck is increased to an inner hole diameter of 620 (originally 360),
2. On the square tube, there are 2 stiffeners on one side. A stiffener device is required, which can be moved up and down, suitable for different positions of the stiffener
3. If the small end position is a square tube, the small end support cannot be rotated, and the support type needs to be changed. After discussion, it was decided to increase the 12-meter guide rail and the movable support of the small end to improve the accuracy of cutting and welding. It is suitable for round poles, square tubes, and octagonal poles. The small end support is servo synchronous rotation. In this way, it is no longer necessary to make a tooling fixture that turns square to round.
4. Because the door is opened on one side of the square tube, the plasma cutting system needs to add a control axis.
5. The position of the door frame, the maximum distance from the base plate to highest of the door is 1300mm, and it is changed to a suspended robot. In order to obtain welding at a distance of 2 meters from the base plate, the suspended robot suspension frame moves 500mm outward.
the general layout is as followings:
Proprietary features:
1. This machine integrates six functions, which can be completed in one loading and unloading. CNC cut flat of the pole bottom, the positioning and assembly of the base plate, the internal and external welding between the base plate and the pole, the welding of the bottom plate stiffener, the electrical door cutting , and the door frame welding . The material flow and loading and unloading time between independent processes are greatly reduced, and the production space is saved.
2. With pole expansion function, eliminate the gap between the inner hole of the base plate and the pole, and realize automatic welding smoothly
3. With the function of automatic placement and welding of the stiffener, the auto feeding system can automatically adjust the up and down positions to meet the automatic feeding of two stiffeners on one side of the square tube。
4. It adopts Japanese Kawasaki Heavy Industries robot with good operability and excellent quality.
5. Adopting famous welding power source, good welding seam quality and high welding efficiency
6. The positioner has a large turning angle, which can realize the most reasonable angle welding
7. Beautiful welding shape and high reliability
8. The CNC cutting of the light pole door , the cutting shape can be circle, square, rectangle, oval, etc. Any graphics that can be drawn by computer CAD can be cut by the special software that comes with the machine.
9. The cutting source is automatic plasma, so the cutting speed will be very fast, and the cut will be smooth and round
10. Due to the use of the Hypertherm Powermax 65 plasma spurce and cutting gun, the cutting gap is relatively small, and the cut pieces can be used as door covers
11. After the electric door is cut, if the door frame needs to be welded, the robot can complete the automatic welding of the door frame. And the door frame welding needs to be equipped with the laser positioning function
12. The entire machine is designed in the form of a one-way assembly line. The poles are stacked on the left side of the machine. The operator can move one by one to the right to complete the welding, and the welded poles are stacked on the right. The pole moves and rises, no crane is required, and the labor intensity of the operator is low
13. Add the 12-meter guide rail and small end movable support to improve the accuracy of cutting and welding. It is suitable for round poles, square tubes and octagonal poles. The small end support is servo synchronous rotation. In this way, it is no longer necessary to make tooling fixtures that turn square to round.
14. Save a lot of labor costs
15. Can adapt to long hours of work throughout the day
Similar photos：
Robot welding system
1. Kawasaki Robot BA006N (Japanese brand)
BA series is a series of robots developed for welding specially. It is designed for welding specially. It is easy to operate and can achieve skilled welding operation through simple teaching operation. A touch LCD color display screen with excellent visual effect and easy operation is installed on the teaching device. Robot welding machine only need a cable connection, can classify welding conditions of storage, and one key call.
| Teaching methods | Simple Operation Teaching AS Language Programming | |
| Manner of execution | Manual mode | Independent axes, basic coordinate system and tool coordinate system |
| Reproduction mode | Interpolation action of each axis/line and arc | |
| Storage capacity | 8MB（8000 steps are equivalent ） | |
| General signal | External Operating Signal | Emergency stop, external hold signal |
| Input and output | 32+32 | |
Kawasaki BA series robots use E01 control cabinet, compact shape, suitable operation system, rich functions, easy maintenance and high scalability. 6.5 inch color LCD screen, touch screen 640 x 480 pixels. Backlighting is used to make the LCD screen easier to see. The operating system adopts WINDOWS CE. The drop-down menu is used for window display, which makes the editing process simple and easy.
| Fuctions | Standard arc welding | |
| Model | BA006N | |
| Arm form | Vertical multiple joints | |
| DOF | 6 axis | |
| Maximum load capacity（KG） | 6 | |
| Maximum range of action[DEG] | JT1 Power line and control line | ±165 |
| JT2 | +150～-90 | |
| JT3 | +45～-175 | |
| JT4 | ±180 | |
| JT5 | ±135 | |
| JT6 | ±360 | |
| Maximum speed of action[DEG/S] | JT1 Power line and control line | 240 |
| JT2 | 240 | |
| JT3 | 220 | |
| JT4 | 430 | |
| JT5 | 430 | |
| JT6 | 650 | |
| Inertia[N.M] | JT4 | 12 |
| JT5 | 12 | |
| JT6 | 3.75 | |
| Inertial moment[KG.M2] | JT4 | 0.4 |
| JT5 | 0.4 | |
| JT6 | 0.07 | |
| Repeated positioning accuracy [MM] | ±0.05 | |
| Horizontal elongation [MM] | 1445 | |
| Weight[KG] | 150 | |
| Power capacity [KVA] | 3.0 | |
| Installation mode | Ground、Top loading | |
| Installation environment | Temperature | 0～45° |
| Humidity | 35～85%( No dew) | |
| Vibration | 0.5G以下Less than 0.5 | |
| Others | Robot installation must be away from the interference of flammable or corrosive liquid or gas appliances | |
| IP Level | IP65 | |
| Recommended Controller | E01 | |
Range of action：
Introduction Collision Preventer of Welding Torch
The 350 welding torch system is a CO2 welding torch, which is commonly used for arc welding in Asia.
The replaceable gun neck welding gun system has the advantages of high rated value and high duty cycle: intelligent interface can realize fast maintenance and repeatable positioning functions, and shorten downtime
The welding gun system has a variety of gun necks and holders for all common machine joints to choose from.
Advantage
：
(1)Typical Asian CO2 welding design
(2)Replaceable gun neck can shorten equipment downtime and reduce maintenance and repair costs
(3) Optimal temperature characteristics ensure long service life of wearing parts
(4) High-quality cable assemblies ensure a long service life of the system
(5) Rugged welding torch structure can achieve high collision stability
| Model | 350 |
| Cooling way | Air |
| Duty cycle | 100% |
| Rated value | 350A CO2 |
| 300A mixed gas (mixed composition) | |
| Wire feed diameter Wire diameter | 0.8-1.4mm |
| Gun neck Welding gun neck | 35° |
NBC-350RL Welding Power System
Equipment description：
NBC-350RL robot special welding machine has two welding modes of low spatter and constant pressure, which can realize argon rich and CO2 gas shielded welding of carbon steel. This product adopts full digital control mode, with strong adaptability, and can communicate with arc welding robot through digital/analog interface.
Device Description:
The NBC-350RL robot special welding machine has two welding modes: low spatter and constant pressure, which can realize carbon steel rich argon and CO2 gas shielded welding. This product adopts an all-digital control method, which is highly adaptable and can communicate with the arc welding robot through a digital/analog interface.
Performance characteristics
(1)Can be matched with Kawasaki robot
(2)Numerous types of digital interface control can directly call the welding parameters stored by the customer
(3)Very small welding spatter, beautiful welding seam shape
(4) Optimized arc ignition, arc closing and ball removal functions
The fully digital control system realizes precise control of the welding process and stable arc length.
Powerful digital error reporting function, a variety of faults have error codes to display.
The system has a built-in welding expert database and automatic and intelligent parameter combination.
Friendly operation interface, unified adjustment mode, easy to master.
。
Soft-switching inverter technology, the whole machine is highly reliable, energy-saving and electricity-saving.
Welding power parameters：
| No. | Item | Parameters |
| 1 | Rated input voltage/frequency | 380V±25% 3P/50Hz |
| 2 | （ KVA）Rated input capacity | 14 |
| 3 | Rated input current (A) | 21 |
| 4 | Rated output voltage (V) | 31.5 |
| 5 | Rated load duration (%) | 60% |
| 6 | Output no-load voltage (V) | 96 |
| 7 | Output current/voltage range (A/V) | 60A/17V～350A/31.5V |
| 8 | Welding wire diameter (mm) | 0.8、1.0、1.2 |
| 9 | Wire feed type | Push wire |
| 10 | （L/min）Air flow rate (L/min) | 15～20 |
| 11 | Torch cooling method | Air cooling |
| 12 | Enclosure rating | IP23 |
| 13 | Insulation class | H |
| 14 | L*W*H （cm）Dimensions L*W*H (cm) | 66*32*56 |
| 15 | （ Kg）Weight | 55 |
| 16 | EMC EMC emission level | A |
Option:Gun cleaning, wire cutting and silicone oil spray device
As the picture shows. The gun cleaning and silicone oil spraying device is used to clean the splash in the nozzle of the welding torch and spray anti-splash silicone oil into the nozzle. The wire cutting device is used to cut off the small ball at the tip of the welding wire and ensure that the dry elongation of the welding wire is consistent, to ensure the success rate of arc starting and the stability of the welding process, as well as the accuracy of the detection at the beginning.
Operating environment
1、Grounding: C grounding, grounding resistance less than 10 ohms.
2、Welding wire: disc-mounted wire
3、Use of environmental conditions (indoor)
Ambient temperature：-5℃~40℃。
Relative humidity：≤80%。 No dew
Programming and Workflow
Programming flow
Workflow
苏ICP备17067978号-1