CNC Light Pole Door Cutting Machine

Current position: Home > Product

Robot light pole bottom plate welding electric door cutting welding integrated machine

Use:

This welding system is used for the welding production of street lamp pole bottom plate. Through the real-time communication between the robot and the welding power supply, different process parameters are adopted according to different welding positions to obtain high-quality welds.

This machine has six major applications in the production of street lamp poles, as follows:

 The bottom of the CNC pole is cut neatly,

 Positioning assembly of the base plate,

 Internal and external girth seam welding between the base plate and the pole,

 Welding of base plate stiffeners,

 CNC cutting door,

 Door frame welding

Suitable for conical rods, round rods, octagonal rods, multi-prisms, isometric rods

Main technical parameters:

numbering	project	parameter
1	Minimum diameter at the bottom of the pole	120mm
2	Maximum pole diameter	300mm
3	Maximum length	14m
4	Minimum thickness	2.5mm
5	Maximum thickness of the pole	12mm
6	The maximum thickness of the expansion tube that can be deformed	8mm
7	Maximum weight of a single pole that fits	500kg
8	The number of triangular stiffeners on the bottom plate	4~8 Description: If the number is large, the stiffener spacing is small and the welding torch is affected, half of the stiffener can be welded
9	Bottom plate triangular stiffener size	General ordinary street lamp poles, smart poles are suitable (different sizes of stiffeners require different molds, which can be processed and made by subsequent users according to the randomly provided mold)
10	Welding speed	Reference speed: 300~500mm/min, different thickness, different welding speed
11	Base plate shape	Round, square, octagonal, quadrilateral multiple sides
12	Minimum base plate thickness	10mm (recommended value, too thin inside and outside welding difficult, easy to burn through.)
13	Maximum base plate thickness	Generally, the pole is suitable
14	Minimum base plate size	150mm×150mm
15	Maximum base plate size	700 diameter, or opposite edge size 700700
16	Requirements for stiffeners and base plate dimensional consistency	The dimensional tolerance is within 1mm, it is recommended to use laser cutting or plasma cutting to ensure the consistency of the size and obtain a better robot welding effect
17	Requirements for dimensional consistency of door frames	Generally, the door frame is purchased, and the dimensional tolerance cannot be less than 1mm, so it is necessary to manually install the door frame, after spot welding is firm (or after clamping, the robot then welds, if the tolerance is relatively small, you can also directly robot welding (Note: If the size tolerance of the door frame is relatively large, it will cause the gap between the door frame and the door to be relatively large, resulting in local leakage welding, and local manual repair welding is required later)
18	Regarding the plasma cutting position of the electric door, the maximum distance that the highest point of the electric door is from the base plate	1400mm
19	Cut shape	Square tube plane cutting + tube cutting (4-axis control)
20	Gate size and shape	There are no restrictions in the cutting range
21	Regarding the position of the welding of the door frame of the electric door, the maximum distance from the bottom plate of the highest point of the electric door	2000mm
22	Suitable for pole type	Conical rods, round rods, octagonal rods, multi-prismatic above octagonal and equal diameter rods are suitable
23	Plasma power supply	Hypertherm Powermax 65 (Made in USA) Hypertherm
24	Maximum perforation and mass cutting thickness	12mm (recommended)
25	Cutting speed	Generally, the cutting time of an electric door of a street lamp pole is 30~40 seconds
26	CNC system	Si Dafeng(SF-2100S)
27	Drawing software	SmartNest
28	Plasma cutting gun	1 set of 1 set
29	Arc pressure height controller	HEAVTH HP105
30	Raise the device	One set of plasma height adjustment device
31	Production speed (including base plate internal and external welding, electric door cutting, door frame welding)	Ordinary street lamp pole: 12~16 minutes 5G pole: 40~45 minutes The specific time depends on the size of the pole, the size of the stiffener, and the size of the electric gate

Special Requirements:

1. The maximum pipe diameter is 400, (originally 300) and the bottom is 250x250 square tube (the maximum can meet the square tube 350x350), the electric chuck is increased to the inner hole diameter 620 (originally 360)

2. On the square tube, there are 2 stiffeners on one side, which need a stiffener device, which can be moved up and down, suitable for different positions of the stiffener

3. If the position of the small head is a square tube, the small head support cannot be rotated, and the support type needs to be changed, and the result is discussed, and it is decided to add 12 meters guide rail and the movable support of the small head to improve the accuracy of cutting and welding, suitable for round rods, square tubes, octagonal rods. The small head support is a synchronous rotation of the servo. This eliminates the need to make square fixtures.

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, leaving the bottom plate up to 1300, change to the hanging robot, in order to get the welding 2 meters away from the bottom plate, the hanging robot suspension frame moves out 500mm.

The overall layout is as follows:

Proprietary Features:

1. This machine integrates six functions, once loading and unloading, it can be completed, the bottom of the pole is cut neatly, the positioning assembly of the bottom plate, the internal and external welding between the bottom plate and the pole, the welding of the bottom plate stiffener, the cutting electric door, the door frame welding. The material flow and loading and unloading time between independent processes are greatly reduced, saving production space.

2. With pipe rising function, eliminate the gap between the hole in the bottom plate and the pole, and smoothly realize automatic welding.

3. With the function of automatic placement and welding of the bottom plate stiffener, the stiffener device can be automatically adjusted up and down to meet the automatic feeding of 2 stiffeners on one side of the square tube.

4. Using Japanese Kawasaki heavy industry robot, good operability and excellent quality.

5. Using famous welding power source, the weld quality is good, and the welding efficiency is high.

6. The positioner has a large flipping angle, which can realize the most reasonable angle welding.

7. Beautiful welding forming and high reliability.

8. CNC cutting of light pole electric door, cutting shape can be round, square, rectangular, oval, etc., any graphics that computer CAD can draw can be cut by the special software that comes with it.

9. The cutting source is automatic plasma, so the cutting speed will be fast, and the incision is smooth and round.

10. Due to the use of the power supply and cutting gun of Hypertherm plasma made in the United States, the cutting gap is relatively small, and the cut piece can be used as a door cover.

11. After the electric door cutting is completed, if the welding of the door frame is required, the robot can complete the automatic welding of the door frame, and the door frame welding needs to be equipped with laser positioning function.

12. The form design of the one-way assembly line of the whole machine, the poles are stacked on the left side of the machine, and the operators can move to the right one after another to complete the welding, and the poles that are welded are stacked to the right. The pole moves and rises, no need to drive, and the operator has low labor intensity.

13. Add 12 meters guide rail and small head movable support to improve the accuracy of cutting and welding, suitable for round rods, square tubes, octagonal rods. The small head support is a synchronous rotation of the servo. This eliminates the need to make square fixtures.

14. Save a lot of labor costs

15. Can adapt to all-weather and long-term work

Photo:

Introduction to the robot system

1. Kawasaki robot

BA series is a series of robots specially developed for welding, dedicated to welding, simple operation, can achieve skilled welding operation through simple teaching operation. The teach pendant is equipped with a touchable LCD color display with excellent visual effect and easy operation. The robot and the welder only need a cable to connect, and the welding conditions can be classified and stored and called up with one click.

Teach-in method	Simple operation teaches programming in AS language
Mode of action	Manual mode	Each axis is independent, basic coordinate system, tool coordinate system
Mode of action	Reproduction mode	Each axis/line, arc interpolation action
Storage capacity		8MB (8000 steps equivalent)
Universal signal	External operating signals	Emergency stop, external hold signal
Universal signal	Input and output	32+32

Kawasaki BA series robots adopt E01 control cabinet, compact size, suitable operating system, rich functions, easy maintenance and high scalability. 6.5 inch color LCD screen, touch screen 640×480 pixels. Backlighting is used to make the LCD picture easier to see. THE OPERATING SYSTEM USES WINDOWS CE. The window display features a drop-down menu that makes editing easy.

function		Standard arc welding
Model		BA006N
Arm form		Vertical polyarticular
Freedom of movement		6 axes
MAXIMUM LOAD CAPACITY(KG)		6
Maximum range of action [DEG]	JT1 power cord and control cable	±165
	JT2	+150～-90
	JT3	+45～-175
	JT4	±180
	JT5	±135
	JT6	±360
Maximum operating speed[DEG/S]	JT1 power cord and control cable	240
	JT2	240
	JT3	220
	JT4	430
	JT5	430
	JT6	650
Inertia[N.M]	JT4	12
	JT5	12
	JT6	3.75
Moment of inertia[KG. @2	JT4	0.4
	JT5	0.4
	JT6	0.07
REPEATABILITY [MM]		±0.05
HORIZONTAL ELONGATION[MM]		1445
Body weight[KG]		150
Power Capacity [KVA]		3.0
Installation method		Ground, roof
Installation environment	temperature	0～45°
	humidity	35~85% (no condensation)
	vibration	Less than 0.5G below 0.5G
	other	The robot must be installed away from flammable or corrosive liquids or gaseous electrical disturbances
IP rating		IP65
Controller recommended		E01

Range of motion:

Introduction to welding torch collision avoidant

The 350 torch system is a CO<> torch commonly used for arc welding in Asia.

The replaceable torch neck torch system offers high ratings and a high duty cycle: Intelligent interfaces enable fast maintenance and repeatable positioning and reduce downtime.

The torch system is available in a wide range of necks and grippers for all commonly used machine joints.

Merit:

(1) Typical Asian CO<> design

(2) The replaceable gun neck can shorten the equipment downtime and reduce the cost of maintenance and repair

(3) The best temperature characteristics ensure a long service life of wearing parts

(4) High-quality cable assemblies ensure a long service life of the system

(5) Robust welding torch structure can achieve high crash stability

Model	350
Cooling method	Air-cooled Air
Duty cycle ratio	100%
rating	350A CO2
rating	300A gas mixture
Wire feed diameter	0.8-1.4mm
Gun neck	35

NBC-350RL welded power supply system

Device Description:

NBC-350RL robot special welding machine has two welding modes, low spatter and constant pressure, which can realize carbon steel argon-rich and CO2 gas shielded welding. This product adopts all-digital control mode, which is highly adaptable and can communicate with arc welding robot through digital/analog interface.

Performance characteristics:

(1) It can be matched with Kawasaki (Kawasaki) robots.

(2) The digital interface control is rich in types, and the welding parameters stored by the customer can be directly called.

(3) The welding spatter is extremely small, and the weld is formed beautifully.

(4) Optimized arc ignition, arc closing and ball removal functions.

Fully digital control system to achieve precise control of welding process and stable arc length.

Powerful digital error function, a variety of faults have error codes to display.

The system has a built-in welding expert database and automatic intelligent parameter combination.

The operation interface is friendly, and the unified adjustment method is easy to master.

Soft switching inverter technology, high reliability, energy saving and power saving.

Welding power parameters:

serial number	category	parameter
1	Rated input voltage/frequency	380V±25% 3P/50Hz
2	Rated Input Capacity (KVA)	14
3	Rated Input Current(A)	21
4	Rated output voltage(V)	31.5
5	Rated load duration rate(%)	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	Gas flow (L/min)	15～20
11	Welding torch cooling method	Air-cooled
12	Enclosure rating	IP23
13	Insulation class	H
14	Overall dimension LWH (cm)	663256
15	Weight( Kg)	55
16	EMC emission class	A

Gun clearing, wire shearing and silicone oil injection device (optional)

As shown in the image. The gun cleaning and silicone oil spray device are used to clean the splash inside the welding torch nozzle and spray anti-splash silicone oil into the nozzle. The wire shearing device is used to cut the small balls at the tip of the welding wire and ensure that the dry extension length of the welding wire is consistent, to ensure the success rate of arc initiation and the stability of the welding process, as well as the accuracy of the detection at the beginning of the end.

Operating environment

1. Grounding: C type grounding, grounding resistance less than 10 ohms.

2. Welding wire: coiled welding wire

3. Use environmental conditions (indoor)

Ambient temperature: -5°C~40°C.

Relative humidity: ≤80%. No condensation. No dew

Programming and workflow

Programming process

Workflow