1. Equipment Overview
The sign welding robot is a multifunctional intelligent automation system specially developed for the bar production line of iron and steel enterprises, which integrates automatic weighing, automatic positioning, automatic data entry, automatic printing of product signs, and automatic welding signs. The product not only adopts integrated design, 3D image recognition, component modular design, and standardized process production, but also occupies a small area and has high speed; Replacing the traditional production process with manual printing of labels, manual data input, manual welding of signs and other cumbersome operations, this product avoids potential safety hazards for on-site workers, and eliminate man-made errors in printing signs, data entry, welding signs, etc. which reduce labor and labor intensity of operators, and meet the needs of high-paced and high-intensity production
The robot completes the printing, taking, and welding of two signs in 25s.
If customer needs it, the robot can also complete the bundle review work (optional).
2. Design Conditions
2.1 Main technological requirements
Product specification: Φ 10～ Φ 40mm;
Fixed length: 9～12m;
Bundled steel temperature: ≤400 ℃ (after hot rolling and cooling)
2.2 installation process
The first way: The sign welding robot is installed on one side of the finished product collection gantry. Each collection system is equipped with two sets of sign welding robots, and one end is hung with a sign.
The second way: the sign welding robot is installed on one side of the finished product collection bench, each collection system is equipped with one sign welding robot, and two signs are hung at one end
3. Equipment function and technical parameters
3.1 Main technical function
(1) It can realize sign printing and cutting,and the data on the sign comes from MES, secondary automation, metering system,The identification data is arranged in order andis automatically printed according to the set order, and at the same time, it can execute the printing action according to the second-level printing signal;The bars are conveyed in the ordercorresponding to the data, reach the automatic welding area of the robot, stopautomatically, wait for the completion of the welding operation of the robot,and then continue the downstream conveying.
(2) It can realize the detection of signs,automatic sign arrangement, and automatic positioning of signs;
(3) The manipulator can automatically take cards, clip cards, and withdraw cards;
(4) It can realize automatic identification of bar position and automatic sign welding;
(5) It can realize automatic sorting, delivery, and withdrawal of welding nails;
(6) Real-time monitoring of the operation of the system and real-time alarm for abnormal situations;
(7) It can realize the function of re-inspection of the number and count of steel bundles, and the re-inspection number and results are transmitted to the secondary system of the production line;
(8) It can realize the high temperature and dust protection functions of the robot;
(9) Provide the independent HMI screen and access control center;
3.2 main technical parameters
(1) One-time welding success rate: ≥ 99.7%;
(2) Number of welding plates: 2 pieces/bundle, flush end welding, welded in the center of the end face of the bar;
(3) Completion time of welding two signs at two ends: ≤ 15s, and completion time of welding two signs at one end: ≤ 25s;
(4) Equipment operation rate: ≥ 99.8%;
(5) Recognition rate of welding point of vision system: 100%;
(6) Capacity of automatic nail feeding system: ＞ 10pieces / min;
(7) Re-inspection accuracy of steel bundle number: 98% / (calculated by bundle
4. System Composition
The welding plate system is mainly composed of a six-axis industrial robot, a 3D visual recognition system, a steel bundle re-check welding system, a welding nail sorting device, a label printing, a positioning device, a safety protection system, an electrical control cabinet, a local console (with the function completely consistent with HMI) and operation control software and hardware.
（1） The six-axis industrial robot is used as the action platform, which can achieve the function of multi-angle free welding. The system is equipped with first-line brand robots.
（2） The special label printer is adopted. The printing and labeling series system is reliable, flexible, and solid. It can communicate with the production line data and can be configured for various applications. It can print ordinary numbers, letters, ASCII codes, one-dimensional codes, and two-dimensional codes.
（3） The automatic plate welding machine applies advanced microcomputer processing technology to control the welding sequence and the energy released by the energy storage capacitor. It can instantly weld and hang the steel plate on the end face of the steel so that the position of the steel plate is obvious and does not damage the integrity of the base metal.
（4） Automatic nail feeding system: nail splitting mechanism, direct vibration flat feeding mechanism, high reliability. The vibration control adopts the intelligent digital pressure regulating vibration feeding controller of cut, which controls the disc feeder and the vibration nail feeding straight slide to complete the nail feeding to a fixed position for the robot to take the nail. For the fault tolerance of the nail feeding device, the success rate of the nail feeding device reaches 99.99% when the specification of the nail reaches the design standard of the nail.
（5） Label printer and welding nail feeding device have automatic thermal switching function of one for use and one for standby, which can be combined freely.
（6） The control cabinet and robot are equipped with a high temperature and dust protection system, which can effectively prevent the impact of high temperature and dust on the system.
（7） The automatic plate welding system has the function of rechecking the number of finished steel bundles. The detected number is compared with the number of steel bundles of corresponding specifications. If there is any abnormality in the steel bundle, it will remind the manual recheck with audible and visual alarm on the control screen and on-site (optional).
LIAONING MINERAL & METALLURGY GROUP CO., LTD . was established in 2007.
Our products are widely used in steel, electric power, hospitals, welding and other fields. With machine vision as the core, it can provide intelligent equipment research and development, manufacturing and transformation services such as unmanned factories in the metallurgical industry and other industries, machine vision, and robot application design.
We are committed to becoming a “leader in visual applications”, advocating the core values of “integrity, cooperation, innovation, expertise, and excellence”, taking the road of “technology shaping the brand, innovation leading the industry”, and attaching importance to the investment in scientific research and technology. The research and development of new products and the construction of the team make unremitting efforts for the goal of scientific and technological development.
We have been supplied to world’s top steel manufacturer Arcelormittal, TATA Steel, EZZ steel etc. We do OEM for Concast and Danieli for a long time
LMM Gith machine vision as the core, it can provide intelligent equipment R&D, manufacturingand transformation services such as unmanned factories in the metallurgicalindustry and other industries, machine vision, and robot application design.
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