摘要
Abstract
Aiming at the problems of low efficiency,large deformation and poor quality consistency in manual welding of the asymmetric box-shaped end structure of HXD1 electric locomotive,the automated welding process using IGM welding manipulator was investigated.The weldability of the end structure was analyzed,and five key technical challenges were ad-dressed:large assembly dimensional deviation,difficulty in continuous welding of right-angle welds at the coupler box rein-forcement plate,insufficient welding torch accessibility in confined spaces,difficulty in welding deformation control,and low programming efficiency.Corresponding solutions were proposed,including laser cutting combined with three-dimensional template positioning and hydraulic clamping fixtures,segmented welding with trajectory replication,extended slim-neck welding torch with positioner posture optimization,rigid fixation with symmetrical welding sequence,and para-metric programming.Using 80％Ar+20％CO2 mixed gas shielded welding with the IGM manipulator,25 locomotive end structures were welded.The results show that the first-pass inspection rate of welds reaches 99.5％,the surface quality meets EN 5817-B requirements,and the ultrasonic testing meets EN 1714 Level Ⅱ requirements.The flatness of the upper cover plate is 2 mm/3 m and that of the coupler box is 0.5～1 mm/1 m,both satisfying the design specifications.The production ef-ficiency is improved by 52.7％,the programming time is reduced by 20％,and the secondary positioning time is decreased by 25％.This process scheme has been applied to 41 locomotive end structures,providing a replicable process reference for automated welding of complex structural components in rail vehicles.关键词
IGM焊接机械手/端部结构焊接/电弧跟踪/工艺优化/工装定位Key words
IGM welding manipulator/end structure welding/arc tracking/process optimization/tooling positioning分类
矿业与冶金
