At present, in the actual production process of iron and steel enterprises, for bars (including medium bars, small bars, rebar) and high-speed wire products, the labeling process after bundling is still in the stage of manual execution. After the workers have printed the signs in the studio, they will be transported to the welding process section by a dedicated person. When the products are bundled and reach the designated location (or cooling bed), an operator must take the signs, take out the welding nails, and hold the welding torch to complete the welding. action. (Installation location).
According to the experience that large and medium-sized iron and steel enterprises’ cold and hot-rolled strip production lines, medium and wide and heavy plate production lines have basically all realized automatic coating of coils, combined with many disadvantages of manual welding signs, such as
①The working environment is high in temperature, dust and noise pollution;
②High labor cost and low welding efficiency;
③Low automation, irregular use of materials (signs, welding nails, and welding torches), and serious waste. In combination with the current state’s proposal for the conversion of new and old kinetic energy, vigorously promote industrial informatization and automation strategies. The equipment is based on robotics and computer image technology, and is connected to an online MES system for transmission, and completes the steps of automatic printing of signs, automatic picking of welding nails, automatic picking of plates, automatic identification of target positions, and optimization of welding positions to complete automatic welding.
1. Environmental conditions and energy:
The electronic control system design and equipment manufacturing of this offer should consider the following conditions: Power supply: three-phase five-wire system, AC380V±10%, 50Hz±1%; Humidity: ≤80%; The highest ambient temperature on site: 50℃; Cooling water: industrial purified water (no corrosion and particulate matter), the maximum temperature is 35℃; Air source pressure: 0～0.5MPa.
2. Bar parameters:
Bar end face specification range: Φ12～Φ50mm; Annual output: 2 million tons (single line); Cut-to-length length: 6～15m; Bundle weight: 2～5t; Bundle steel temperature: ≤200 ℃ (after hot rolling and cooling)
3. Welding card related technical parameters:
Welding card related technical parameters One-time welding success rate: ≥99.8%; 2 signs welding completion time: ≤ 30s; Equipment operation rate: ≥99.8%; The success rate of vision system taking pictures: 100%; Automatic nail feeding system capacity:> 10 pcs/min, output accuracy rate> 99.5%; The accuracy rate of the re-inspection of the steel bundle count is 100%.
1. Able to print and cut signs;
2. It can detect whether signs are present, automatically organize signs, and automatically locate signs;
3. It can realize the automatic picking, clamping, and withdrawal of the cards by the manipulator;
4. can realize automatic recognition of bar position and automatic sign welding;
5. It can realize automatic sorting, feeding, and returning of welding nails;
6. It can realize real-time monitoring of the operation of the system and real-time alarm for abnormal situations;
7. Able to realize the re-inspection of the number of steel bales;
8. It can realize that the robot has a collision self-diagnosis function;
9. It can realize the robot’s high temperature and dust protection function.
① The position of the welding plate should avoid bars with uneven, protruding, or indented cross-sections;
② When a bundle of bars contains finished bars protruding more than 50mm, there should be an alarm message to remind employees to deal with it;
③Video surveillance should be installed in the robot area, and the operation process of the equipment can be observed in the central control room.
④The robot ignores abnormal fixed-length bars or non-rulers and does not handle welding plates. At the same time, there is an alarm message to remind employees to deal with it.
The Automatic welding tag machine and auxiliary equipment are installed in the circular area shown in the figure. The required plane area can be controlled within 4.5 square meters, the space volume is controlled at 9m³, that is, the length is 2250mm, the width is 2000mm, and the height direction is controlled within 2000mm. This is the fixed installation position of the flush end of the rebar. For the installation of the other end, considering that the rebar specification has two lengths of 9000mm and 12000mm, please provide the working conditions for the robot to change orbit.
Regardless of the end of the equipment installed, it is necessary to consider whether there will be cranes passing heavy objects above the area to avoid heavy objects falling and damaging the equipment. For this reason, users are requested to consider the safety issues caused by heavy objects falling. Sign automatic welding system
The welding system is mainly composed of six-axis industrial robot, visual recognition system, welding system, welding nail sorting device, label printing and positioning device, safety protection system, electrical control cabinet and operation control software.
A 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 international first-line brand robot ABB products. The robot runs from the initial position to the nail picking position in the welding nail sorting system, and uses the clamping force of the welding gun nozzle to remove the welding nails and move them to the position above the sign, ready for the next step of sign information verification and automatic picking.
The system is equipped with a welding nail detection unit. When the nail removal fails, the system will alarm, and the robot will return to the nail removal position to take the nail again.
the robot vision recognition system scans the end face of the finished bar, marks the end face of the identified bar, and automatically counts the count of the bundle of bars. Through the communication with the rolling line control system, it can receive count alarm setting value, send count statistics result and alarm information. At the same time, the re-inspection image is transmitted to the operating room for manual confirmation by the weighman. (Simultaneously with 3 welding mark position recognition)
When the new workpiece arrives at the designated position and stops, the PLC control system sends the new workpiece arrival command to the visual recognition system (2D), and the visual recognition system will automatically take pictures, and image acquisition, and automatically select the appropriate one Mark the cross-section of the target rebar and send the position information of the target cross-section to the robot. (Simultaneously with the re-inspection of 2 finished products)
After the weighing is completed, the weighing control system sends the weighing information, the number of bundles (passed through the re-inspection), specification information and QR code to the label printer through the Ethernet, and the label printer automatically Print the signs. After the signs are printed, they are sent to the sign sorting mechanism, and the sign sorting mechanism will position the signs for the purpose of checking the sign information and adsorption (automatic pickup) of the signs.
After the sign is printed and positioned, the robot that has been waiting above the sign will automatically scan and decode the two-dimensional code of the sign, and the information obtained by the system at both ends of the rebar will be decoded and weighed simultaneously The raw data of the control system are compared at the same time. After confirming that the information is correct, the sign will be picked up automatically. The picking up of the sign is completed by vacuum suction. After the robot picks up the sign, it will automatically move to the initial position of the welding sign and wait for the order of the welding sign. When the sign is blurred or the sign information on both ends is inconsistent, the robot will send out an alarm message to remind the staff to deal with it.
When the sign is accidentally lost during the pick-up process, the vacuum adsorption system will automatically alarm and feed it back to the industrial computer, and the industrial computer will re-print a sign with the same information for the robot to take again.
The robot performs axial distance measurement of the target according to the target rebar position information provided by the visual recognition system. The distance measurement is realized by a laser rangefinder, and the distance information is fed back to the system.
The robot automatically runs to the welding mark position after obtaining the target position of the welding mark according to visual recognition and distance measurement, and then powers on to complete the welding. In order to ensure the firmness and accuracy of the welding, and to protect the welding torch from excessive contact force, we can integrate the force sensor behind the welding torch at the same time.
After the welding torch contacts the cross-section, the welding will be completed when the force exceeds a certain value.
After the robot finishes welding the signs, it releases the welding nails and signs, and then automatically returns to the original position (initial position), waiting for the next welding cycle.
At the same time, the welding mark completion signal is sent to the PLC control system of the collection area to notify the system that the rod bundle can be removed. PLC, select S7-1200 series products, reserve Ethernet communication interface for communication with finishing automation system, and can cooperate with finishing automation complete set to complete communication debugging.
The PLC cabinet and the robot control cabinet adopt an integrated cabinet designed by the supplier. The electrical system control cabinet and the robot control cabinet are placed on site, and the gas distribution box and terminal box are set on site.
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