Detailed Analysis of the Groove System Scheme Based on Sheet Metal Parts

Customer Request

1.1 Use and Processing Requirements

The side plates for the transition groove, the base frame’s side plates, the upper and lower plates of the coupling pad, and similar components require precise cutting. This includes space groove cutting on large structural plates, straight or curved cuts on flat positioning parts, and small pieces like tongue plates. The goal is to perform angle cutting to enhance the appearance of exposed bevels on large structural parts and improve the quality of groove welds.

Cutting Objects: Primarily hot-rolled medium and heavy plates such as low carbon steel and alloy steel.

Cutting Gas: Propane and oxygen.

Cutting Method: The robot groove cutting workstation uses a single-station layout.

1.2 Technical Parameters and Performance Requirements

☆ Equipment Technical Parameters

☞ Effective Cutting Width: 1500 mm; Effective Cutting Length: 5000 mm;

☞ Effective Cutting Thickness: 100 mm; Maximum Groove Angle >60°;

Flame Cutting Speed: 100–800 mm/min; Continuous Operation for 24 Hours;

Maximum Workbench Load Capacity: Not less than 2.0t;

☆ Working Environment Conditions

☞ Power Supply: Three-phase AC 380V 50Hz;

☞ Ambient Temperature: -10°C to 50°C, Humidity ≤80%;

Surrounding Environment: Well-ventilated with minimal vibration;

Cutting Gas: LPG or natural gas + oxygen;

Gas Pipeline Pressure: 0.35–0.5 MPa; Maximum Gas Flow: 120–150 m³/h;

Oxygen Pipeline Pressure: 0.5 MPa; Compressed Air Pressure: 0.5–0.6 MPa;

Power Supply: Three-phase AC 380V±10%, 50Hz±2%;

Environmental Conditions: -10°C to 50°C, Humidity ≤80%, Non-corrosive air;

Surrounding Environment: Good ventilation, vibration below 0.5G;

Compressed Air: >0.5 MPa;

2. Workstation Overview

2.1 Welding Process

The side plate for the transition groove, the base frame's side plate, the upper and lower plates of the coupling pad, and similar parts require accurate groove cutting. This includes straight and curved cuts on large structural plates and small parts like tongue plates. The purpose is to perform angle cutting to improve the appearance of exposed bevels and the quality of groove welds.

Cutting Objects: Mainly hot-rolled medium and heavy plates, including low carbon and alloy steels.

Cutting Gas: Propane and oxygen.

Cutting Method: The robot groove cutting workstation is designed with a single-station layout.

Workpiece Loading/Unloading: Manual loading and unloading.

2.2 Workstation Overview

This workstation is arranged in a single station. It mainly consists of a grooving robot, workpiece positioner, flame cutting system, safety measures, and an integrated control cabinet.

2.3 Workstation Operation Process

(1) Teaching Assignment

1. Place the workpiece on the fixture and position it properly.

2. Turn on the equipment.

3. Switch the operation mode button on the robot control box to the teaching mode.

4. Confirm before starting the teaching process (only required for the first run).

5. Perform the teaching operation using the teaching operator (only needed for the first time).

a) Welding Procedure

1. Control the robot remotely and define the path.

2. Set the command code.

For example, when the welding start point is sensed, only the command code and groove type need to be specified, and the robot will automatically generate the sensing action.

3. Set the parameters in the system.

4. Check for errors in the teaching program and ensure it is transferred correctly. If there are issues, make necessary adjustments.

5. Move the robot to the retracted position (start and end points of the program).

6. Save the program on an external memory device, such as a flash card.

(2) Regeneration Operation (Automatic Mode)

1. Insert the safety bar into the safety area.

2. Switch the robot operation box to regeneration mode.

3. Confirm that no one is in the safety area and that there is no interference in the robot's motion range.

4. Set the program number using the external start unit to initiate the regeneration process.

5. Once started, the program runs automatically without requiring operator supervision, unless an abnormal stop occurs.

6. If an issue like a torch malfunction occurs, the status indicator light changes from yellow to red to alert the worker.

7. The exception handling procedure is as follows:

1) Switch the operation mode back to teaching mode and enter the safety area.

2) Identify the abnormal condition and resolve the cause. If the robot has a temporary stop recovery function, it can restart automatically from the last stop point.

3) After fixing the issue, exit the safety area and insert the safety plug.

4) Switch back to regeneration mode and restart the process.

8. After completing the regeneration, switch back to teaching mode, enter the safety area, and check the groove condition. If any adjustments are needed, update the database accordingly.

9. Save the updated program on an external memory device.

10. For repeated tasks, once the same part is clamped, the pre-programmed teaching sequence is called, the external start is triggered, the groove is cut, and the part is unloaded—completing one cycle.