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

Customer Request

1.1 Usage and Processing Requirements

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

Cutting Objects: Mainly 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: Liquefied petroleum gas 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%;

Temperature: -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

Components such as the side plate of the transition groove, base frame, and coupling pad upper and lower plates are processed. Large structural plates require space groove cutting, while straight or curved cuts are used for smaller parts like tongue plates. Angle cutting improves the visual finish of exposed bevels and enhances the quality of groove welding.

Cutting Objects: Mainly hot-rolled medium and heavy plates like low carbon steel and alloy steel.

Cutting Gas: Propane and oxygen.

Cutting Method: The robot groove cutting workstation is designed in a single-station configuration.

Work Loading and Unloading: Manual loading and unloading is used.

2.2 Workstation Overview

This workstation is arranged in a single station. It consists of a robotic arm, 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 "Teaching Mode."

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

5. Perform the teaching operation using the teaching pendant (only needed once initially).

a) Welding Procedure

1. Control the robot remotely to define the path.

2. Enter command codes. For example, when sensing the start point, only specify the command code and groove type, and the robot will automatically generate the sensing action.

3. Set parameters within the system.

4. Check for errors in the program and ensure it's 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 (e.g., flash drive).

(2) Regeneration Operation (Automatic Mode)

1. Insert the safety bar.

2. Switch the operation mode key on the robot control box to "Regeneration Mode."

3. Ensure no one is in the safety area and that the robot’s motion range is clear.

4. Use the external start unit to select the program number and begin regeneration.

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

6. If an issue like torch malfunction happens, the status indicator changes from yellow to red to alert the operator.

7. Follow the exception handling steps:

1) Switch back to "Teaching Mode" and enter the safety zone.

2) Identify the problem and resolve it. If the automatic recovery function is enabled, the robot can resume from the last stop point.

3) Exit the safety zone, insert the safety plug, and restart the process.

4) After completing the operation, switch back to "Teaching Mode," check the groove condition, and update the database if needed.

5) Save the updated program on an external memory device.

6) Repeat the cycle for similar workpieces by calling the pre-programmed sequence, starting the cut, and unloading the finished part.