防窜焊接滚轮架：窜动检测及防窜控制系统设计

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摘要

焊接滚轮架是在焊接生产中与焊接工序相配一种辅助装置。在大厚壁、大型化、高容量、耐磨蚀的锅炉、石油、化工压力容器的焊接过程中，由于筒体的几何形状的不规则（偏离理想回转体）和焊接滚轮架的制造安装误差等原因，筒体在滚轮架上转动时，会不可避免的发生轴向窜动，从而影响环缝的焊接质量。本课题从理论上深入分析了筒体在焊接过程中产生轴向窜动的主要原因，分析了筒体轴向位移的调节机理，同时提出了采用螺旋升降装置和步进电机传动，用PLC控制器以脉冲控制的方式使步进电机精准的控制升降台的上升和下降的位移。

此防窜焊接控制系统有效地解决了窄间隙埋弧焊、内壁堆焊的问题，智能化控制焊接过程中出现的轴向窜动，此设计实现了精密化、大型化、数字化、智能化等优点。不仅提高了生产效率而且确保批量生产过程中焊接质量的稳定性，节省因窜动进行人工调节的时间，减少劳动力，提高焊接的精度和质量，降低成本。关键词:窜动理论分析窜动检测调节执行机构硬件部分设计软件部分设计

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Abstract

Welding roller bed is in the welding production and welding process to match an auxiliary device The Welding and Production in the big Thick-Cliff、The Large-Scale、High-Content、Endure-Ablation of the pressure vessel of the Boiler、Oil、chemical,because of reason of the abnormity of geometry-form of the cylinder (departure ideal gyration object)and the error of the manufacture-installation ,the cylinder wheel on the roller bed,inevitably it will occur axial drifting,so that affect the welding quality. This topic of cylinder were analyzed theoretically in the welding process to produce axial channeling move, the main reason of the regulation mechanism of cylinder axial displacement are analyzed, at the same time puts forward adopting spiral lifting gear and step motor driving, PLC controller to control by means of pulse to make precise stepper motor control displacement of the rise and fall of the lifting platform.

The anti channeling welding control system can effectively solve the narrow gap submerged arc welding, the welding problem, intelligent control in the welding process of the axial channeling move, this design implements the motors, large-scale, digital and intelligent advantages. Not only improves the production efficiency and ensure the stability of welding quality in mass production process, save for channeling manually adjust time, reduce the labor force, improve the accuracy of welding and quality, reduce costs.

Key words: Dynamic analysis The axial dynamic detection Adjust the actuator The hardware part of the design Software part design

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目录

摘要........................................................................................................................III Abstract........................................................................................................................ II 1.绪论.. (1)

1.1 国内外焊接滚轮架发展现状 (1)

1.2课题的研究内容及意义 (2)

2.防窜焊接滚轮架系统的结构设计及工作原理 (2)

2.1 系统的结构设计 (2)

2.2 系统的工作原理 (2)

3.筒体轴向窜动的理论分析 (3)

3.1 焊接过程中常出现的一些问题 (3)

3.2 轴向窜动的主要原因 (4)

3,3 滚轮架简体轴向窜动机理 (4)

3.4 焊件不发生轴向窜动的充分条件 (6)

4.筒体轴向窜动的检测、调节及执行机构设计 (7)

4.1 轴向窜动检测 (7)

4.2 调节方式的选择 (8)

4.3 调节执行机构的调节原理 (9)

4.4 升降装置的选型 (10)

5.系统控制部分 (12)

5.1系统硬件部分设计 (12)

5.1.1 PLC控制器 (13)

5.1.2步进电机的计算与选型 (16)

5.1.3 步进电机驱动器的选用 (21)

5.1.4 联轴器的选择 (22)

5.1.5 位移传感器选型 (23)

5.1.6 限位开关选型 (23)

5.1.7 控制面板的设计 (23)

5.2 系统软件部分设计 (23)

5.2.1 防窜控制模式选择 (23)

5.2.2主程序控制图 (24)

5.2.3 梯形图程序 (25)

6.总结 (29)

参考文献 (30)