大型空腔类构件密封自动锡焊系统构建和焊接质量研究

发布时间：2018-10-30 08:38

【摘要】：空腔类构件的密封锡焊主要是通过人工软钎焊工艺实现的,其焊接工序复杂,焊接质量不稳定,焊接效率低,废品率高。随着自动焊接技术的发展,实现空腔类构件焊接过程的自动化将成为必然趋势。本文以某类内部安装多功能电子器件的大型空腔类构件的自动密封锡焊系统构建和焊接质量为研究对象,以HP20D工业机器人为平台,设计了末端执行器和构件工装变位机,研究了密封锡焊工艺参数对焊接质量的影响,实现了对空腔类构件的高质量锡焊。建立了机器人的关节连杆坐标系,获得了机器人的D-H参数；对机器人进行了运动学分析,确定机器人末端位置与六关节转动角度的空间关系,求得机器人运动学正解和逆解,对机器人运动学性质进行了仿真。对上位机控制功能进行了二次开发；设计了机器人运动控制界面,实现了在上位机上控制机器人末端执行器的插补方式和运动速度,并能够实现焊接程序文件的上传与下载。设计了末端执行器；该执行器设计主要包括整体结构、加热装置、温度和功率控制系统的设计,保证了末端执行器与机器人的可靠连接、热量的安全传递、功率可调和温度可控。设计了构件工装变位机,并对工装变位机进行了静力学和模态分析；结果表明,主要变形部分是旋转支撑架,但是最大变形量微小,可忽略不计；变位机固有频率主要分布在50Hz到230Hz之间。建立了焊接温度场有限元模拟模型,模拟结果表明,焊接速度为1mm/s～2mm/s时,焊接质量较好；热源上各点的温度沿焊接方向相继达到峰值然后急剧下降,在准稳态条件下其温度峰值达到并超过材料的熔点,锡焊横截面上各点的温度变化趋势相似。焊接速度越高,形成的焊接温度场区域越小,而焊接温度小于焊接速度低时的温度。研究了焊接角度、边界热源、焊接速度、焊接次数和焊接温度对焊接质量的影响规律。结果表明,当焊接角度为60°,使用热风枪对构件进行预热并保持焊接温度,焊接速度为1～2mm/s,采用二次走焊工艺,焊接温度为350℃～450℃时,构件焊接质量较好。
[Abstract]:Sealing tin welding of cavity components is mainly realized by manual soft brazing. The welding procedure is complex, the welding quality is unstable, the welding efficiency is low, and the scrap rate is high. With the development of automatic welding technology, it will become an inevitable trend to automate the welding process of cavity components. In this paper, the construction and welding quality of automatic sealing tin welding system for large cavity components with multifunctional electronic devices are studied, and the end actuator and component tooling positioner are designed on the platform of HP20D industrial robot. The effect of process parameters of sealed tin welding on welding quality was studied, and high quality tin welding for cavity components was realized. The coordinate system of the robot is established, and the D-H parameters of the robot are obtained. The kinematics analysis of the robot is carried out to determine the spatial relationship between the end position of the robot and the rotation angle of the six joints, and the forward and inverse kinematics solutions of the robot are obtained, and the kinematics properties of the robot are simulated. The control function of the upper computer is redeveloped, the robot motion control interface is designed, the interpolation mode and the motion speed of the robot end actuator are controlled on the upper computer, and the welding program file can be uploaded and downloaded. The end actuator is designed. The design of the actuator mainly includes the whole structure, heating device, temperature and power control system, which ensures the reliable connection between the end actuator and the robot, the safe transfer of heat, and the controllable power harmonic temperature. The static and modal analysis of the machine is carried out. The results show that the main deformation part is the rotating support frame, but the maximum deformation is small, which can be ignored. The natural frequency of the positioner is mainly distributed between 50Hz and 230Hz. The finite element simulation model of welding temperature field is established. The simulation results show that the welding quality is good when the welding speed is 1mm/s~2mm/s. The temperature of each point on the heat source reaches the peak along the welding direction and then drops sharply. Under the quasi-steady condition, the temperature peak reaches and exceeds the melting point of the material, and the variation trend of the temperature at each point on the cross section of the tin welding is similar. The higher the welding speed is, the smaller the welding temperature field is, and the smaller the welding temperature is when the welding speed is low. The influence of welding angle, boundary heat source, welding speed, welding times and welding temperature on welding quality was studied. The results show that when the welding angle is 60 掳, the hot air gun is used to preheat the component and the welding temperature is kept, the welding speed is 1 ~ 2 mm / s, and the welding quality is better when the welding temperature is 350 鈩，

本文编号：2299506