The tower foot is the base part of the tower or equipment, located between the tower body and the foundation, mainly plays the role of connecting, fixing and distributing the load. As the core load-bearing component of the tower structure, the design and manufacturing technology of the tower foot directly affects the safety and functionality of the whole structure. The welding quality is directly related to the stability, wind resistance and service life of the tower, so the welding process is very high.
The welding process of the tower foot is complicated, there are many kinds of workpieces, and the working environment is usually harsh. Enterprises generally face the following problems in the production process:
1. The workpiece error is large
The blanking team error of the tower foot industry is large, and it is usually processed by artificial flame bevel or semi-automatic trolley, which is difficult to ensure the consistency of the bevel. This inconsistency poses a great challenge to the adaptability of welding trajectory and welding process, and easily leads to welding defects.
2. High process requirements
The foot welds mainly include fillet welds and groove welds, and the plate thickness ranges from 8mm to 60mm, with a large span. Different thicknesses require different welding process parameters, and traditional welding equipment is difficult to quickly adapt to this diversity, resulting in poor process adaptation.
3. Insufficient assembly accuracy
If the workpiece preparation or assembly accuracy is insufficient (such as weld gap deviation), it is easy to lead to welding bias, incomplete welding and other defects, which need to be reworked or scrapped, increasing the production cost and time cost.
4. The weld shape is complex
Most of the weld seams at the foot of the tower are irregular three-dimensional curves, and the robot needs to determine the weld path through fixed seeking point and dynamic calibration. And the tower feet are mostly large components, there are dead angles in the welding area, and the welding torch is difficult to reach a specific Angle. Traditional teaching programming relies on manual experience, which is inefficient and difficult to adapt to complex structures.
A steel structure head enterprise in order to cope with the above pain points, layout of industry 4.0, to create a digital intelligent factory, the use of Minyue technology based on AI technology of non-teaching steel structure adaptive welding scheme, the use of double numerical control tower foot positioner, intelligent welding workstation access to the company's MES system.
Non-programming teaching solves the problem of high time cost
Through the SmartVision system, the 3D camera is used to scan the workpiece and the complex environment, realizing the 3D reverse modeling of the workpiece and the environment, without manual programming and teaching, and perfectly solving the "position deviation caused by manual placement" without precision positioning of the fixture.
Robotsmart- Intelligent decision system, through artificial intelligence technology, autonomous control robot planning work path, multi-machine collaboration, task allocation. Through AI intelligent algorithm, automatic weld extraction, welding process matching, overpass collision, singularity hyperspace simulation and simulation analysis and optimization of independent decision-making, reduce the dependence on physical equipment, reduce downtime costs, and improve programming efficiency. Improve safety through intelligent simulation iteration, adapt to small batches of multi-variety workpieces, and flexibly adapt to various technologies and welding scenarios.
Simple training, a general worker can control four robots. Reduced reliance on skilled workers and reduced safety risks associated with manual operations.
Weld tracking system solves the problem of complex weld shape
smart eye- Weld tracking system for precise positioning of the workpiece, confirmation of weld information through high-precision sensors, and correction of deviations between the 3D model and the actual workpiece.
For the complex welding process, the system can flexibly adjust the welding parameters, adapt to different plate thickness, weld type and workpiece size, multi-layer and multi-pass welding process automatic generation, groove welding adaptive.
With the continuous development of artificial intelligence and industry 4.0 technology, the foot welding process will move towards higher precision and higher efficiency. Through the application of intelligent solutions, the tower welding industry will gradually get rid of the shackles of traditional processes, achieve the dual improvement of production efficiency and product quality, and promote the transformation of industrial automation from experience-driven to intelligent drive. Lower the programming barrier for complex tasks.
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