Automated Welding Process Using IGM Welding Manipulator and Its Application to Asymmetric End Structure of HXD1 Electric Locomotive

ZHONG Junlin; WANG Fulin; LIN Yuanchun; DENG Min; ZENG Hongbing

doi:10.7512/j.issn.1001-2303.2026.05.16

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Automated Welding Process Using IGM Welding Manipulator and Its Application to Asymmetric End Structure of HXD1 Electric Locomotive
Vol. 56, Issue 5, Pages: 131-139(2026)
Received：10 March 2026，

Revised：2026-05-12，

Published：20 May 2026
DOI： 10.7512/j.issn.1001-2303.2026.05.16
稿件说明：

移动端阅览

钟俊林，王福林，林元春，等.IGM焊接机械手自动化焊接工艺及在HXD1机车非对称端部结构中的应用［J］.电焊机，2026，56（5）：131-139. DOI： 10.7512/j.issn.1001-2303.2026.05.16.

ZHONG Junlin, WANG Fulin, LIN Yuanchun, et al.Automated Welding Process Using IGM Welding Manipulator and Its Application to Asymmetric End Structure of HXD1 Electric Locomotive[J].Electric Welding Machine, 2026, 56(5): 131-139. DOI： 10.7512/j.issn.1001-2303.2026.05.16.

摘要

针对HXD1电力机车端部非对称箱形结构手工焊接效率低、变形大、质量一致性差的问题，开展IGM焊接机械手自动化焊接工艺研究。分析了端部结构焊接工艺性，针对组装尺寸偏差大、车钩箱加强板直角焊缝连续焊接困难、狭窄空间焊枪可达性不足、焊接变形控制难及编程效率低等5项关键技术难题，分别提出激光切割下料结合立体样板定位与液压夹紧工装、分段焊接与轨迹复制工艺、加长细颈焊枪配合变位机姿态优化、刚性固定与对称焊接顺序及参数化编程等解决方案。采用80%Ar+20%CO

混合气体保护焊配合IGM机械手焊接25台端部，焊缝一次探伤合格率达99.5%，表面质量符合EN 5817-B级规定，超声波探伤符合EN 1714 Ⅱ级要求，上盖板平面度2 mm/3 m、车钩箱平面度0.5~1 mm/1 m均满足设计要求；生产效率提高52.7%，编程时间缩短20%，二次寻位时间减少25%。该工艺方案已推广应用至41台机车端部焊接，为轨道车辆复杂结构件自动化焊接提供了可复制的工艺参考。

Abstract

Aiming at the problems of low efficiency

large deformation and poor quality consistency in manual welding of the asymmetric box-shaped end structure of HXD1 electric locomotive

the automated welding process using IGM welding manipulator was investigated. The weldability of the end structure was analyzed

and five key technical challenges were addressed: large assembly dimensional deviation

difficulty in continuous welding of right-angle welds at the coupler box reinforcement plate

insufficient welding torch accessibility in confined spaces

difficulty in welding deformation control

and low programming efficiency. Corresponding solutions were proposed

including las

er cutting combined with three-dimensional template positioning and hydraulic clamping fixtures

segmented welding with trajectory replication

extended slim-neck welding torch with positioner posture optimization

rigid fixation with symmetrical welding sequence

and parametric programming. Using 80% Ar + 20% CO

mixed gas shielded welding with the IGM manipulator

25 locomotive end structures were welded. The results show that the first-pass inspection rate of welds reaches 99.5%

the surface quality meets EN 5817-B requirements

and the ultrasonic testing meets EN 1714 Level II requirements. The flatness of the upper cover plate is 2 mm/3 m and that of the coupler box is 0.5~1 mm/1 m

both satisfying the design specifications. The production efficiency is improved by 52.7%

the programming time is reduced by 20%

and the secondary positioning time is decreased by 25%. This process scheme has been applied to 41 locomotive end structures

providing a replicable process reference for automated welding of complex structural components in rail vehicles.

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