机器人点焊板材厚度检测的数值模拟与变量程序应用研究

卢健能; 柯世金; 谈毅; 罗邦芬

doi:10.7512/j.issn.1001-2303.2024.06.07

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机器人点焊板材厚度检测的数值模拟与变量程序应用研究
Research on Variable Program Application of Plate Thickness Detection in Robot Resistance Spot Welding
2024年54卷第6期页码：39-44
纸质出版日期： 2024-06-25 ，
DOI： 10.7512/j.issn.1001-2303.2024.06.07
稿件说明：

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卢健能，柯世金，谈毅，等.机器人点焊板材厚度检测的数值模拟与变量程序应用研究［J］.电焊机，2024，54（6）：39-44.

LU Jianneng, KE Shijin, TAN Yi, et al.Research on Variable Program Application of Plate Thickness Detection in Robot Resistance Spot Welding[J].Electric Welding Machine, 2024, 54(6): 39-44.
卢健能，柯世金，谈毅，等.机器人点焊板材厚度检测的数值模拟与变量程序应用研究［J］.电焊机，2024，54（6）：39-44. DOI： 10.7512/j.issn.1001-2303.2024.06.07.

LU Jianneng, KE Shijin, TAN Yi, et al.Research on Variable Program Application of Plate Thickness Detection in Robot Resistance Spot Welding[J].Electric Welding Machine, 2024, 54(6): 39-44. DOI： 10.7512/j.issn.1001-2303.2024.06.07.

摘要

针对轿车车门内板点焊过程中，机器人伺服焊枪经过多个焊点操作后工件间隙扩大，以及钣金厚度变化造成的焊接质量下降问题。基于ANSYS有限元技术对高强度双相钢机器人点焊过程进行热传导数值模拟分析，研究板材厚度变化对焊接热传导效率及熔核直径大小的影响。试验结果表明，当板材厚度为1.9~2.0 mm时，熔核直径达到最大值，随着板材厚度的增加，熔核直径减小，焊接质量下降。为解决这一问题，运用KUKA机器人伺服焊枪的板材厚度动态检测功能和变量程序跳转指令，在板材厚度超出公差值（1.8~2.5 mm）时中断机器人焊接程序并及时报警，减少了板材间隙增大带来的飞溅、虚焊等缺陷，提高形核质量和焊接精度，保证车门内板高强度双相钢点焊的前后焊点质量稳定。

Abstract

This study addresses the issue of welding quality degradation in the spot welding process of car door inner panels

where the gap between workpieces expands and the sheet metal thickness changes after the robot servo welding gun passes through multiple welding points. Based on ANSYS finite element technology

a thermal conduction numerical simulation analysis of the robot spot welding process for high-strength dual-phase steel was conducted to investigate the impact of plate thickness variation on welding heat conduction efficiency and nugget diameter size. The experimental results indicate that when the plate thickness is between 1.9~2.0 mm

the nugget diameter reaches its maximum value

and as the plate thickness increases

the nugget diameter decreases

leading to a decline in welding quality. To resolve this issue

the dynamic detection function of the KUKA robot servo welding gun for plate thickness and the variable program jump command were utilized. When the plate thickness exceeds the tolerance value (1.8~2.5 mm)

the robot welding program is interrupted and an alarm is issued in a timely manner

reducing defects such as spatter and false welding caused by the increase in plate gap

and improving nucleation quality and welding precision

thus ensuring the stability of the front and back welding points' quality in the spot welding of high-strength dual-phase steel for car door inner panels.

关键词

机器人点焊板材厚度熔核直径热传导模拟变量程序

Keywords

robot resistance spot weldingplate thicknessnugget diameterheat conduction simulationvariable program

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