Welding Torch Research And Technological Experiment For Automatic Stud Welding With Hybrid Resource

Currently, most of the blocks attached of the armored vehicles turret body are made by the technological procedures of manual electrode arc welding and semi-automatic gas shielded arc welding. However, there are some welding defects such as under fusion, crack, and pores. In practice, a hybrid thermal source made of the induction heat source and stud welding worked as an effective process for the large diameter studs and heavy, big steels.Based on the comprehensive and systematic analysis of domestic and international stud welding technology, a welding torch organization plan was proposed, suitable for the large diameter hybrid thermal source stud welding. The electromagnetism raising mechanism, cushioning mechanism, the altitude mixture control mechanism, the water cooling organization, and etc were researched and designed. In addition, the components materials of the welding torch were calculated and chose. Finally, the stud welding torch that could weld the large diameter stud was developed.Domestic & foreign entire solid state induction heating technology was studied. At the meantime, the technological process and the heating characteristics of the induction - electric arc hybrid thermal source were investigated. Based on the above-mentioned analysis, the hybrid thermal sources inductive loop was designed, which could realize the hybrid thermal sources stud welding to the d=10～30mm stud and proposes the optimization plan to the induction heating process's cooling system.Moreover, clamps of the welding torch and the induction coil, welding process protective devices, welding actuator device were designed. The arc-type 3000A stud machine, 29KW the solid state IGBT and the central controller were integrated to form the manual hybrid thermal sources stud to weld principle prototype.Because of the need of the heavy vehicle's development and production, the MOTOMAN-ES165N robot was taken as the attached studs' movement and the control device, and the entire automated robot stud welding system was designed. This system has the functions to take the clamp cover, attached studs, feed the studs automatically. The entire installment blueprint of the hybrid thermal sources to welding the studs was designed.The results of welding test indicated that the welding torch had good operational performance, the welded joint forming. Furthermore, the heat-affected zone had not been overheated nor cracked. Compared with the German stud welding torch, the welding torch had no obvious disparity.