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Türkiye'nin ilk nokta kaynağı robotunun incelenmesi

On the first spot welding robot of Turkey and developments of welding robots

  1. Tez No: 21969
  2. Yazar: GÖKHAN KALAYLI
  3. Danışmanlar: PROF. DR. SELAHADDİN ANIK
  4. Tez Türü: Yüksek Lisans
  5. Konular: Makine Mühendisliği, Mechanical Engineering
  6. Anahtar Kelimeler: Belirtilmemiş.
  7. Yıl: 1992
  8. Dil: Türkçe
  9. Üniversite: İstanbul Teknik Üniversitesi
  10. Enstitü: Fen Bilimleri Enstitüsü
  11. Ana Bilim Dalı: Belirtilmemiş.
  12. Bilim Dalı: Belirtilmemiş.
  13. Sayfa Sayısı: 159

Özet

ÖZET Günümüzde gelişen teknolojiye ve onun getirdiği yükümlülüklere karşı durabilmenin temel şartlarından biri olan bazı sanayii robotlara gereksinim vardır. Bunun bilincinde olan bazı sanayii kuruluşlarımız bu tür sistemlerin kullanımına kısmen ya da tamamen geçmiştir., Otasan San. A.Ş' de bu kuruluşlarımızdan biri olarak bu konunun ölçülerindendir. Nitekim, türkiye'nin ilk nokta kaynağı robotuda bu firma tarafından devreye alınmıştır. Tezin konusu esas itibariyle bu nokta kaynağı robotunun incelenmesidir. Aynı zamanda bu çalışma; diğer kaynak robotları ve nokta kaynağı prensipleri hakkında bilgiler verilmiştir. Bu çalışmada, Otosan'da devreye alınan Kawasaki EX100F Model nokta kaynağı robotu ile eşdeğer robotların teknik ve mekanik özellikleri ile çalışma koşulları incelenmiş ve bu konuda çalışacak kişilere yardımcı kaynak olarak sunulmuştur. vı

Özet (Çeviri)

Turkey is also begun to be used industrial robots, especially welding robots, handling robots as many developing countries. Because, this is the result of devolopment. First of all, The spot welding robot which is Kawasaki EX100F Model has been begun to be used by Otosan Automobile A.Ş in Turkey. By this robot, Chassis side members of transits and P1001 s have been welded. Robots are required to have much higher mobility and dexterity than traditional machine tools. They must be able to work in a large reachable range, acces crowded places, handle a variety of workpieces and perform Flexible tasks. A robot mechanical structure is basically composed of cantilevered beams, forming a sequence of arm links connected by hinged joints. Finally, robots are required to interact much more heavily with peripheral devices than traditional numerically controlled machine tools. Machine tolls are essentially self-contained systems that handle workpieces in well-defined locations. By contrast, the environment in which robots are used is often poorly structures and effective means must be developed to identify the locations of the workpieces as well as to communicate to peripheral devices and other machines in a coordinated fashion. Before 1950, Production lines used a large number of partable weldstations to assemble the different parts of a car body. One man was needed for each operation, which meant that work slow, difficult an painstaking (assembly line work= Taylorism). This division of production tasks nevertheless offered the advantage of Flexibility and provided some degree of adaptability, making certain modifications to the body type or even changes of model possible without undue expense. From 1950 to 1975, The search for improved productivity mode it necessary to use multiple spotwelding machines and transfer lines. vu1The principle consisted of moving the parts to be assembled through a series welding stations. In general, each station had an electrode for each spotweld. A line could have up to several hundred elect rodes. These lines were not very Flexible and one drawback was that there was always a risk that it would be impossible to amortize them if the model for which were designed did not sell well. It was sometimes necessary to use completely new lines, and sometimes even to build other workshops if the manufacturer wished to change the body model. Around 1965., a step toward Flexibility was by introdu cing equipment into the machines and the assembly lines to offer the possibility of producing two or even there diffe rent versions of a single model. Selection was determined by a“mechanical memory”with binary“on/off”operation. Since 1975, The minicomputer technological revolution has provided the memory storu6a copacity required for produc tion planning and control. Moreover, with the introduction of robots, it became possible to make the tooling flexible thus enabling it to carry out the different instruction transmitted by computer from the planning department. In this way, it was possible to restore the original Flexibility of the former welding gun method by eliminating difficult and painstaking tasks and by improving accuracy and repeatability and therefore production quality through automation. It became practical to process several varia tions of the same model and several different types of geometries one after another in random order. The use of robots (robotics) and computers (industrial data processing) made Flexible car body assembly lines and production shops possible. The. aim is to be able to adapt production facilities as closely as possible to sink variations in the orders recieved these constituing a tangible reflection of market trends and changing tastes. Buyers' tastes may vary greatly due to many different external factors. This makes thorough and strict organization necessary at all stages, from supplies of component parts and units to the actual assembly, restricting intermediate or buffer stock to the bare minimum. Minicomputers to control the component parts and the assembly, process, and robots to carry out the work, together make this flexibility possible vmThe planning of an assembly and welding line always requires detailed studies in order to optimize the proposed solution (s). These studies can be divided into a certain number of successive phases. In general, the parameters pertaining to the spot welds, such as quantity, location and strength, are specified by the product designer. Selection of tack-welding points: In the geometry conforming station (s), it is essential to carry out a simultaneous study of the number of spotwelds required to maintain the geometry of the assembly and the relative positioning of the robot gun with respect to the reference elements. Assembly procedure: The order in which the are loaded along the line must be carefully planned in order to allow for maximum accessibility of the welding elements until completion of the assembly. Weld pattern planning: At this stage, welds which can be performed with the same welding element, are divided into groups. In the same way, a preli minary analysis of basic welding times has to be made for welding the different groups according to their positions in the şssembly. Welding gun planning: On the basis of the above gtudy, the minimum number and the configuration of the various welding elements necessary for these welds or weld groups can be established. Production rate: Based on the assembly procedure, the rate of production dictates the overall design and the com ponents of an assembly line. Line utilization factor: This is a function of all the elements involved in the make-up of the line, ranging from the supply of parts to be welded to the Flow finished products coming off the line. This factor depends upon the design of the welding stations. It decreases when several stations are installed in succession; it increases when several intermediate buffer stocks are provided. Weldtime: with the knowledge of the time per part, the handline and canformation time can be calculated and thus the time allowed for welding. The welding time thus estab lished provides a preliminary basis for the choice of the type of assembly line to be implemented. In fact, when the calculated time is obviously insufficient, a option concerns the number of welding lines assigned in paralel for the same assembly Minimum number of robots: The welding and movement times, taking into account the acceleration and decelerations values, make it possible to pre-plan the number of points that can be welded in one cycle by a single robot. Taking in to account the studies concerning spotweld pattern and the tyjpes of weld guns necessary or possible, it is possible to define the following fundamental concept; the minimum number of robots theorotically necessary for the assembly. This number must, of course, be subsequently verified. xxRobot selection fallows directly from the assembly line studies described in this chapter. Position of the part: For example; for large assemblies, (underbody or body-in white) due to their large dimensions, these assemb lies should be processed, in their normal or“car”positions For example; for medium-scale sub-assemblies. (body sides or main floor) the positioning of this parts in space will be based on a compromise between the following criteria: - Loading restrictions of the component parts, - geometry and positioning to be provided - position of the spot welds and access possibilities of the robot (taking the bulk of the geometry confor ming tools into account). Part transfer may be by means of bar transfer,“skids”or“lorries”carriages or wire-guided carriages. Welding robot, obviously, the most common case involves positioning the assembly to be welded in Front of the robot and main taining it in position while the welding gun mounted on the robot is in operation. Handling robot, this type of robot positions the workpiece in front of one more fixed guns. In this case the workpiece is held by an“iron hand”attached the robot. Assembly line planning: At this stage in the planning and design studies of an assembly line, data concerning all of the following restrictions are available: N The parts to be assembled, according to their structure and composition. - The geometry conforming of these and the corresponding number of stations required. - The spot welds and the number of robots necessary to weld them. - The production rate and the number of lines required to meet the production requirements - The desired degree of flexibility However, only partial data concerning the following restrictions are available at this point: - The basic principles relating to the transfer and positioning of the assembly- The final selection of the robot its equipment and its setup configuration - The environment and the available space Why flexible automation? - Automotion system initially sought to provide low cost production of a carefully defined component or product. Such automation succeeded, but severely restricted changes to a different product in the some facility Today, through carefully developed ROBOFLEX systems, can be provided flexible automation allowing rapid changes in pro duction, whether for random built body-framing systems, quick change-over door lines, universal Roboflex underbody facili ties, or variable production-mix slide-panel lines. Roboflex sy terns are imaginative answers to today's variable production requirements. XI

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