基于TRIZ理论的超声辅助随焊滑台的设计

Design of ultrasonic-assisted welding sliding table based on TRIZ theory

  • 摘要: 针对现阶段超声辅助焊接过程中,存在超声能量衰减、人工手持超声波振幅杆进行冲击时很难控制冲击参数稳定、试件较多时容易引起工作疲劳等问题,提出了基于TRIZ理论的随焊滑台进行创新设计,利用功能分析法找到引起问题的根本原因,从而转化成矛盾矩阵,通过分析矛盾矩阵,选用合适的发明原理对现有设备进行改进与优化。文中以三维滑台代替了焊接平台,采用PLC进行控制,通过夹具将焊枪与超声波振幅杆连接,实现了超声辅助随焊。最后使用优化后的随焊滑台进行焊接试验,通过改变超声功率,检验随焊滑台运行能力,并对焊件进行了金相观察、力学性能测试。结果表明,基于TRIZ理论的随焊滑台进行焊接的试件,微观组织得到改善、焊接接头抗拉强度得到提高,其HAZ宽度均符合性能要求。文章所述随焊滑台采用三轴全伺服电机驱动,增加了焊接过程的稳定性与精度,通过在随焊夹具上安装气缸,保证了超声冲击效果,有效代替人工进行超声辅助随焊过程。创新点: 将TRIZ理论与机械专业知识结合使用,并对样机进行试验测试,使设计过程更加合理。

     

    Abstract: For the current stage of ultrasound-assisted welding process, there are problems such as ultrasonic energy decay, difficulty to control impact parameters stable when manual handling ultrasonic amplitude rod for impact and more test pieces easily causing work fatigue, an innovative design of welding sliding table based on TRIZ theory was proposed. Functional analysis was used to find root cause of those problems, which was transformed into a contradiction matrix. By analyzing the contradiction matrix, the existing equipment was improved and optimized by selecting appropriate invention principle. Welding platform was replaced by a three-dimensional sliding table in this paper and PLC was used for control, and welding gun and ultrasonic amplitude rod were connected by fixture to realize ultrasonic assisted sliding welding. Finally, welding tests were carried out with the optimized welding sliding table. Operating capability of welding sliding table was checked by changing ultrasonic power, and metallographic observation and mechanical properties of the welded parts were tested. The results showed that based on TRIZ theory, test pieces were welded with welding sliding table, microstructure was improved, tensile strength of welded joints was improved and its width of HAZ was in line with performance requirements. In this paper, welding sliding table was driven by a three-axis full servo motor, which increased stability and accuracy of welding process. By installing a cylinder on welding fixture, ultrasonic impact effect was ensured, and ultrasonic assisted welding process was effectively replaced for manual work.Highlights: TRIZ theory was combined with mechanical expertise and experimental testing of prototypes was conducted to make design process more rational.

     

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