Xining to Chengdu high-speed railway is a part of the "eight vertical and eight horizontal" high-speed railway network from Lanzhou, Xining to Guangzhou Lansi (West) corridor, longitudely spanning Qinghai, Gansu and Sichuan provinces, 60% of the route is located at an altitude of more than 3,000 meters, the construction is extremely difficult, especially the tunnel construction requires a long time to face altitude sickness and large temperature difference between day and night, etc. It is a great challenge for manual operation and transportation.
Based on the advantages of the whole industrial chain and rich experience in welding application, STEP robot provides efficient, intelligent and flexible arch production solutions for the tunnel construction of the West-Chengdu high-speed railway, and helps the leapfrog development of China's rail transit.
Photo credit: Open Media
Double machine cooperation, efficient production
Production process flow
√ H type steel is automatically transferred to arch bending machine through the track for arch bending processing
√ After the arch is formed, the workpiece size is determined by laser recognition technology and then cut by robot
√ The welding robot determines the shape and position of the workpiece through 3D vision, and then transmits it to the handling robot for assembly through Ethernet
√ After assembly, the welding robot will position the welding workpiece as a whole, and then weld the main position of the workpiece
STEP robot master-slave control technology, so that welding robots and handling robots can cooperate with each other, efficient production; At the same time, the double robot and double station design, double efficiency; The design of double platform formwork can guarantee the welding precision and machining efficiency effectively and realize the circulating machining.
Adaptive flexible welding, reliable and consistent quality
The welding workspace is reconstructed through visual sensing to identify the position of the workpiece, and the welding robot moves precisely to the initial welding position. The STEP welding robot SA6/1400 perfectly matches the standard arc welding task with its 6kg load and 1400mm working radius, and the streamlined design of the robot's wrist ensures the robot has the least destructive contours and the highest degree of freedom of motion. Real-time detection and pre-processing in the welding process, online correction of the robot's trajectory at the same time automatically adjust the welding process parameters, beat than the traditional contact positioning, line laser positioning to improve 20%, at the same time can be compatible with more than 100mm deviation of the workpiece, to ensure the realization of weld forming and welding quality consistency and high reliability.
Crack the labor shortage to achieve the fastest delivery
For the production of tunnel H-beam arch, the gap of operation technicians is becoming larger and larger, and the advantages of STEP intelligent welding system and traditional arch welding are prominent.
√ Robot as the carrier to achieve a highly flexible intelligent welding instead of artificial
√ Higher working efficiency and more reliable welding quality than manual
√ All points are generated by vision, and the whole system can be put into operation quickly
Customer voice
"Recruiting workers is difficult due to the project's remote location and harsh environment. The high quality products and services of STEP robots have solved our worries. The high stability of the robots and the rapid response service in 24 hours provide us with stable and timely delivery capabilities, which is why we finally chose STEP." The director of the project said.
As a pioneer in robot welding applications, STEP has taken the lead in many market segments. This STEP robot greatly expands the application boundary of welding robots by virtue of its technical advantages of 3D visually-guided intelligent welding system, and meets the new demand for intelligent welding in the rail transit industry.
In the future, STEP will continue to work with partners in subdivided industries, break through more welding technical difficulties, incubate more competitive welding solutions, empower partners, and jointly promote the progress and development of domestic robot welding industry.