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勾舌电弧熔覆机器人项目获国家技术创新资金支持
  Published:2007-11-10 11:52:02  Author:北京嘉克
Beijing ARC   http://www.arceq.com


    2007年10月下旬,由北京嘉克新兴科技有限公司承担的“铁路列车挂钩钩舌电弧熔覆机器人”项目经过科技部科技型企业技术创新基金管理中心组织有关专家、单位评审、评估,获得科技部、财政部的无偿资金资助,这是北京嘉克新兴科技有限公司第二次得到创新基金的支持。
 
     该项目是针对铁路列车钩舌而开发研制的电弧熔覆机器人,经权威部门的技术鉴定,认为它是一种投资少、见效快、效益显著的产业,能解决当前生产中的实际问题,其实施将会产生重大的经济效益和社会意义。
 
    近几年铁路经历了六次大提速,作为牵引动力的机车步入快车道,但同时,列车的提速对机车的各项性能也提出了更高要求,使连接车厢之间的挂钩钩舌因长期工作在撞击、摩擦和拉扯的条件下,造成其磨损过快的问题显得更为突出。
 
    列车挂钩钩舌磨损后可能使高速运行中的列车出现“跳钩”,甚至不能可靠地连接车厢,给列车运行带来巨大安全隐患。
 
    以前,对被磨损挂钩钩舌的处理办法一般是报废,或用堆焊修复方法补足其磨损部分。现有堆焊修复一般采用手工堆焊,条件好一些的车辆段采用埋弧焊,但由于钩舌S型柱面为弧柱面,无论哪一种焊法都会过量补焊,焊后再用专用机床对钩舌S型柱面进行机加工,使其达到所需形状和尺寸。在机加工过程中要人工随时用量板卡量以确定切削量,因此掺杂了许多不确定的人为因素,不仅难以保证钩舌“S”面的成型质量,而且加工工作量很大,费时、费工、费料,最终造成钩舌修复与其它修复工序在时耗上严重不匹配,修车进度、出车数受到严重影响。
 
    此外,为了提高钩舌使用寿命,堆焊一般需要选择高硬度、高耐磨的熔覆材料,这又将导致后序机械加工非常困难。因此,如何使钩舌堆焊能一次成型,焊后不再加工即达到所需形状尺寸和表面质量要求,这是长期以来摆在焊接工作者面前的难题之一。
 
    该项目所开发的列车钩舌电弧熔覆机器人就是针对上述问题,用电弧熔覆方法,实现了钩舌修复一次成型,且省工省料,修复后钩舌使用寿命明显增强。
 
    该项目属超窄间隙滑模明弧熔覆一次成型技术创新,采用了熔覆规范参数动态规划控制技术、熔池状态传感及控制技术、焊枪姿态及位置控制技术——焊枪轨迹规划及路径规划、电弧弧长传感及跟踪技术、自适应排列熔覆焊道等几项关键技术,具有很高的技术含量。
 
    嘉克公司成立于2000年,多年来,嘉克始终坚持把技术创新作为企业发展的源动力,不断地追求技术进步,不断推出新技术和新产品,始终在技术含量较高的领域投入力量,致力于研发和制造国内领先的自动焊接专机、自动堆焊设备、耐磨材料及提供硬面堆焊服务。
 
    如今,嘉克已成为自动焊接设备、堆焊设备、耐磨材料生产及硬面堆焊服务领域的居于国际先进地位的专业化公司。嘉克开发的窄间隙埋弧焊机、小直径直管/弯管内壁堆焊机、马鞍型/法兰自动焊机等专用焊机不仅在国内具有领先地位,在国际堆焊尖端技术领域也占有一席之地。嘉克开发的明弧在线/离线自动堆焊设备拥有六项国家专利,是国内堆焊设备中的佼佼者,在电力行业的市场占有率达到90%以上。此外,嘉克的耐磨材料和耐磨堆焊工程在行业中也起到了技术先导的作用。
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  1、Online/offline overlaying remanufacturing service
1、Overlaying remanufacturing service for the rollers/segments of the cement mill.
2、overlaying remanufacturing for the coal grinding roller/segment
3、overlaying remanufacturing for the rollers of roller press
4、overlaying remanufacturing for the steel and iron slag rollers and segments.
5、overlaying remanufacturing for the wear plate

2、Overlaying the mill roller/segment
1、composite overlaying remanufacturing for LM grinding roller/segment
2、composite overlaying remanufacturing for MPS grinding roller/segment
3、composite overlaying remanufacturing for ATOX grinding roller/segment
4、Overlaying remanufacturing for Polysius compound roller/segment
5、Overlaying remanufacturing for UBE compound roller/segment
6、Overlaying remanufacturing for MPS、MLS compound roller/segment
7、Overlaying remanufacturing for HP、RP compound roller/segment
8、Overlaying remanufacturing for HRM compound roller/segment
9、Overlaying compound remanufacturing for TRM roller/segment
10、Overlaying compound remanufacturing for ZGM roller/segment
11、Overlaying compound remanufacturing for CITIC roller/segment

3、Self-protective wear -resistant flux cored wire
1、ARCFCW1001 self-protective wear resistant flux cored wire
2、ARCFCW1006 self-protective wear -resistant flux cored wire
3、ARCFCW1016 self-protective wear -resistant flux cored wire
4、ARCFCW9018self-protective wear -resistant flux cored wire
5、ARCFCW9061self-protective wear -resistant flux cored wire
6、ARCFCW9993 self-protective wear -resistant flux cored wire
7、ARCFCW9996 self-protective wear -resistant flux cored wire
8、ARCFCW9998self-protective wear -resistant flux cored wire
9、ARCFCW9991 self-protective wear -resistant flux cored wire

4、Arc Spraying
1、Arc Spraying Technology

5、Automatic over-laying welding equipment
1、off-line automatic open-arc overlaying equipment for mill roller/segment
2、on-line automatic open-arc overlaying equipment for mill roller/segment
3、 automatic repairing system for roller press
4、Open-arc automatic welding machine for Inner pipe
5、strip surfacing machine
6、Automatic open-arc overlaying welding machine for wear plate
7、Automatic overlaing robot for the inner bend pipe
8、Automatic Overlaying welding machine for the inner side of small-diameter straight pipe.
9、water cooling hot wire TIG overlaying equipment

6、Specialized automatic welding machine
1、Automatic welding machine for the u-shape ones
2、Round bead operation machine
3、Antomatic welding machine for flange/steel ring channel/intersection line
4、Arc deposited formed machine
5、Antomatic welding machine for the ball-shape /horizontal /vertical workpiece
6、Automatic cutting machine for saddle-shape workpiece
7、Automatic submerged welding machine for saddle-shape workpiece
8、Automatic gas protective welding machines for saddle-shape workpiece

7、Automatic welding equipment
1、Automatic submerged welding machine for narrow-gap workpiece
2、Automatic Submerged arc welding machine(handling frame style or carriage wheel style)
3、Automatic gas-protective welding machine(operation frame style and carriage wheel style)
4、All position automatic welding machine for the pipe
5、Automatic welding machine for the steel cylinder
6、Automatic welding machine for the metal strip

8、welding equipment for railway construction
1、Arc deposited robot for the train hook tongue
2、induction-heated furnace for the rivet.
3、Automatic welding production line for box girder

9、Welding Auxiliary Machines
1、Welding manipulator
2、Welding positioner
3、Welding turning roller
4、fixture
5、 Oscillator/sensor
6、Dust discharger/interconnecting cables/water-cooled torch
7、Hydraulic double bracing positioner

10、Frequency Converse Rectifier
1、Frequency converse rectifier(automatic welding power source/carbon arc air gouging power
2、Hand arc frequency converse rectifier
3、Frequency converse rectifier type argon tungsten-hand arc welding machine
4、Frequency converse rectifier type Self-protective/gas protective welding machine
5、Frequency converse rectifier type heat sensor power source

 
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