The automatic welding line equipment integrates core modules such as welding power supply, motion control, sensor detection and program control to achieve precise adjustment of welding parameters and automatic execution of welding operations. Its working principle can be decomposed into the following key links:

I. Welding Power Supply: The core of energy conversion

Power supply type adaptation

Select the type of power supply according to the welding process requirements

Resistance welding: It adopts a high-frequency inverter power supply to achieve rapid response and precise control of current (for example, when spot welding a car body, the current can reach its peak within milliseconds).

Laser welding: Equipped with a high-power laser generator (such as a fiber laser), it outputs a laser beam with a wavelength of 1064nm, and the energy density can reach 10⁶-10⁷W/cm².

Ultrasonic welding: By generating high-frequency vibrations of 20-40 KHZ through an ultrasonic source and a transducer, electrical energy is converted into mechanical energy.

Dynamic parameter adjustment

During the welding process, the power supply adjusts the output in real time based on the feedback from the sensor.

Current/Voltage: During the welding of aluminum alloys, the current fluctuation is controlled within ±2% through the PID algorithm to prevent cracks caused by unstable heat input.

Pulse mode: For thin plate welding, pulse MIG welding technology is adopted. By adjusting the ratio of peak current to base current (such as 3:1), the heat-affected zone is reduced.

Ii. Welding Head Motion Control: Precise Positioning and Trajectory Planning

Multi-axis linkage system

The equipment is usually equipped with 3-6 axis mechanical arms or a Cartesian coordinate system motion platform to achieve spatial positioning of the welding head.

X/Y/Z axis: Controls the movement of the soldering head in the plane and height directions (for example, when soldering PCB boards, the Z-axis positioning accuracy reaches ±0.01mm).

Rotation axis (A/B/C axis) : Adjust the Angle of the welding head to adapt to complex weld seams (for example, when welding pipe circumferential seams, the rotation speed of the A axis is synchronized with the welding speed).

Trajectory generation and optimization

Offline programming: Generate the welding path through the CAD model, and automatically adjust it to the actual workpiece coordinate system after importing it into the equipment.

Online teaching: The operator manually guides the welding head to complete the demonstration action, and the equipment records the trajectory and generates the program (for example, when welding a car seat frame, the teaching time can be shortened to 10 minutes per workpiece).

Visual guidance: Integrated CCD camera or laser scanner, real-time correction of trajectory deviation (for example, when welding the middle frame of a mobile phone, the visual system can detect positioning errors at the 0.05mm level).