Abstract
Resistance spot welding gun is generally used to bond parts in the automotive and consumer electronics industries. In the automotive industry, chassis assembly operations use resistance spot welding. High production speeds allow for mass production and automation, resulting in diverse uses of resistance spot welding. To automate the welding process, it is mounted on a multi-joint robot and the welding gun is designed considering the specifications of the robot. High-strength structural design is needed to prevent deformation during pressurization, but the weight of the weld gun affects the efficiency of the robot. For this reason, it is necessary to design a welding gun with high stiffness and light weight. In this study, the analysis is carried out to measure the stress and deformation amount of weld gun. Optimization for weight reduction is performed by genetic algorithm method and topology optimization. The optimization of the resistance spot weld gun frame is performed, and the optimized model is verified through experimental verification. The production cost of industry has been reduced through the high stiffness and light weight of welding gun.
Highlights
Resistance spot welding (RSW) is widely used for the joining of sheet metal parts such as the manufacture of automobiles, trucks, buses, automotive electrical appliances, aircraft structures, and many other products [1,3]
Various types of welding are possible through the modular frame design, and the modular frame is welded by C type, X type according to the welding situation
In the case of the C type, a pressing force of 800 kgf is directly transmitted to the frame to perform a static analysis, and in the case of the X type, the reaction force changes according to the movement of the modular frame, so that the transient analysis is performed
Summary
Resistance spot welding (RSW) is widely used for the joining of sheet metal parts such as the manufacture of automobiles, trucks, buses, automotive electrical appliances, aircraft structures, and many other products [1,3]. To cope with various welding conditions such as automobile and other industries, the RSW gun is attached to the multi-joint robot. Since the weight of the welding gun is continuously increased due to the need of high pressing force, the payload of the multi-joint robot increases so that the specifications of the multi-joint robot are determined more than necessary. The problem mentioned above becomes possible to use the low-specification multi-joint robot by reducing the production cost and reducing the payload of the multi-joint robot by reducing the weight of the welding gun structure. The frame structure optimization and the experimental verification of the resistance spot welding gun are performed to reduce the weight of the welded structure
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