【FSW新思讯】搅拌摩擦焊机器人VS龙门设备在大批量焊接生产中的性能对比及应用分析_公司动态

【FSW新思讯】搅拌摩擦焊机器人VS龙门设备在大批量焊接生产中的性能对比及应用分析

时间：2025-03-12 来源：搅拌摩擦焊点击：123

搅拌摩擦焊机器人VS龙门设备在大批量焊接生产中的性能对比及应用分析

Performance Comparison and Application Analysis of FSW Robots vs. Gantry Systems in High-Volume Welding Production

一、前言

I. Introduction

近年来，我国新能源汽车产业发展迅猛，在新能源汽车生产过程中，焊接工艺至关重要，直接影响产品质量与生产效率。自动化焊接设备凭借其高效、稳定的特性，在大批量生产中占据重要地位。搅拌摩擦焊（FSW）作为一种先进的固相连接技术，在汽车制造领域得到广泛应用。本文围绕FSW机器人H1K500与龙门FSWG-3222展开对比研究，深入剖析两者在实际生产中的表现。

In recent years, the new energy vehicle industry in China has experienced rapid development. In the production process of new energy vehicles, welding technology is crucial, directly impacting product quality and production efficiency. Automated welding equipment, with its high efficiency and stability, plays a significant role in mass production. Friction Stir Welding (FSW), as an advanced solid-state joining technology, has been widely applied in the automotive manufacturing sector. This article conducts a comparative study focusing on the FSW robot H1K500 and the gantry FSWG-3222, providing an in-depth analysis of their performance in actual production.

二、FSW 机器人和龙门参数对比

II. Parameter Comparison Between FSW Robots and Gantry Equipment

自动化生产线在解决大批量生产问题上优势显著，通过各类自动化设备与控制系统协同工作，实现生产过程自动化，提高生产效率与产品质量一致性。自动化焊接设备的选型需综合考虑精度、速度、负载能力等核心参数。表1为FSW机器人H1K500（图1）与龙门FSWG-3222（图2）的详细参数对比：

Automated production lines have significant advantages in solving mass production problems. Through the collaboration of various automated equipment and control systems, they achieve automation in the production process, improving production efficiency and product quality consistency.The selection of automated welding equipment requires comprehensive consideration of core parameters such as precision, speed, and load capacity. Table 1 shows a detailed parameter comparison between the FSW robot H1K500 (Figure 1) and the gantry-type FSWG-3222 (Figure 2):

三、FSW 机器人H1K500与龙门FSWG-3222特点分析

III. Feature Analysis of FSW Robot H1K500 and Gantry FSWG-3222

3.1 FSW 机器人H1K500参数特点

3.1 Parameter Characteristics of FSW Robot H1K500

3.1.1 运动灵活性

3.1.1 Mobility

FSW机器人H1K500具备6轴甚至更多自由度，当产品焊缝较长时，可通过增加第七轴拓展焊接范围，能够在三维空间内实现复杂运动轨迹，在新能源汽车电池盒焊接中，可灵活调整姿态，精准焊接不同位置和角度的焊点，适应多样化产品设计需求。

The FSW robot H1K500 features six or more degrees of freedom. For products with extended weld seams, its welding coverage can be expanded by integrating a seventh axis, enabling the execution of intricate motion paths within three-dimensional space. During the welding of battery enclosures for new energy vehicles, the robot dynamically adapts its positioning to achieve precise welding across varied locations and angles, effectively accommodating diverse product design specifications.

3.1.2 负载能力

3.1.2 Load Capacity

依据FSW焊接工艺要求，该机器人负载能力为500kg，能够满足市面在制电池托盘的的焊接需求。

According to the FSW welding process requirements, this robot has a load capacity of 500kg, which is capable of meeting the welding demands for battery trays currently in production on the market.

3.1.3 精度

3.1.3 Precision

FSW机器人重复定位精度可达±0.08mm，在精密零部件焊接中表现卓越，确保产品质量稳定。

The FSW robot achieves a repeat positioning accuracy of ±0.08 mm, ensuring exceptional performance in welding precision components and maintaining consistent product quality.

3.2 龙门FSWG-3222参数特点

3.2 Parameter Characteristics of Gantry FSWG-3222

3.2.1 运动范围

3.2.1 Motion Range

龙门FSWG-3222运动范围较大，可覆盖较大工作区域。但当产品焊缝较长时，增加设备行程会导致成本同步上升。

The Gantry FSWG-3222 offers a large working range, capable of covering extensive operational areas. However, extending the machine’s travel distance to accommodate longer weld seams will result in a proportional increase in costs.

3.2.2 刚性与稳定性

3.2.2 Rigidity and Stability

因其结构特点，龙门FSWG-3222刚性和稳定性较高。在高速、高精度焊接时，能有效减少振动，保障焊接质量。

Owing to its robust structural design, the Gantry FSWG-3222 exhibits high rigidity and stability. During high-speed, high-precision welding operations, it effectively minimizes vibration, ensuring consistent weld quality.

3.2.3 负载能力

3.2.3 Load Capacity

大型龙门FSWG-3222负载能力极强，可承载数吨甚至数十吨重量，在大焊深结构方面优势明显。

The large-scale Gantry FSWG-3222 demonstrates exceptional load capacity, supporting weights ranging from several tons to tens of tons. This makes it particularly advantageous for applications requiring deep-penetration welding or handling heavy structural components.

四、FSW 机器人H1K500与龙门FSWG-3222设备应用对比

IV. Application Comparison Between FSW Robots H1K500 and Gantry FSWG-3222

4.1 空间布局灵活性

4.1 Spatial Layout Flexibility

龙门FSWG-3222结构庞大，安装运行需固定的大型厂房空间，对场地要求苛刻。安装完成后，位置和布局调整困难，灵活性差。例如，对其所在产线进行改造或重新布局时，拆卸、移动和重新安装设备需耗费大量时间和成本。

The Gantry FSWG-3222features a massive structure and requires a fixed large factory space for installation and operation, imposing stringent facility requirements. Once installed, repositioning or reconfiguring the system is highly challenging due to its limited flexibility. For instance, modifying or relocating the system within a production line necessitates significant time and cost for disassembly, transportation, and reinstallation.

机器人H1K500设备体积相对较小，安装布局灵活。可根据生产需求在不同车间区域快速部署，甚至在同一车间内灵活调整工作位置，适应不同产品生产流程变化。如企业临时增加新产品生产线时，机器人设备可迅速调配投入生产。

The robot H1K500 features a compact footprint and adaptable installation layouts. It allows for rapid deployment across multiple workshop zones or dynamic repositioning within the same facility to accommodate evolving production workflows. For example, when a company urgently scales up a new product line, the robot can be quickly mobilized into production.

4.2 产品适应性

4.2 Product Adaptability

龙门FSWG-3222主要适用于大型、标准化程度较高的产品生产。由于其运动方式和加工范围相对固定，对产品型号变化大、设计复杂的产品适应性较差。

The Gantry FSWG-3222 is primarily suited for large-scale, standardized product manufacturing. Its fixed motion patterns and limited processing range make it less adaptable to products with frequent design changes or complex geometries.

机器人H1K500设备凭借多自由度灵活运动特性，能快速适应产品设计变化和多样化生产需求。通过简单程序调整，即可实现对不同形状、尺寸产品加工和装配操作的快速响应。

The robot H1K500 , with its multi-axis flexibility, can swiftly adapt to evolving product designs and diverse production demands. Through simple programming adjustments, it rapidly accommodates processing and assembly tasks for products of varying shapes and sizes.

4.3 生产流程调整灵活性

4.3 Production Process Flexibility

龙门FSWG-3222生产流程相对固定，确定加工工艺和流程后，更改难度大。生产过程中若需优化或调整工艺流程，可能需对设备硬件结构和控制系统进行大幅改动，影响生产进度并增加成本。

The production process for the Gantry FSWG-3222 is relatively rigid. Once machining parameters and workflows are defined, modifications require extensive overhauls to hardware structures and control systems, leading to production delays and increased costs.

机器人H1K500生产流程调整便捷。通过修改控制程序，可快速改变机器人运动轨迹、操作方式和工作顺序，适应不同生产流程需求。

The robot H1K500 simplifies production process adjustments. By modifying the control program, it can rapidly reconfigure motion trajectories, operation modes, and work sequences to accommodate diverse production requirements.

4.4 运行与维护成本

4.4 Operational and Maintenance Costs

龙门FSWG-3222能耗高，需持续大量电力维持运行，设备结构复杂，零部件磨损快，维护保养成本高。出现故障时，维修时间长，会影响生产进度，造成较大经济损失。

The gantry FSWG-3222 exhibits high energy consumption, requiring continuous high-power input to sustain operation. Its complex structural design and accelerated component wear contribute to elevated maintenance costs. In the event of equipment failure, prolonged downtime for repairs can disrupt production schedules, leading to significant financial losses.

机器人设备能耗低，运行成本相对较少，机器人的机械结构简单，日常维护主要是检查和更换易损件，维护成本低。

The robot operates with lower energy consumption and simplified mechanical components. Routine maintenance primarily involves inspecting and replacing wear-prone parts, ensuring minimal operational and maintenance expenses.

龙门布局案例VS机器人布局案例如下图所示：

The layout examples for the Gantry FSWG-3222 and FSW robot are illustrated in the figure below:

五、结论

V. Conclusion

综合对比分析FSW机器人H1K500与龙门FSWG-3222在参数、特点及应用方面的差异可知，在大批量产品焊接生产中，两者各有优劣。

A comprehensive comparative analysis of the FSW robot H1K500 and the gantry FSWG-3222 in terms of parameters, features, and application scenarios reveals that each system has distinct advantages and limitations in high-volume welding production.

机器人H1K500：运动灵活性高、产品适应性强、生产流程调整便捷、运行与维护成本低，更适合产品多样化、生产流程多变的生产场景；

FSW Robots H1K500: They exhibit high motion flexibility, strong product adaptability, convenient production process adjustment, and low operation and maintenance costs, making them more suitable for production scenarios with diversified products and variable production processes.

龙门FSWG-3222：运动范围大、刚性与稳定性好、负载能力强，在大型、标准化产品生产，尤其是大焊深焊接方面具有优势。

Gantry FSWG-3222: They offer a large motion range, good rigidity and stability, and strong load capacity, giving them an advantage in the production of large, standardized products, especially those requiring deep welding.

企业选型建议：

Enterprise Selection Recommendations:

1、若产品类型多、更新快，且场地有限，优先选择FSW机器人。

2、若生产大型标准化工件，且对负载和稳定性要求高，可选择龙门设备。

3、对于混合生产需求，可考虑“机器人+龙门”协同布局，兼顾效率与柔性。

1、If product types are diverse, updates are frequent, and space is limited, FSW robots should be the preferred choice.

2、If large, standardized workpieces are produced, and high load and stability requirements are imposed, Gantry equipment can be selected.

3、For mixed production needs, a collaborative layout of "robots + Gantry" can be considered to balance efficiency and flexibility.

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