# Orbital-Based Automatic Multi-Layer Multi-Pass Welding Equipment for Small Assembly Plates
## 2 Design and Analysis of Rail-Mounted Automatic Welding Equipment
### Static Analysis of the Equipment's Core Mechanisms  
To prevent deformation and damage caused by excessive loads on parts or mechanisms during operation, this section conducts a static analysis of the aforementioned mechanical design modules and the simplified mechanisms under eccentric loading [18]. Specifically, the analysis involves defining boundary conditions for the model, designing load analysis, material property analysis, structural performance analysis, and result analysis, while also examining high-stress regions and the deformation of the overall model. The mechanism dimension parameter analysis is presented in Table 2, where the parameters exclude the dimensions of external components. Before performing the static analysis, the interaction relationships between mechanical mechanisms and components are practically integrated and organized, fully considering their contact types. This approach clarifies the types and \begin{table}
\begin{tabular}{c c c} \hline \hline
**Mechanism** & **Parts** & **Material** \\ \hline \multirow{3}{*}{Track mechanism} & Rack, Vertical profile bracket, Single-edge guideway & Aluminum alloy (6061-T6, 6063-T5) \\  & Single section track support bracket, Track roller & Bearing steels (Ccr15) \\  & Gear & Stainless steels \\ \hline Base & Pedestal, Robotic arm connector & Aluminum alloy (7075-T6) \\  & & \\ \hline \multirow{3}{*}{Quick-insert mechanism} & Connecting base, Tapered positioning head (male, female), Noches & \\  & Locking screw hole, Protruding platform, Welding gun & Aluminum alloy (7075-T6, 6061-T6) \\  & holder, Locking screw & \\  & Laser sensor protective case, Sensor cover & \\  & Spring hinge & Stainless steels \\  & Micro telescopic cylinder, Welding gun & 45\% Steel \\ \hline \multirow{3}{*}{Fixing mechanism} & Adjusting slide, Slider connecting plate, & Aluminum alloy (7075-T6, 6061-T6) \\  & Clamping block, Small assembly holder & 45\% Steel \\ \cline{1-1}  & Adjusting screw & \\ \cline{1-1}  & Guide bar & Bearing steels (Ccr15) \\ \cline{1-1}  & Adjustable setting handle & Rigid plastic \\ \cline{1-1}  & Base plate, Bearing plate, Fixed support & Carbon structural steel (Q235-A, Q235-B) \\ \hline \hline \end{tabular}
\end{table} 
Table 1: Equipment composition and material selection details. Figure 4: Schematic diagram of quick-insert mechanism. methods of simulation analysis and enhances the close connection between theoretical analysis and actual conditions. The specific details are provided in Table 3.  
The length, width, and height of the finite element model of the simplified eccentrically loaded mechanism correspond to the Z, X, and Y axes of the Cartesian coordinate system, respectively. For the finite element models of the other analysis mechanisms, the length, width, and height also correspond to the Z, X, and Y axes of the Cartesian coordinate system. The static data analysis is presented in Table 4. Fixed constraints with six degrees of freedom are applied to each mechanism. The mesh is divided using tetrahedral solid elements, with both their size and quality adopting global average values. In the following, the actual performance conditions of the mechanical mechanisms are combined with the simulation analysis module of ANSYS 2023 software to derive the corresponding reliability limit values for the analyzed mechanism types. This provides a reliable reference for engineering applications. \begin{table}
\begin{tabular}{c c c c c c} \hline \hline
**Serial** & **Name of** & **Mesh** & **Mesh** & **Number of** & **Number of** \\
**Number** & **Organisation** & **Size/mm** & **Quality** & **Nodes** & **Units** & **Constrained Position** \\ \hline
1 & Railcart & 5 & 0.7 & 286,768 & 177,938 & Bottom roller \\
2 & Track section & 6 & 0.6 & 512,882 & 146,523 & Bottom of guide \\
3 & Robotic arm & 5 & 0.8 & 56,847 & 35,403 & Install base underside \\  & Connecting seat & 5 & 0.6 & 223,900 & 124,038 & Back mounting hole \\
4 & Fixing mechanism & 5 & 0.4 & 322,139 & 144,224 & Railcart underside \\ \hline \hline \end{tabular}
\end{table}