**The First Person in Welding Robot Programming: Liu Jianshu**
In the EMU bogie welding workshop, the sound of electric welding fills the air as robotic arms swing with precision, creating a scene that feels like something out of a science fiction movie. Liu Jianshu moves between the robot arms, observing the welding of crossheads and side beams of the moving car bogies. More than 30 robots operate here, each performing its role under the guidance of Liu Jianshu, who writes the programs that direct them through complex welding processes.
Since joining the company in 1999, Liu has been working on the front lines of production. “At first, I used to weld manually,†he recalls. “That was the foundation of my skills. Then I transitioned to welding robots, learning programming and operation. I found it very interesting and suitable for my personality.†For 17 years, Liu has remained at this position, one of the few from his original batch of workers to stay.
Unlike manual welding, where a torch is held by hand, operating a welding robot requires precise programming. “To complete a complicated welding process without a torch, you have to work harder and trade effort for technology,†Liu explains. The “remote control†he uses is actually a “teaching device,†a small computer connected to the robot’s internal software. It allows him to program and operate the robot efficiently.
Liu, without access to technical documents, taught himself and developed nearly 200 automatic welding procedures for over 30 large parts. His innovations solved problems that both domestic and foreign experts had struggled with, earning him the title of “First Person in Welding Robot Programming.†In 2015 and 2017, he was honored as a skill expert at CRRC Sifang Co., Ltd. and a Chongjie Skill Expert in China.
**Controlling Welding Robots to Boost Efficiency by Four Times**
“The programming of a welding robot involves guiding it through a process once, and all the data collected forms a program that can be optimized. Once programmed, the robot can work independently,†Liu explains. At each welding point, he inputs the required angle, parameters, and trajectory into the system. After testing and optimization, the robot can perform the task accurately and consistently.
“Each time I program, I start with small batches of workpieces for testing. Back then, I had to test more than ten before I felt confident. Now, just one or two tests are enough,†he says. Liu breaks down the entire welding process into thousands of points, each containing detailed programming data. On an EMU bogie, there are over 7,000 such points, making the programming process extremely meticulous—like teaching a robot how to do the job once and for all.
His innovative method, “multi-layer multi-channel split-layer one-time surfacing,†revolutionized the welding of bogie beams. Previously, manual welding was slow and imprecise, requiring frequent cleaning of the surface. With robot programming, the welding becomes highly accurate, with consistent positioning and no interruptions. This breakthrough enabled full automation of the bogie beam welding process, reducing welding time from about 3–4 shifts to just 30 hours, increasing efficiency by nearly four times.
**Robots Working in Tight Spaces**
CRRC Sifang Co., Ltd. operates China’s first flexible automatic welding production line. However, during development, a complex weld trajectory in the narrow space of the side beam posed a challenge. The robot could not accurately locate the area, resulting in poor welds and excessive defects detected by ultrasonic testing. Even experienced programming experts struggled to fix the issue after scrapping four side beams, causing serious delays.
Liu, a skilled electric welder, took on the challenge. “The space was only 10 cm wide, making it semi-blind welding. Many welds were hidden, and controlling the welding torch with the robot arm was extremely difficult,†he recalls. Using his extensive experience, Liu carefully planned each weld, adjusting speed to avoid errors. He divided the weld paths into smaller segments and spent eight days working overtime to achieve successful programming. His solution impressed foreign experts, who marveled at the robot’s flexibility and precision.
Thanks to Liu’s efforts, the side beam now achieves 100% quality inspection. The defect rate from ultrasonic testing dropped from 5% to just 0.3%, marking a major improvement in the welding process.
**Liu Jianshu, a Welder Who Won Top Honors**
Many would find it hard to believe that someone with only a high school education could solve problems that even foreign experts struggled with. Liu’s journey was one of self-learning and perseverance. While studying, he learned foreign technical documents using a dictionary, eventually breaking through on his own. His achievements have made him a well-known figure in the field of robot programming.
Liu credits his success to the development of high-speed rail and the opportunities provided by his company. “The growth of high-speed rail created a platform for me. The company also gave me trust and support in developing and applying robot programming,†he says. Since 2010, robots have handled more than 80% of the key welds on bogies, making this position critical but often overlooked.
Because the welding robot job can be monotonous, Liu has focused on passing on his knowledge. His three apprentices can now handle some programming tasks independently. “Programming requires experience and dedication. Only through years of practice can you gain the intuition needed for effective programming,†he emphasizes.
His hard work and innovation have earned him numerous honors. In 2015, he received the title of Qingdao Model Worker and won the Locomotive Medal as a core member. In 2016, the scientific and technological innovation project “Flexible Welding Manufacturing Technology for High-Speed Train Steering Frame†won the first prize in China CRRC Science and Technology.
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