CN102601493A - Embedded multi-device real-time control welding robot system and control method - Google Patents
Embedded multi-device real-time control welding robot system and control method Download PDFInfo
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Abstract
The invention provides an embedded multi-device real-time control welding robot system and a control method. The system comprises a welding robot, a robot control cabinet, a robot teaching box, a handheld embedded real-time controller, a two-dimensional movement platform, a wire feeder and an arc welding power source, wherein the handheld embedded real-time controller serves as a control core and is electrically connected with the robot control cabinet, the two-dimensional movement platform, the wire feeder and the arc welding power source. The control method is used for realizing the functions of rectifying deviation of welding tracks, adjusting and displaying welding parameters and controlling start and stop of the wire feeder and on and off of the arc welding power source in real time. By the aid of the system and the control method, teaching of welding paths of the welding robot before welding, setting of the welding parameters, real-time control of the position of a welding gun during welding and real-time adjustment of the welding parameters can be combined.
Description
Technical field
The present invention relates to the Technology of Welding Robot field, be specifically related to a kind of embedded many equipment welding robot system and the control method of control in real time.
Background technology
In welding field, under the irregular situation of baroque weldment, particularly weld seam (such as parabola; S curve, cylinder are used to line mutually), often adopt the teach programming mode; Through teaching, reproduction, accomplish the TRAJECTORY CONTROL of welding process to welding robot.But in welding process, weldment often produces relative motion because of temperature distortion causes welding gun and weldment.The welding gun vertical up-or-down movement surperficial with respect to weldment often shows as blow-out and welding wild effect; The welding gun horizontal movement surperficial with respect to weldment often shows as welding gun substantial deviation weld seam.Tracing it to its cause, is the uncertainty that the temperature distortion of workpiece has caused the relative position of welding gun and weld seam in the welding process.The way that solves is on the basis of welding robot teaching, and the movement locus of welding gun in the welding process is carried out real-time deviation correcting.This external welding is a complicated process, need adjust parameters such as weldingvoltage, welding current and speed of welding in real time according to the welding situation in the welding process, and can in time stop weld job under the abnormal conditions running into.Therefore, need a cover easy to operate, can control welding track and adjustment welding parameter in real time in welding process, and can control Arc Welding Power, the welder of multiple devices such as wire-feed motor simultaneously.
Chinese invention patent application " method and apparatus of control welding robot "; Application number is 98125934.0; The main feature of this invention is in welding process, and the temperature through temperature sensor acquisition weldment contrasts with the predetermined reference temperature; Thereby under the situation that does not stop weld job, adjustment weldingvoltage, welding current and speed of welding value.The weak point of its control method mainly is: 1. can not be in welding process carry out real-time deviation correcting.Welding gun to producing for a certain reason in the welding process departs from the weld seam problem, only adopts temperature sensor not detect, and also just can't make the side-to-side movement of controller control welding gun phase butt welded seam.2. can not dynamically adjust the welding gun height.When in the welding process because the welding temperature distortion causes welding gun to leave the distance of weldment when too high or too low, can cause easy blow-out or electric arc wild effect.Only can't be from improving welding quality in essence through adjustment weldingvoltage, welding current and speed of welding.
Existing application for a patent for invention " welding robot system ", application number are 99111556.2, and its application also is welding robot control.The main feature of this invention is to pass through in the welding process welding robot system of main PC control welding robot mobile route.Its PC obtains the path deviation through vision sensor in welding process, send the correction of order control welding gun and move.The weak point of this system mainly is: the problem of welding gun height can not be dynamically adjusted in 1. same existence in welding process.2. can not adjust the welding parameter of weldingvoltage, welding current, speed of welding in the welding process.3. system uses vision sensor and PC, has improved the cost of system.4. use PC expansion trouble, inconvenience is controlled many welding equipments (like Arc Welding Power, wire-feed motor etc.) simultaneously.
Existing application for a patent for invention " man-machine interaction method and the device for carrying out said that are used for welding robot ", application number is 201110023122.9, its application also is welding robot control.
The main feature of this invention is by human-computer interaction interface, and control information is transferred to the welding robot controller, accomplishes the preceding setting of weldering by the welding robot controller, and adjustment waits operation during weldering.The weak point of this device mainly exists: 1. under the man-machine interaction meeting main window a plurality of subwindows are set, subwindow respectively has its function, and for example the mobile control function of welding gun and the adjustment function of welding parameter adhere to different subwindows separately.In the welding process, need the frequent subwindow that switches to send Different control information, inconvenient operation.2. welding process moves based on welding situation control welding gun and changes welding parameter, generally requires real-time higher, adopts this kind control method to be difficult to meet the demands.When pressing touch-screen; Need touch screen controller and receive touch information, and convert it to contact coordinate, send order through serial ports from touch point detection device; Thereby receive order by the welding robot controller again and judge that which control is pressed; Final order of just sending the control welding robot, the bigger time overhead of this process need cost is not suitable for the occasion that parameter modification is frequent or the weld job real-time is had relatively high expectations.
Summary of the invention
The objective of the invention is to overcome the above-mentioned deficiency that prior art exists; Be provided as a kind of embedded many equipment welding robot system and the control method of control in real time; Its maximum characteristics are that this system serves as the control core with hand-held Embedded Real-Time controller; Hand-held Embedded Real-Time controller is electrically connected with robot switch board, two-dimension moving platform, wire-feed motor and Arc Welding Power, has the correction welding track, adjusts welding parameter, the demonstration welding parameter, controls the start and stop of wire-feed motor and the function of cut-offfing of Arc Welding Power in real time.The path of welding teaching of welding robot before can realizing welding, welding parameter are set with the real-time control, the real-time adjustment of welding parameter of welding torch position in the welding process and are combined, and specifically technical scheme is following.
A kind of embedded many equipment are the welding robot system of control in real time; Comprise: welding robot, robot switch board, robot teach box, hand-held Embedded Real-Time controller, two-dimension moving platform, wire-feed motor and Arc Welding Power; Wherein, Two-dimension moving platform is installed on the end of welding robot, and two-dimension moving platform is equipped with welding gun; Hand-held Embedded Real-Time controller is electrically connected with two-dimension moving platform, robot switch board, wire-feed motor and Arc Welding Power respectively; Robot teach box links to each other with the robot switch board, is used for welding robot is carried out teaching; Hand-held Embedded Real-Time controller is used to control the start and stop of wire-feed motor and cut-offfing of Arc Welding Power; The control two-dimension moving platform drives the welding gun motion; Send to order and give the robot switch board and, in welding process, adjust the voltage and current of Arc Welding Power output in real time by robot switch board control welding robot motion.
In the welding robot system of above-mentioned embedded many equipment control in real time, said robot switch board comprises the CPU that is used for receiving order that hand-held Embedded Real-Time controller sends and the motion of control welding robot and is used to store the position of welding process welding robot and the RAM of velocity information.
In the welding robot system of above-mentioned embedded many equipment control in real time; Said hand-held Embedded Real-Time controller comprises single-chip microcomputer and the power supply that is connected with said single-chip microcomputer respectively and reset circuit, clock oscillation circuit, electromagnetic relay module, RS-232 interface, independent key-press module, A/D modular converter, stepper motor driving circuit, LCD MODULE; Wherein, The electromagnetic relay module is connected with Arc Welding Power with wire-feed motor, is used to control the start and stop of wire-feed motor and cut-offfing of Arc Welding Power; RS-232 interface is connected with the robot switch board, is used to realize the serial communication between hand-held Embedded Real-Time controller and the robot switch board; Also be provided with the knob that is used to regulate the Arc Welding Power electric current and voltage on the hand-held Embedded Real-Time controller; The A/D modular converter is connected through said knob with Arc Welding Power, is used to detect the electric current and voltage of Arc Welding Power output; Stepper motor driving circuit is connected with stepper motor on the two-dimension moving platform, is used for drive stepping motor; LCD MODULE is used to show welding parameter; Said independent key-press module includes the welding track that is used to rectify a deviation, adjustment welding parameter, start and stop wire-feed motor, cut-offs each button of Arc Welding Power.
In the welding robot system of above-mentioned embedded many equipment control in real time, two-dimension moving platform comprises X platform and Y platform, drives ball screw by stepper motor through shaft coupling and drives; The Y platform is installed on the X platform, and said welding gun is installed on the Y platform.
Above-mentioned embedded many equipment are the control method of the welding robot system of control in real time, comprises the real-time control of welding torch position in path of welding teaching and the welding process of welding robot and the real-time adjustment of welding parameter, specifically comprises the steps:
Before the welding, carry out the movement locus teaching of welding robot, use hand-held Embedded Real-Time controller to set welding parameter through robot teach box;
Use hand-held Embedded Real-Time controller to open Arc Welding Power and wire-feed motor, weld job begins;
In welding process, observe on-the-spot welding situation; When welding gun departs from weld seam, welding gun to the distance of weldment when excessive or too small; Drive welding gun relative to the weldment level or vertically move through hand-held Embedded Real-Time controller control welding robot or two-dimension moving platform, rectify a deviation; When arc voltage, welding current, speed of welding is excessive or when too small, adjust the weldingvoltage electric current in real time through hand-held Embedded Real-Time controller, and controls speed of welding through the control welding robot, realizes the control of welding energy input;
When welding occurs unusual or weld job when accomplishing, close wire-feed motor and Arc Welding Power through hand-held Embedded Real-Time controller.
In the above-mentioned control method, hand-held Embedded Real-Time controller sends control command through RS-232 interface, the motion of control welding robot in welding process; Hand-held Embedded Real-Time controller sends instruction; Obtain current position and the speed parameter of welding robot among the switch board RAM of robot by the robot switch board through the internal robot instruction; Send current position and speed parameter to RS-232 again, show in real time through LCD MODULE after hand-held Embedded Real-Time controller is received data.
In the above-mentioned control method, step motor drive X platform and Y platform through on the hand-held Embedded Real-Time controller control two-dimension moving platform drive welding gun and carry out the adjustment of X, Y direction in welding process, realize control in real time.
In the above-mentioned control method, before the welding, welding robot is carried out teaching, and weldingvoltage and welding current parameter are set and open Arc Welding Power and wire-feed motor with hand-held Embedded Real-Time controller through robot teach box.In welding process; Welding situation according to the scene; Send the mobile route that welding robot is revised in order through hand-held Embedded Real-Time controller; Carry out real-time deviation correcting and adjustment welding gun height, avoid in the welding process problems such as the welding gun substantial deviation weld seam that causes and welding instability that deform because weldment is heated.Can adjust parameters such as speed of welding, weldingvoltage, welding current in real time through hand-held Embedded Real-Time controller simultaneously, further improve welding quality.When running into abnormal conditions or needing weld job to stop, button that can directly pressing above the hand-held Embedded Real-Time controller in time stops weld job, guarantees safety.Between welding robot robot end and welding gun, two-dimension moving platform is installed; Thereby can make hand-held Embedded Real-Time controller in welding process directly the control two-dimension moving platform drive the welding gun control of rectifying a deviation; Needn't send order indirectly by robot switch board control welding robot through serial communication, adapt to real-time and require higher occasion.
Compared with prior art, the present invention has following advantage and technique effect: 1, hand-held Embedded Real-Time controller can real-time deviation correcting welding track and adjustment welding gun height.2, hand-held Embedded Real-Time controller can be adjusted weldingvoltage, welding current, speed of welding in real time, realizes the control of welding energy input.3, serve as that the welding robot system of controlling core is expanded easily with hand-held Embedded Real-Time controller, convenient many welding equipments (like Arc Welding Power, wire-feed motor, welding robot) of controlling in real time.4, two-dimension moving platform is installed on the end of welding robot, and two-dimension moving platform is installed welding gun, thereby hand-held Embedded Real-Time controller can directly be controlled two-dimension moving platform and drives welding gun rectify a deviation control and welding gun height adjustment, real-time height.5, the hand-held Embedded Real-Time controller that is adopted adopts button, processing ease, and cost is low.
Description of drawings
Fig. 1 is that embedded many equipment of the present invention are controlled the welding robot system sketch map in real time.
Fig. 2 is a hand-held Embedded Real-Time controller principle block diagram of the present invention.
Fig. 3 is a two-dimension moving platform X-Y scheme of the present invention.
Fig. 4 is a workflow diagram of the present invention.
The specific embodiment
To further explain of the present invention, but the invention is not restricted to these embodiment below in conjunction with accompanying drawing and embodiment.
As shown in Figure 1, these embedded many equipment are controlled welding robot system in real time and are mainly comprised welding robot 7, robot switch board 4, robot teach box 3, hand-held Embedded Real-Time controller 2, two-dimension moving platform 1, wire-feed motor 6 and Arc Welding Power 5.Wherein, system is a core with hand-held Embedded Real-Time controller 2, is connected with Arc Welding Power 5, wire-feed motor 6, two-dimension moving platform 1, robot switch board 4 equal live wires.
Robot teach box 3 links to each other with robot switch board 4, is used for operating personnel welding robot 7 is carried out teaching.Tutorial program is explained and 7 motions of operation welding robot by the CPU of robot switch board 4.
As shown in Figure 2; Hand-held Embedded Real-Time controller is core with the single-chip microcomputer, and peripheral circuit and module comprise: power supply and reset circuit, clock oscillation circuit, electromagnetic relay module, RS-232 interface, independent key-press module, A/D modular converter, stepper motor driving circuit, LCD MODULE.
Power supply and reset circuit, clock oscillation circuit constitute single-chip minimum system with single-chip microcomputer.
The electromagnetic relay module is used for starting and stopping Arc Welding Power 5 and wire-feed motor 6; Only just can control a plurality of welding equipments simultaneously through the button on the hand-held Embedded Real-Time controller 2; Easy to operate; Safe and reliable, when in the welding process during unusual circumstance, can in time close Arc Welding Power and stop welding.
RS-232 interface is realized the serial communication between hand-held Embedded Real-Time controller 2 and the robot switch board 4.On the one hand, hand-held Embedded Real-Time controller 2 sends control command through RS-232, after the CPU of robot switch board 4 receives data, and 7 motions of control welding robot.Satisfy real-time deviation correcting motion and welding gun height adjustment in the welding process.On the other hand; Hand-held Embedded Real-Time controller 2 sends instruction; Obtain parameters such as current position of welding robot among the RAM of robot switch board 47 and speed through internal robot instruction by robot switch board 4; Send data to RS-232 again, show in real time through LCD MODULE after hand-held Embedded Real-Time controller 2 is received data.
Independent key-press module is mainly used in and sends the motion of revising order control welding robot in the welding process except the start and stop of control Arc Welding Power 5 and wire-feed motor 6, carries out real-time deviation correcting, adjusts welding gun height and speed of welding.The CPU of hand-held Embedded Real-Time controller 2 obtains the state of each independent button through the timing inquiry mode; Which kind of order judgement will send to welding robot 7, comprise " moving on the welding gun ", " welding gun moves down ", " moving fast ", " moving down fast " " welding gun moves to left ", " welding gun moves to right ", " moving to left fast ", " moving to right fast ", " acceleration ", " deceleration " " two is extraordinarily fast ", " two demultiplications speed ".
The A/D modular converter links to each other with rheostat knob on the hand-held Embedded Real-Time controller 2.Rheostat is connected with the internal circuit of arc-welding voltage, is used to adjust the weldingvoltage current value.When through knob adjustment weldingvoltage and welding current, the CPU of hand-held Embedded Real-Time controller 2 obtains the electric current and voltage value corresponding with knob position through the A/D modular converter, shows current electric current and voltage value by LCDs then.
In embodiment 1, the real-time deviation correcting function in the welding process and the adjustment of welding gun height are that hand-held Embedded Real-Time controller 2 carries out the serial communication realization through RS-232 interface and robot switch board 4.This process comprises: on the hand-held Embedded Real-Time controller 2 button press, the CPU of hand-held Embedded Real-Time controller 2 detect button press and judge, hand-held Embedded Real-Time controller 2 interrupts through the CPU response that serial ports sends order data, robot switch board 4, robot switch board 4 receives data and deal with data, robot switch board 4 sends and drives 7 actions of order control welding robot.This process has spent more time overhead.Present embodiment increases two-dimension moving platform 1 on the basis of embodiment 1.As shown in Figure 3, this two-dimension moving platform 1 comprises X platform d and Y platform e, drives platform motion by stepper motor a through drive lead screw b.The X platform d of two-dimension moving platform is installed on welding robot c end, and Y platform e is installed on the X platform d, and on the Y platform, welding gun f is installed.Can drive X platform d and Y platform e through the stepper motor a on the hand-held Embedded Real-Time controller control two-dimension moving platform; In welding process, directly drive welding gun f and carry out the adjustment of X, Y direction; Thereby carry out the welding track correction; The adjustment welding gun is applicable to the occasion that real-time is had relatively high expectations to the distance of workpiece.In addition, in the programming of hand-held Embedded Real-Time controller 2, also need not relate to calling of welding robot movement function, realize more simple and convenient.
As shown in Figure 3, before the welding,, carry out teaching through 3 pairs of welding robots of robot teach box 7 according to the concrete condition of weld seam, through hand-held Embedded Real-Time controller 2 weldingvoltage and welding current parameter are set.In the welding process, the technical staff observes the welding situation.Generally speaking, weldment all can be heated and produce distortion, particularly thin plate weldment.This moment, the solder technology personnel used hand-held Embedded Real-Time controller 2 to control in real time; For example when the welding gun track departs from weld seam; " welding gun moves to left ", " welding gun moves to right " button that can press on the hand-held Embedded Real-Time controller 2 are adjusted in real time; If when departing from greatly, can press " moving to left fast ", " moving to right fast " button.When because the distortion of workpiece when causing the vertical range of welding gun and weldment to change, can be pressed " moving on the welding gun ", " welding gun moves down " button is adjusted in real time, has " moving on quick ", " moving down fast " button equally.When welding gun process circular arc or irregular curve, can pass through " acceleration ", " deceleration " " two is extraordinarily fast ", " two demultiplications speed " again by the key control speed of welding, the assurance welding quality.Fill out discontented or groove when piling up when observing the weldment groove, the electric current and voltage knob that can operate on the hand-held Embedded Real-Time controller 2 carries out the adjustment of electric current and voltage.When the welding appearance is unusual, in time close Arc Welding Power 5 and wire-feed motor 6 through the button on the hand-held Embedded Real-Time controller 2, stop welding operation, guarantee safety.
Claims (7)
1. embedded many equipment welding robot system of control in real time; It is characterized in that comprising: welding robot, robot switch board, robot teach box, hand-held Embedded Real-Time controller, two-dimension moving platform, wire-feed motor and Arc Welding Power; Wherein, Two-dimension moving platform is installed on the end of welding robot, and two-dimension moving platform is equipped with welding gun; Hand-held Embedded Real-Time controller is electrically connected with two-dimension moving platform, robot switch board, wire-feed motor and Arc Welding Power respectively; Robot teach box links to each other with the robot switch board, is used for welding robot is carried out teaching; Hand-held Embedded Real-Time controller is used to control the start and stop of wire-feed motor and cut-offfing of Arc Welding Power; The control two-dimension moving platform drives the welding gun motion; Send to order and give the robot switch board and, in welding process, adjust the voltage and current of Arc Welding Power output in real time by robot switch board control welding robot motion.
2. embedded many equipment according to claim 1 are the welding robot system of control in real time, it is characterized in that said robot switch board comprises the CPU that is used for receiving order that hand-held Embedded Real-Time controller sends and the motion of control welding robot and is used to store the position of welding process welding robot and the RAM of velocity information.
3. embedded many equipment according to claim 1 are the welding robot system of control in real time; It is characterized in that said hand-held Embedded Real-Time controller comprises single-chip microcomputer and the power supply that is connected with said single-chip microcomputer respectively and reset circuit, clock oscillation circuit, electromagnetic relay module, RS-232 interface, independent key-press module, A/D modular converter, stepper motor driving circuit, LCD MODULE; Wherein, The electromagnetic relay module is connected with Arc Welding Power with wire-feed motor, is used to control the start and stop of wire-feed motor and cut-offfing of Arc Welding Power; RS-232 interface is connected with the robot switch board, is used to realize the serial communication between hand-held Embedded Real-Time controller and the robot switch board; Also be provided with the knob that is used to regulate the Arc Welding Power electric current and voltage on the hand-held Embedded Real-Time controller; The A/D modular converter is connected through said knob with Arc Welding Power, is used to detect the electric current and voltage of Arc Welding Power output; Stepper motor driving circuit is connected with stepper motor on the two-dimension moving platform, is used for drive stepping motor; LCD MODULE is used to show welding parameter; Said independent key-press module includes the welding track that is used to rectify a deviation, adjustment welding parameter, start and stop wire-feed motor, cut-offs each button of Arc Welding Power.
4. embedded many equipment according to claim 1 are the welding robot system of control in real time, and it is characterized in that: two-dimension moving platform comprises X platform and Y platform, drives ball screw by stepper motor through shaft coupling and drives; The Y platform is installed on the X platform, and said welding gun is installed on the Y platform.
5. the real-time control method of the welding robot system of control of each said embedded many equipment of claim 1 ~ 4; It is characterized in that comprising the real-time control of welding torch position in path of welding teaching and the welding process of welding robot and the real-time adjustment of welding parameter, specifically comprise the steps:
Before the welding, carry out the movement locus teaching of welding robot, use hand-held Embedded Real-Time controller to set welding parameter through robot teach box;
Use hand-held Embedded Real-Time controller to open Arc Welding Power and wire-feed motor, weld job begins;
In welding process, observe on-the-spot welding situation; When welding gun departs from weld seam, welding gun to the distance of weldment when excessive or too small; Drive welding gun relative to the weldment level or vertically move through hand-held Embedded Real-Time controller control welding robot or two-dimension moving platform, rectify a deviation; When arc voltage, welding current, speed of welding is excessive or when too small, adjust the weldingvoltage electric current in real time through hand-held Embedded Real-Time controller, and controls speed of welding through the control welding robot, realizes the control of welding energy input;
When welding occurs unusual or weld job when accomplishing, close wire-feed motor and Arc Welding Power through hand-held Embedded Real-Time controller.
6. according to the said control method of claim 5, it is characterized in that hand-held Embedded Real-Time controller sends control command through RS-232 interface, the motion of control welding robot in welding process; Hand-held Embedded Real-Time controller sends instruction; Obtain current position and the speed parameter of welding robot among the switch board RAM of robot by the robot switch board through the internal robot instruction; Send current position and speed parameter to RS-232 again, show in real time through LCD MODULE after hand-held Embedded Real-Time controller is received data.
7. according to the said control method of claim 5; It is characterized in that through step motor drive X platform and Y platform on the hand-held Embedded Real-Time controller control two-dimension moving platform; In welding process, drive welding gun and carry out the adjustment of X, Y direction, realize control in real time.
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