CN102615389A - Arc welding robot oscillating electric arc tracking system and method based on DSP (Digital Signal Processor) - Google Patents
Arc welding robot oscillating electric arc tracking system and method based on DSP (Digital Signal Processor) Download PDFInfo
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Abstract
The invention provides an arc welding robot oscillating electric arc tracking system and method based on DSP (Digital Signal Processor). The system comprises an arc welding robot, an electric arc sensor, a filtering and protecting circuit and the DSP, wherein the arc welding robot at least comprises a welding gun which can oscillate left and right in the welding heading direction so as to weld a workpiece; the electric arc sensor is connected with the arc welding robot and comprises a Hall current sensor and a measuring resistor which are connected in series; the filtering and protecting circuit is connected with the electric arc sensor; the DSP realizes signal transmission with the arc welding robot by a robot interface circuit; and the DSP at least comprises a path rectification module and a pendulum deflection regulation module which are used for respectively regulating the welding direction and pendulum deflection of the arc welding robot. In the arc welding robot oscillating electric arc tracking system, the welding line can be laterally and longitudinally tracked by the electric arc tracking system, and the pendulum deflection is regulated, the flexibility of the robot is improved, and the arc welding robot oscillating electric arc tracking system is favorable for intelligently applying the robot in the practical industrial production.
Description
Technical field
The present invention relates to welding technology field, what be specifically related to is a kind of arc welding robot swing arc tracking and control system based on DSP, comprises that follow the tracks of at the weld seam center and the amplitude of oscillation is adjusted in real time.
Background technology
Along with the development of Robotics, welding robot has been widely used in fields such as automobile, space flight manufacturing.In order to expand welding robot in manufacturing range of application; Improve constantly application level; Research and development have certain perception, judge the welding robot that the feedback information of decision making function is intelligent or the intellectualized technology of development welding robot, will be one of developing direction of Automation of Welding.Because the influence of various factors such as welding surroundings, actual welding condition often changes because of interference, tends to make welding gun to depart from the weld seam center, thereby causes welding quality to descend even failure.Therefore, development can the perception external disturbance, detect in real time the deviation of weld seam and in time automatically the intelligent welding robot system of adjustment path of welding become the research focus of present scientific research and production.In other words, the development of seam tracking system becomes the key factor that realizes Automation of Welding, intellectuality and guarantee welding quality.
In order to realize weld joint tracking, then need supporting appropriate sensor auxiliary robot to obtain perception to external world.At present, the sensing mode that is applied on the welding robot is varied, wherein the electric arc sensing technology simple because of its low cost, device, realize that reason such as easy occupies critical role in weld joint tracking research.The electric arc sensing is divided into mechanical reciprocally swinging formula and rotary scanning type again.Though people's research emphasis needs supporting additional rotary arc sensor on rotating the arc in recent years, price is also than higher.So, utilize the reciprocally swinging function of robot self to realize electric arc sensing and weld joint tracking, then more with a wide range of applications and market competition advantage.
Present most of robots electric arc sensing product is the foreign technology manufacturing, and cost is too high; Domestic also have many experts and scholars in the research of carrying out the swing arc sensing; For example; China's number of applying for a patent: 200820053115.7; By name " weld joints of gas metal arc welding by magnetic controlled electric arc sensor real-Time Tracking Control device " carries out soldering joint automatic tracking through magnetic control arc sensor, the welding system, control system and the executing agency that are made up of welding gun and the source of welding current etc.But it mainly relies on computer and handles and control, and is unfavorable for the system integration and extensive use in the industry.And this invention also need be installed the swing that special magnetic control means could be realized electric arc, has improved cost to a certain extent.
Summary of the invention
The present invention is directed to above-mentioned deficiency of the prior art and needs; Utilize welding robot self swing characteristic; Proposed arc welding robot swing arc tracking system and method, can realize that the horizontal and vertical tracking and the amplitude of oscillation at the weld seam center of robot adjusted in real time based on DSP.
To achieve these goals; The present invention proposes a kind of arc welding robot swing arc tracking system based on DSP, comprising: arc welding robot, and said arc welding robot comprises a welding gun at least; Said welding gun can swing at the welding direct of travel, and workpiece is welded; Arc sensor links to each other with said arc welding robot, and said arc sensor comprises the Hall current sensor and the measuring resistance of series connection; Filtering and holding circuit link to each other with said arc sensor; DSP, through robot interface's circuit, the signal transmission between realization and the said arc welding robot, said DSP comprises path correction module and amplitude of oscillation adjusting module at least, adjusts the direction and the amplitude of oscillation of said arc welding robot welding respectively.
Optional, the turn ratio of said Hall current sensor is 1: 2000, the resistance of said measuring resistance is 10 ohm.
Optional, said filtering and holding circuit adopt the second order Butterworth multichannel feedback-type low-pass filter circuit that infinitely gains to carry out filtering.
Optional, the highest protection magnitude of voltage of said filtering and holding circuit is set at 3 volts.
To achieve these goals, the present invention also proposes a kind of arc welding robot swing arc tracking based on DSP, may further comprise the steps: said arc welding robot of initialization and said DSP; Said arc welding robot and said DSP realize carrying out shake communication; Said arc welding robot welds workpiece, and welding current signal is imported arc sensor, converts the weldingvoltage signal to; Said weldingvoltage signal gets into filtering and holding circuit denoising, and after limiting the highest protection magnitude of voltage of said weldingvoltage signal, sends to said DSP; Said DSP converts said weldingvoltage signal to welding current signal; And said welding current signal is carried out Fourier transformation and calculated the said arc welding robot electric current aggregate-value that swings, obtain the horizontal and vertical swing adjusted value of welding gun of said arc welding robot; Said DSP sends said swing adjusted value to said arc welding robot through robot interface's circuit; Said arc welding robot is adjusted the welding direct of travel and the amplitude of oscillation according to said swing adjusted value in real time.
Optional, also comprise change calculations current corresponding variable quantity according to weld width in the welding process, thus the deviate between theory of computation swing width and the actual swing width.
Optional, said arc sensor adopts Hall current sensor and cooperates the measuring resistance of a fixed resistance value, obtains the voltage of measuring circuit, is about to said welding current signal and converts the weldingvoltage signal to.
Optional, the turn ratio of the Hall current sensor of selecting for use is 1: 2000, the resistance of said measuring resistance is 10 ohm.
Optional, said DSP converts said weldingvoltage signal to welding current signal used formula and is: actual welding current=(recording voltage/measuring resistance) * turn ratio.
Optional, said filtering and holding circuit adopt the second order Butterworth multichannel feedback-type low-pass filter circuit that infinitely gains to carry out filtering.
Optional, the highest protection magnitude of voltage of said filtering and holding circuit is set at 3 volts.
The present invention is based on the arc welding robot swing arc tracking system of DSP and the useful technique effect of method is: the arc welding robot swing arc tracking system and the method that the present invention is based on DSP provide system platform; Satisfied the requirement of welding robot local intelligence; Current signal in the weave bead welding termination process is converted to voltage signal and it is carried out denoising and collection; And then convert the voltage signal of gathering into actual welding current signal according to formula as previously mentioned; Through the foundation of a series of Digital Signal Processing and communication, finally can realize the adjustment of the weld joint tracking and the amplitude of oscillation well, thereby obtain better welding quality.
Description of drawings
Fig. 1 is based on the arc welding robot swing arc tracking system of DSP and the system block diagram of method.
Fig. 2 is based on the arc welding robot swing arc tracking system of DSP and the schematic flow sheet of method.
The specific embodiment
Below, in conjunction with accompanying drawing the present invention is done further detailed description, present embodiment provided detailed embodiment and concrete operating process, but protection scope of the present invention is not limited to following embodiment being to implement under the prerequisite with technical scheme of the present invention.
As shown in Figure 1, the arc welding robot swing arc tracking and the control system based on DSP of present embodiment comprise: welding robot, arc sensor, filtering and holding circuit, DSP, robot interface's circuit, wherein:
Welding robot, last joint are installed GMAW weldering welding gun, swing with respect to the welding travel direction, and workpiece is welded; Transmission begins to weld, stop the welding and the position signalling that swings to DSP; Accept the shifted signal that DSP sends, the change path of welding is realized weld seam correction and amplitude of oscillation adjustment;
Arc sensor adopts Hall current sensor and cooperates the measuring resistance of certain resistance, takes out the voltage at measuring resistance two ends, that is to say to convert welding current into voltage form, is sent to filtering and holding circuit;
Filtering and holding circuit adopt second order Butterworth MFB type low-pass filter circuit to carry out the effect that denoising is played in filtering; The maximum voltage value of external measuring resistance being changed out through holding circuit is limited to 3V, and is sent to the A/D module of DSP;
DSP, through robot interface's circuit obtain from robot begin the welding or stop welding signal after, the A/D module of DSP begins or stops sampling and the analog-to-digital conversion to current signal; The voltage signal gathered is converted into actual welding current value through formula as previously mentioned; Carry out Fourier transformation, calculate the electric current accumulated value that swings; Obtain horizontal and vertical side-play amount or the amplitude of oscillation adjusted value of welding gun, and send signal to robot through robot interface's circuit.
Robot interface's circuit is built suitable circuit and is selected suitable resistance for use, and safety realizes the transmission between robot signal and the DSP signal; Adopt light-coupled isolation that the interfering signal of the interfering signal of robot and DSP is isolated.
Said welding robot comprises: welding robot human body and be installed in the instrument on the robot end joint, and this instrument specifically can be a welding gun; Simultaneously, also be furnished with the source of welding current, robot controller, protective gas and cooling device.
Said arc sensor comprises: Hall current sensor, measuring resistance and ± the 15V dc source; Wherein: the turn ratio of Hall current sensor is 1: 2000; Measuring resistance is 10 ohm; Ground connection after the signal output terminal of Hall current sensor is connected with measuring resistance, positive and negative two terminals of Hall current sensor are connected on respectively on dc source+15 ends and-15 ends.
Said filtering and holding circuit comprise: second order Butterworth MFB type low-pass filter circuit, Zener diode.Be protection DSP, after the denoising of signal process filter circuit, voltage be limited in the 3V through the Zener diode voltage stabilizing.
Said DSP comprises: the development board based on the TMS320F2812DSP chip of TI company contains the A/D modular converter; Described voltage signal with collection converts the used formula of actual welding current signal into and is:
Actual welding current=(recording voltage/measuring resistance) * turn ratio.
Said robot interface's circuit comprises: TLP521-4 light-coupled isolation, divider resistance, the robot signal sends to DSP through light-coupled isolation and divider resistance.
The present invention also proposes a kind of arc welding robot swing arc tracking based on DSP, may further comprise the steps: said arc welding robot of initialization and said DSP; Said arc welding robot and said DSP realize carrying out shake communication; Said arc welding robot welds workpiece, and welding current signal is imported arc sensor, converts the weldingvoltage signal to; Said weldingvoltage signal gets into filtering and holding circuit denoising, and after limiting the highest protection magnitude of voltage of said weldingvoltage signal, sends to said DSP; Said DSP converts said weldingvoltage signal to welding current signal; And said welding current signal is carried out Fourier transformation and calculated the said arc welding robot electric current aggregate-value that swings; Obtain the horizontal and vertical swing adjusted value of welding gun of said arc welding robot; According to the change calculations current corresponding variable quantity of weld width in the welding process, thus the deviate between theory of computation swing width and the actual swing width; Said DSP sends said swing adjusted value to said arc welding robot through robot interface's circuit; Said arc welding robot is adjusted the welding direct of travel and the amplitude of oscillation according to said swing adjusted value in real time.
When the present invention works, on the basis of hardware system, also rely on a whole set of software program to realize the process that electric arc is followed the tracks of.Therefore, the present invention is directed to arc welding robot swing arc tracking and control system, respectively welding robot and DSP have been carried out writing of program based on DSP.Under the support of this two parts program, can realize collection and processing to arc signal, carry out the communication between robot and the DSP, final motion correction and the amplitude of oscillation adjustment control of accomplishing robot.
Below, the welding robot and the DSP course of work are set forth respectively.
Be depicted as the flow chart of welding robot program like Fig. 2-a, mainly comprise: system initialization, external communication connect, get into interrupt routine, send steps such as welding stop signal, specifies as follows:
(1) system initialization: robot is carried out system initialization, carry out variable-definition;
(2) external communication connects: send communication request signal to DSP;
(3) accomplish with the DSP carrying out shake communication: when the return signal of DSP is received by robot, then accomplish the carrying out shake communication of robot and DSP;
(4) judge whether that welding stops: after the welding beginning; If welding does not stop, then getting into interrupt routine at set intervals, robot sends communication instruction to DSP; After the DSP response; The controlled quentity controlled variable from DSP can be received by robot, carries out coordinates of motion parameter modification, and then gets back in the main program of robot;
(5) send the welding stop signal: when the robot welding gun moves to the weld seam terminating point, blow-out automatically, stop motion; Robot sends signal to DSP, informs that welding stops;
(6) finish: robot program's end of run.
Dsp software control is the second largest part of software programming of the present invention; Mainly comprise: the initialization of DSP, with the output of robot communication, data acquisition, Digital Signal Processing and feature extraction, controlled quentity controlled variable etc.; Shown in the following Fig. 2-b of the flow chart of its operation, specify as follows:
(1) initialization DSP: after system brings into operation, at first DSP kernel register is carried out initialization, configuration dominant frequency, high-speed peripheral and low speed peripheral hardware frequency etc.; Then to general input/output port (GPIO) initialization of register and be provided with in which way and external device communication; The initialization peripheral hardware interrupts expansion (PIE) module and interrupt vector table; At last to system employed as: analog/digital (A/D) module, incident management (EV) module, serial communication interface peripheral hardware registers such as (SCI) are done initialization;
(2) with the robot initial communication: behind the initialization DSP, whether the continuous inquiry of program has the external robots communication signal, and when inquiring robot when communication instruction is arranged, DSP answers, and accomplishes carrying out shake communication with robot;
(3) arc signal collection: after DSP has received welding signal, the collection of beginning arc signal, acquisition mode is the sampling of timer down trigger, sample frequency can be set and preserve the processing sampled result;
(4) Digital Signal Processing and extract characteristic value: the voltage signal gathered is converted into actual welding current value through formula as previously mentioned; Carry out Fourier transformation and add up, obtain horizontal and vertical current change quantity and extract characteristic value, confirm the correction amount according to pre-set threshold with the mean value that swings; The mean value of the signal that several cycles after mean value and the stable welding of two accumulated values of the left and right sides that the signal of gathering is got are corresponding subtracts each other, and the current change quantity 3 that causes as weld width is also confirmed amplitude of oscillation adjusted value according to pre-set threshold;
(5) output controlled quentity controlled variable: the controlled quentity controlled variable that calculates sends to robot according to communications protocol with the exclusive or check sign indicating number (BCC) of controlled quentity controlled variable and instruction through the SCI serial communication after the robot communication signal arrives.
(6) judge whether that welding stops: not receiving the welding stop signal that robot sends, then turn back to the arc signal collection, repeat following flow process;
(7) EP (end of program): after receiving the signal that welding stops, the DSP program stops automatically.
As stated; Under the soft ware platform of hardware systems such as robot, arc sensor, filtering and holding circuit, DSP, robot interface's circuit and robot program, DSP program; Can realize collection and processing to arc signal; Carry out the communication between robot and the DSP, final motion correction and the amplitude of oscillation adjustment control of accomplishing robot.
Present embodiment is the important foundation platform that makes up welding robot GMAW local intelligence welding system; On this basic platform, can resist to a certain extent because the interference that various destabilizing factors such as the workpiece assembly precision is low, workpiece machining error are brought; Adjust the path deviation and the amplitude of oscillation of welding robot in real time; Improve " flexibility " of robot, thereby reach the purpose that improves welding quality, have important effect expanding the application of robot in the Automation of Welding field.
Though the present invention discloses as above with preferred embodiment, so it is not in order to limit the present invention.Have common knowledge the knowledgeable in the technical field according to the invention, do not breaking away from the spirit and scope of the present invention, when doing various changes and retouching.Therefore, protection scope of the present invention is as the criterion when looking claims person of defining.
Claims (11)
1. the arc welding robot swing arc tracking system based on DSP is characterized in that, comprising:
Arc welding robot, said arc welding robot comprises a welding gun at least, said welding gun can swing at the welding direct of travel, and workpiece is welded;
Arc sensor links to each other with said arc welding robot, and said arc sensor comprises the Hall current sensor and the measuring resistance of series connection;
Filtering and holding circuit link to each other with said arc sensor;
DSP, through robot interface's circuit, the signal transmission between realization and the said arc welding robot, said DSP comprises path correction module and amplitude of oscillation adjusting module at least, adjusts the direction and the amplitude of oscillation of said arc welding robot welding respectively.
2. arc welding robot swing arc tracking system according to claim 1 is characterized in that: the turn ratio of said Hall current sensor is 1: 2000, and the resistance of said measuring resistance is 10 ohm.
3. arc welding robot swing arc tracking system according to claim 1 is characterized in that: said filtering and holding circuit adopt the second order Butterworth multichannel feedback-type low-pass filter circuit that infinitely gains to carry out filtering.
4. according to claim 1 or 4 described arc welding robot swing arc tracking systems, it is characterized in that: the highest protection magnitude of voltage of said filtering and holding circuit is set at 3 volts.
5. the arc welding robot swing arc tracking based on DSP is characterized in that, may further comprise the steps:
Said arc welding robot of initialization and said DSP;
Said arc welding robot and said DSP realize carrying out shake communication;
Said arc welding robot welds workpiece, and welding current signal is imported arc sensor, converts the weldingvoltage signal to;
Said weldingvoltage signal gets into filtering and holding circuit denoising, and after limiting the highest protection magnitude of voltage of said weldingvoltage signal, sends to said DSP;
Said DSP converts said weldingvoltage signal to welding current signal; And said welding current signal is carried out Fourier transformation and calculated the said arc welding robot electric current aggregate-value that swings, obtain the horizontal and vertical swing adjusted value of welding gun of said arc welding robot;
Said DSP sends said swing adjusted value to said arc welding robot through robot interface's circuit;
Said arc welding robot is adjusted the welding direct of travel and the amplitude of oscillation according to said swing adjusted value in real time.
6. arc welding robot swing arc tracking according to claim 5; It is characterized in that: also comprise change calculations current corresponding variable quantity according to weld width in the welding process, thus the deviate between theory of computation swing width and the actual swing width.
7. arc welding robot swing arc tracking according to claim 5; It is characterized in that: said arc sensor adopts Hall current sensor and cooperates the measuring resistance of a fixed resistance value; Obtain the voltage of measuring circuit, be about to said welding current signal and convert the weldingvoltage signal to.
8. arc welding robot swing arc tracking according to claim 7 is characterized in that: the turn ratio of the Hall current sensor of selecting for use is 1: 2000, and the resistance of said measuring resistance is 10 ohm.
9. arc welding robot swing arc tracking according to claim 7 is characterized in that: said DSP converts said weldingvoltage signal to welding current signal used formula and is: actual welding current=(recording voltage/measuring resistance) * turn ratio.
10. arc welding robot swing arc tracking according to claim 7 is characterized in that: said filtering and holding circuit adopt the second order Butterworth multichannel feedback-type low-pass filter circuit that infinitely gains to carry out filtering.
11. according to claim 5 or 10 described arc welding robot swing arc trackings, it is characterized in that: the highest protection magnitude of voltage of said filtering and holding circuit is set at 3 volts.
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Cited By (12)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN102861970A (en) * | 2012-09-27 | 2013-01-09 | 中铁山桥集团有限公司 | Welding method of orthotropic plate U-shaped rib fillet welding robot and special equipment thereof |
| CN105643062A (en) * | 2016-04-08 | 2016-06-08 | 湘潭大学 | Rotating arc based method for recognizing complex curved surface shape and controlling welding gun pose |
| CN105728904A (en) * | 2016-05-12 | 2016-07-06 | 湘潭大学 | System and method for tracking weaving arc space weld based on MEMS (micro-electromechanical systems) sensor |
| CN106735749A (en) * | 2016-12-22 | 2017-05-31 | 河北省自动化研究所 | A kind of laser assisted weld seam Intelligent tracing system |
| CN108883487A (en) * | 2016-04-04 | 2018-11-23 | 株式会社神户制钢所 | Electric arc profiling welding method and electric arc profiling welding device |
| CN109093229A (en) * | 2017-06-20 | 2018-12-28 | 天津玛斯特车身装备技术有限公司 | The arc-welding automated system of robot special type part |
| CN111037169A (en) * | 2020-01-03 | 2020-04-21 | 成都卡诺普自动化控制技术有限公司 | Tracking method for self-adaptive welding seam track of 6-degree-of-freedom robot |
| CN112059366A (en) * | 2020-08-26 | 2020-12-11 | 郑州煤矿机械集团股份有限公司 | Method for automatically welding flux-cored wire in vertical direction of hydraulic support structural part |
| CN112222584A (en) * | 2020-09-08 | 2021-01-15 | 湘潭大学 | Double-transverse magnetic field magnetic control micro-beam plasma arc welding seam tracking method for welding ultrathin-wall pipe |
| CN112658444A (en) * | 2020-12-15 | 2021-04-16 | 唐山松下产业机器有限公司 | Arc sensing control method and system for welding robot |
| TWI758961B (en) * | 2020-11-19 | 2022-03-21 | 財團法人金屬工業研究發展中心 | Method for multi-pass welding |
| CN114346366A (en) * | 2020-10-12 | 2022-04-15 | 株式会社神户制钢所 | Arc tracking welding method and welding device |
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Cited By (15)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN102861970A (en) * | 2012-09-27 | 2013-01-09 | 中铁山桥集团有限公司 | Welding method of orthotropic plate U-shaped rib fillet welding robot and special equipment thereof |
| CN108883487A (en) * | 2016-04-04 | 2018-11-23 | 株式会社神户制钢所 | Electric arc profiling welding method and electric arc profiling welding device |
| CN105643062A (en) * | 2016-04-08 | 2016-06-08 | 湘潭大学 | Rotating arc based method for recognizing complex curved surface shape and controlling welding gun pose |
| CN105643062B (en) * | 2016-04-08 | 2018-03-09 | 湘潭大学 | Complex-curved shape recognition and welding gun posture control method based on rotating the arc |
| CN105728904A (en) * | 2016-05-12 | 2016-07-06 | 湘潭大学 | System and method for tracking weaving arc space weld based on MEMS (micro-electromechanical systems) sensor |
| CN106735749B (en) * | 2016-12-22 | 2019-10-11 | 河北省自动化研究所 | A kind of laser assisted weld seam Intelligent tracing system |
| CN106735749A (en) * | 2016-12-22 | 2017-05-31 | 河北省自动化研究所 | A kind of laser assisted weld seam Intelligent tracing system |
| CN109093229A (en) * | 2017-06-20 | 2018-12-28 | 天津玛斯特车身装备技术有限公司 | The arc-welding automated system of robot special type part |
| CN111037169A (en) * | 2020-01-03 | 2020-04-21 | 成都卡诺普自动化控制技术有限公司 | Tracking method for self-adaptive welding seam track of 6-degree-of-freedom robot |
| CN112059366A (en) * | 2020-08-26 | 2020-12-11 | 郑州煤矿机械集团股份有限公司 | Method for automatically welding flux-cored wire in vertical direction of hydraulic support structural part |
| CN112222584A (en) * | 2020-09-08 | 2021-01-15 | 湘潭大学 | Double-transverse magnetic field magnetic control micro-beam plasma arc welding seam tracking method for welding ultrathin-wall pipe |
| CN114346366A (en) * | 2020-10-12 | 2022-04-15 | 株式会社神户制钢所 | Arc tracking welding method and welding device |
| CN114346366B (en) * | 2020-10-12 | 2023-08-15 | 株式会社神户制钢所 | Arc tracking welding method and welding device |
| TWI758961B (en) * | 2020-11-19 | 2022-03-21 | 財團法人金屬工業研究發展中心 | Method for multi-pass welding |
| CN112658444A (en) * | 2020-12-15 | 2021-04-16 | 唐山松下产业机器有限公司 | Arc sensing control method and system for welding robot |
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