CN105414821A - Welding robot welding seam automatic tracking system - Google Patents
Welding robot welding seam automatic tracking system Download PDFInfo
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- CN105414821A CN105414821A CN201610010179.8A CN201610010179A CN105414821A CN 105414821 A CN105414821 A CN 105414821A CN 201610010179 A CN201610010179 A CN 201610010179A CN 105414821 A CN105414821 A CN 105414821A
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Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K37/00—Auxiliary devices or processes, not specially adapted to a procedure covered by only one of the preceding main groups
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K37/00—Auxiliary devices or processes, not specially adapted to a procedure covered by only one of the preceding main groups
- B23K37/02—Carriages for supporting the welding or cutting element
- B23K37/0211—Carriages for supporting the welding or cutting element travelling on a guide member, e.g. rail, track
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Abstract
The invention provides an automatic welding seam tracking system of a welding robot, which comprises a welding arm, wherein a rotating box and a position adjusting mechanism are arranged on the welding arm, a laser sensor and a welding gun are arranged on the rotating box, the position adjusting mechanism comprises a first motor and a second motor, the laser sensor is connected with the second motor, the first motor, the second motor and the laser sensor are communicated with a DSP control system, a laser is arranged on the laser sensor, and the laser is used for emitting laser to the surface of an object to be welded. The DSP control system is connected with two drivers, and the two drivers are respectively connected with the first motor and the second motor. The laser sensor comprises a laser, a CCD camera and a Bluetooth, the laser is used for emitting laser to the surface of the welded object, the CCD camera is used for shooting the image of the surface of the welded object, and the Bluetooth transmits the shot image to the DSP control system.
Description
Technical field
The present invention relates to robot welding field, particularly a kind of welding robot weld seam automatic tracking system.
Background technology
Welding robot can be raised the efficiency, optimize quality, improve working conditions, and thus develops and applies welding robot and play huge effect to Chinese national economy.Current welding robot is mostly programmable playback robot, and this robot accurately can complete the operation of teaching in its working space.In the process of welding robot welding, if welding condition is basicly stable, then robot can ensure welding quality.But due to the impact of various factors, actual welding condition often changes.Such as: because the impacts such as strong arc light radiation, high temperature, flue dust, splashing, groove situation, mismachining tolerance, fixture clamping precision, surface state and workpiece thermal deformation can make welding gun depart from weld seam, thus cause welding quality decline even weld failure.
Summary of the invention
Goal of the invention: technical problem to be solved by this invention is for the deficiencies in the prior art, provides a kind of welding robot weld seam automatic tracking system.
In order to solve the problems of the technologies described above, the invention provides a kind of welding robot weld seam automatic tracking system, comprise welding arm, described welding arm is provided with rotary box and position adjusting mechanism, described rotary box is provided with laser sensor and welding gun, described position adjusting mechanism comprises the first motor and the second motor, described laser sensor connects the second motor, described first motor, the second motor and laser sensor are communicated to DSP control system, described laser sensor is provided with laser instrument, and laser instrument is used for soldered body surface Emission Lasers.
In the present invention, described DSP control system connects two drivers, and two drivers connect the first motor and the second motor respectively.
In the present invention, described position adjusting mechanism also comprises driving-belt and rotary box power transmission shaft, rotary box power transmission shaft passes rotary box and is connected to by rotary box on welding arm, driving-belt is connected on the first motor driving shaft and rotary box power transmission shaft, first motor driving shaft is by driving-belt driven rotary case power transmission shaft, rotary box power transmission shaft driven rotary case swings, thus controls welding torch position.
In the present invention, the described install bin that needs is provided with the second motor and sensor driving shaft, laser sensor is arranged on sensor driving shaft, the second motor driving shaft band dynamic sensor driving shaft, and sensor driving shaft drives laser sensor to move on sensor driving shaft.
In the present invention, described laser sensor is CCD camera, and CCD camera is for taking the image of soldered body surface.
Present invention also offers a kind of weld seam method for automatic tracking, described weld seam method for automatic tracking comprises the following steps:
Step 1: the second motor drive laser scanning weld seam, detects the deviation of welding gun relative to solder joint;
Step 2: Bluetooth transmission deviation signal;
Step 3:DSP control system accepts deviation signal;
Step 4:DSP control system produces control signal and sends to driver;
Step 5: the first motor drives welding gun, realizes the real-time tracking of butt welded seam.
In the present invention, described DSP control system adopts Fuzzy-P bimodulus Discrete control to carry out the correction of weld seam after accepting deviation signal, produce control signal, Fuzzy-P bimodulus Discrete control adoption rate when deviation is greater than four millimeters controls, and adopts fuzzy control when deviation is less than or equal to four millimeters.Described Fuzzy-P bimodulus Discrete control formula is:
When | during e|≤4mm, U=[α 1E+ (1
-α 1) EC]
When | during e| > 4mm, U=[α 2E+ (1
-α 2) EC]
Wherein, e is deviation, is recorded by laser seam sensor, and modifying factor α 1=0.4, α 2=0.6, U are the controlled quentity controlled variable exported; EC is the fuzzy quantity of deviation variation rate, and EC is the function about e, is automatically produced according to departure e by DSP control system, and E is the fuzzy quantity of deviation, and E is the function about e, is automatically produced according to departure e by DSP control system.
In the present invention, in described step 2, by bluetooth, the image that laser sensor is taken is passed to DSP control system.Beneficial effect: 1, the present invention is by motor and the square transversal scanning in welded joints of laser tape dynamic sensor, detect the lateral separation between sensor and weld seam and fore-and-aft distance, and drive welding gun horizontal stepper motor and longitudinal stepper motor action by three-dimensional regulating mechanism, realize the real-time automatic tracking of welding robot welding gun butt welded seam, welding torch position can be adjusted in real time according to the change of welding condition, reduce workman and adjust number of operations.
2, the present invention adopts Fuzzy-P bimodulus Discrete control method, and the error range adjusted is large, and wherein divide deviation adjusting method to ensure the accurate of welding, adjustment side is flexible.
3, the invention provides a kind of welding robot system scaling method guided based on line structured light vision sensor, it is flexible, precision is high, speed is fast, good stability, real-time, and method is simple, and amount of calculation is little, highly versatile.
Accompanying drawing explanation
To do the present invention below in conjunction with the drawings and specific embodiments and further illustrate, above-mentioned or otherwise advantage of the present invention will become apparent.
Fig. 1 is welding arm structure figure;
Fig. 2 is welding arm structure schematic diagram;
Fig. 3 is welding robot seam tracking system block diagram; Fig. 4 is the weld joint tracking step motor control system based on DSP;
Fig. 5 is software flow figure.
Detailed description of the invention
Below in conjunction with accompanying drawing, the present invention is elaborated.
Embodiment:
As Fig. 1 and Fig. 2, the present embodiment comprises welding arm 1, rotary box 2, position adjusting mechanism 3, laser instrument 4, laser sensor 5, welding gun 6, first motor 7, second motor 8, first motor driving shaft 9, rotary box power transmission shaft 10, second motor driving shaft 11 and sensor driving shaft 12, the first motor is provided with in described welding arm 1, first motor is by the conveyer belt on the first motor driving shaft 9 activation point governor motion 3, conveyer belt driven rotary case power transmission shaft 10, driven rotary case 2 rotates, thus control the welding gun that is arranged on rotary box and laser instrument, second motor is arranged on rotary box, second motor controls laser instrument transverse shifting on rotary box by the second motor driving shaft 11 and sensor driving shaft 12.
As Fig. 3, the present embodiment comprises non-contact laser weld seam sensor, pendulous device, welding gun three-dimensional regulating mechanism, DSP (Digital Signal Processing) control system, native system adopts scanning type laser sensing welding seam tracking method, be arranged on welding gun front portion by laser seam sensor and observe weld seam, by the square transversal scanning in welded joints of the second driven by motor laser seam sensor, detect the lateral separation between sensor and weld seam and fore-and-aft distance, this distance is exactly the deviation of welding gun butt welded seam.DSP control system accepts the deviation signal of welding gun butt welded seam, and adopts Fuzzy-P bimodulus Discrete control to carry out the correction of weld seam, produces control signal.This control signal sends into the welding gun three-dimensional regulating mechanism being arranged on welding gun and rotary box junction, drives welding gun horizontal stepper motor and longitudinal stepper motor action, realizes the real-time automatic tracking of welding robot welding gun butt welded seam.
Non-contact laser weld seam sensor internal comprises a ccd video camera and one or two semiconductor laser.Laser stripe, as structure light source, is projected to the surface of the work of sensor bottom by semiconductor laser with predetermined angle.The striped of sensor bottom directly observed by video camera.Video camera front portion is an optical filter, allows laser to pass through, but elimination other light all, such as welding arc.Sensor therefore can closely welding arc.Sensor is arranged on welding gun front portion (forward sight distance) with the distance preset, and therefore it can observe weld seam.After when welding gun, Founder determines position in welded joints, weld seam should, close to the center of laser stripe, so just can make cameras observe to laser stripe and weld seam.
Because laser stripe is with certain angles, if workpiece range sensor is near, just relatively forward at the laser stripe of surface of the work.Otherwise if workpiece range sensor is far away, the laser stripe of surface of the work just relatively rearward.Therefore, by the position of cameras observe laser stripe, sensor just can the vertical range of measuring distance workpiece.From the laser stripe on workpiece in shape, sensor also can measure profile and the position at striped inside weld on surface, therefore can lateral separation between measuring transducer and weld seam.From cameras observe to image processed by the electronic component signal transacting link.Image is first collected and form digitized laser stripe image, and then control software design uses specifically to arrange and stripe segmentation is become many line segments.Utilize these line segments, the position of weld seam can be measured, and convert it into the distance calculated with mm.Native system designs for pipe welding robot, is mainly used in the welding of double V-groove circumferential weld.According to actual parameter, select MLP2/60 type laser seam sensor, the horizontal field of view of this model sensor when standard setting height(from bottom) is 60mm, and effective depth of field is-35 to+55mm.
The present embodiment adopts the TMS320LF2812 microprocessor of American TI Company.The architecture of the TMS320 series DSP of American TI Company aims at real time signal processing and designs, and processing capability in real time and controller peripheral functionality roll into one by this series DSP controller, for control system provides a desirable solution.Detected the deviation of welding gun butt welded seam by laser seam sensor after, DSP control system accepts the deviation signal of welding gun butt welded seam, and adopts Fuzzy-P bimodulus Discrete control to carry out the correction of weld seam, produces control signal.This control signal sends into welding gun three-dimensional regulating mechanism, drives weld joint tracking stepper motor (welding gun horizontal stepper motor and longitudinal stepper motor) action, realizes the real-time automatic tracking of welding robot welding gun butt welded seam.The object of control system briefly, be exactly according to input control signal, sensor sample signal, realize the control of butt welding machine device people welding gun horizontal stepper motor and longitudinal stepper motor, the very corn of a subject is the opening of motor, stops, speed, direction control.Operation principle for stepper motor adopts frequency control method for control speed, changes pulse train phase sequence method realize motor commutation with level signal control and drive system changes phase inside sequence circuit, and wherein control impuls is exported by the inner PWM of DSP provides.After power amplification, enter welding gun and follow the tracks of each phase winding of stepper motor, based on DSP weld joint tracking step motor control scheme as shown in Figure 4.This programme adopts Japanese SANYO103H7123 type stepper motor, and adopt the OEM750 of Parker company of the U.S. as driver, driver completes the digital subdivision task of stepper motor, motor segmentation step number can reach 4000 ~ 20000 steps/turn, and follows the tracks of the regulable control motor of weld seam with above-mentioned stepper motor after segmentation as welding gun.Because 2812 chip internals have PWM output function, obtain control impuls needed for stepper motor driver thus so very convenient.In addition, in order to most succinct method application programming, DSP control circuit to send out pulse be continuous impulse, as long as i.e. user program operation, just constantly externally send pulse, if directly send this pulse to stepper motor, then stepper motor will continuous continual operation.Therefore an enable signal is set in system, can pulse be obtained with the level of enable signal height control step motor.
Due to uncertainty, the time variation of welding process, weld joint tracking process can not describe by accurate Mathematical Modeling, therefore, applies traditional control theory and comprises the effect that modern control theory is difficult to obtain satisfaction.Along with the development of fuzzy control theory, Weld Seam Tracking Control is developed towards intelligent direction.The present embodiment adopts Fuzzy-P bimodulus Discrete control.The control procedure of this controller is: when large deviation, adoption rate controls, to improve response speed, the minimizing regulating time of system; And during little deviation, adopt fuzzy control, reduce the overshoot of system, improve stationarity and the control accuracy of system responses.The switching of two kinds of control modes realizes according to predetermined deviation threshold.Experimentally, the fragmentation threshold that native system is chosen is ep=4mm, that is: when deviation is greater than 4mm, adoption rate controls; When deviation is less than or equal to 4mm, adopt fuzzy control.In fuzzy control, its key is the foundation of fuzzy control rule.In equation fuzzy control, conventional fuzzy control Mathematical Modeling is:
U＝[αE+(1-α)EC]α∈(0,1)(1)
Wherein, U is the controlled quentity controlled variable exported; The fuzzy quantity that E (e) is deviation; The fuzzy quantity that EC (ec) is deviation variation rate.α is modifying factor, and α gets the value between 0 ~ 1, it reflects the different weights of deviation e and deviation variation rate ec.General when e is larger, the principal contradiction of control system is elimination e, so time should increase α value, make e in control law, account for larger weight, to improve the dynamic characteristic of system; When e is less, the principal contradiction of control system suppresses system overshoot, makes system reach stable state as early as possible, so time should reduce α value, the value then corresponding increase of 1-α, makes ec in control law, account for larger weight.Visible, by adjusting the value of α, can revise fuzzy control rule, α is once determine that fuzzy control rule also just determines.In actual welding, due to the impact by various processing operating mode, the duty of weld seam deviation situation and system is very complicated, adopts the fuzzy control of the fixing α factor can not meet the needs of actual welds tracking.Therefore, native system adopts two factor Self-Adjust Fuzzy Control methods, and its Mathematical Modeling is as follows:
When | during e|≤4mm, U=[α 1E+ (1-α 1) EC]
When | during e|>4mm, U=[α 2E+ (1-α 2) EC]
α1,α2∈(0,1),α1≤α2
By experiment, the modifying factor α 1=0.4 of native system is determined, α 2=0.6.According to the fuzzy control rule determined, make fuzzy control rule table.In actual welds is followed the tracks of, according to inclined extent, the different α factors can be selected, namely have selected different fuzzy control rules, by the fuzzy control rule table of correspondence, obtain required controlled quentity controlled variable.
As Fig. 5, systems soft ware coordinates the function such as adjustment achieving the scanning of laser seam sensor, the collection of signal and calculating, welding torch position with hardware.What program circuit was concrete is, when welding robot man-hour, first in control program, setting the deviation of the permission of DSP | e| is 4mm, then the deviation delta e of welding gun butt welded seam that records of detection laser sensor, and whether judgment bias is greater than fragmentation threshold, namely judge | e| >=Δ e, if judged result is true, then adoption rate controls, otherwise then uses fuzzy control, produce control signal feeding motor driver Butt welding gun position to rectify a deviation, until detect that welding terminates.
The invention provides a kind of welding robot weld seam automatic tracking system; the method and access of this technical scheme of specific implementation is a lot; the above is only the preferred embodiment of the present invention; should be understood that; for those skilled in the art; under the premise without departing from the principles of the invention, can also make some improvements and modifications, these improvements and modifications also should be considered as protection scope of the present invention.The all available prior art of each part not clear and definite in the present embodiment is realized.
Claims (8)
1. a welding robot weld seam automatic tracking system, it is characterized in that, comprise welding arm, described welding arm is provided with rotary box and position adjusting mechanism, described rotary box is provided with laser sensor and welding gun, described position adjusting mechanism comprises the first motor and the second motor, described laser sensor connects the second motor, described first motor, the second motor and laser sensor are communicated to DSP control system, described laser sensor is provided with laser instrument, and laser instrument is used for soldered body surface Emission Lasers.
2. a kind of welding robot weld seam automatic tracking system according to claim 1, it is characterized in that, described DSP control system connects two drivers, and two drivers are connected respectively the first motor and the second motor.
3. a kind of welding robot weld seam automatic tracking system according to claim 1, it is characterized in that, described position adjusting mechanism also comprises driving-belt and rotary box power transmission shaft, rotary box power transmission shaft passes rotary box and is connected to by rotary box on welding arm, driving-belt is connected on the first motor driving shaft and rotary box power transmission shaft, first motor driving shaft is by driving-belt driven rotary case power transmission shaft, and rotary box power transmission shaft driven rotary case swings, thus controls welding torch position.
4. a kind of welding robot weld seam automatic tracking system according to claim 1, it is characterized in that, described rotary box is provided with the second motor and sensor driving shaft, laser sensor is arranged on sensor driving shaft, second motor driving shaft band dynamic sensor driving shaft, sensor driving shaft drives laser sensor to move on sensor driving shaft.
5. a kind of welding robot weld seam automatic tracking system according to claim 1, it is characterized in that, described laser sensor is CCD camera, and CCD camera is for taking the image of soldered body surface.
6. a welding robot weld seam automatic tracking system, is characterized in that, comprises weld seam method for automatic tracking, and described weld seam method for automatic tracking comprises the following steps:
Step 1: the second motor drive laser scanning weld seam, detects the deviation of welding gun relative to solder joint;
Step 2: laser sensor transmission deviation signal;
Step 3:DSP control system accepts deviation signal;
Step 4:DSP control system produces control signal and sends to driver;
Step 5: the first motor drives welding gun, realizes the real-time tracking of butt welded seam.
7. a kind of welding robot weld seam of one according to claim 6 automatic tracking system, it is characterized in that, described DSP control system adopts Fuzzy-P bimodulus Discrete control to carry out the correction of weld seam after accepting deviation signal, produce control signal, Fuzzy-P bimodulus Discrete control adoption rate when deviation is greater than four millimeters controls, deviation adopts fuzzy control when being less than or equal to four millimeters, and described Fuzzy-P bimodulus Discrete control formula is:
When | during e|≤4mm, U=[α 1E+ (1-α 1) EC],
When | during e| > 4mm, U=[α 2E+ (1-α 2) EC],
Wherein, e is deviation, is recorded by laser seam sensor, and modifying factor α 1=0.4, α 2=0.6, U are the controlled quentity controlled variable exported; EC is the fuzzy quantity of deviation variation rate, and EC is the function about e, is automatically produced according to departure e by DSP control system, and E is the fuzzy quantity of deviation, and E is the function about e, is automatically produced according to departure e by DSP control system.
8. a kind of welding robot weld seam automatic tracking system according to claim 7, is characterized in that, by bluetooth, the image that laser sensor is taken is passed to DSP control system in described step 2.
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| CN106041377A (en) * | 2016-08-12 | 2016-10-26 | 广东省自动化研究所 | Intelligent and compact type welding line visual tracking system |
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| CN111590169A (en) * | 2020-06-03 | 2020-08-28 | 刘勇 | Automatic welding machine with welding seam tracking function and working method |
| CN114274158A (en) * | 2021-12-31 | 2022-04-05 | 北京博清科技有限公司 | Control method and controller of crawling welding robot and welding system |
| CN115213523A (en) * | 2022-08-10 | 2022-10-21 | 中科时永(苏州)科技有限公司 | Welding seam tracking and laser deviation correcting calibration system and laser tracking welding robot |
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| CN108927619B (en) * | 2018-08-23 | 2020-11-10 | 深圳市神视检验有限公司 | Method and device for controlling motion state of robot |
| CN111590169A (en) * | 2020-06-03 | 2020-08-28 | 刘勇 | Automatic welding machine with welding seam tracking function and working method |
| CN111590169B (en) * | 2020-06-03 | 2021-08-24 | 威海博泰精密机械有限公司 | Automatic welding machine with welding seam tracking function and working method |
| CN114274158A (en) * | 2021-12-31 | 2022-04-05 | 北京博清科技有限公司 | Control method and controller of crawling welding robot and welding system |
| CN114274158B (en) * | 2021-12-31 | 2024-02-02 | 北京博清科技有限公司 | Control method, controller and welding system of crawling welding robot |
| CN115213523A (en) * | 2022-08-10 | 2022-10-21 | 中科时永(苏州)科技有限公司 | Welding seam tracking and laser deviation correcting calibration system and laser tracking welding robot |
| CN118081220A (en) * | 2024-04-24 | 2024-05-28 | 河南威猛振动设备股份有限公司 | Somatosensory interaction equipment and interaction method of intelligent welding robot |
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Application publication date: 20160323 |