CN111347136B - Arc welding robot tool coordinate system on-line quick calibration system and method thereof - Google Patents

Arc welding robot tool coordinate system on-line quick calibration system and method thereof Download PDF

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Publication number
CN111347136B
CN111347136B CN202010316233.8A CN202010316233A CN111347136B CN 111347136 B CN111347136 B CN 111347136B CN 202010316233 A CN202010316233 A CN 202010316233A CN 111347136 B CN111347136 B CN 111347136B
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tcp
coordinate system
industrial robot
axis
welding gun
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CN111347136A (en
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乔贵方
张颖
吕仲艳
康传帅
温秀兰
万其
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Nanjing Institute of Technology
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Nanjing Institute of Technology
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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
    • B23K9/00—Arc welding or cutting
    • B23K9/24—Features related to electrodes
    • B23K9/28—Supporting devices for electrodes
    • 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
    • B23K9/00—Arc welding or cutting
    • B23K9/32—Accessories
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B25—HAND TOOLS; PORTABLE POWER-DRIVEN TOOLS; MANIPULATORS
    • B25J—MANIPULATORS; CHAMBERS PROVIDED WITH MANIPULATION DEVICES
    • B25J11/00—Manipulators not otherwise provided for
    • B25J11/005—Manipulators for mechanical processing tasks

Abstract

The invention discloses an arc welding robot tool coordinate system on-line quick calibration system and a method thereof, wherein the system comprises a robot control cabinet, an industrial robot provided with a welding gun and a TCP calibration device; the TCP calibration device comprises a support, a device body and two-dimensional laser sensors; the device body is provided with two inner side walls which are vertical to each other; the two-dimensional laser sensors are respectively and fixedly arranged on the two inner side walls, the coordinate systems of the two-dimensional laser sensors are positioned on the same plane, and the central axes of laser ranges emitted by the two-dimensional laser sensors are vertical to each other; the TCP calibration device is placed on one side of the industrial robot, and a detection plane of the TCP calibration device is parallel to an XOY plane of a base coordinate system of the industrial robot; the robot control cabinet is respectively connected with the industrial robot and the TCP calibration device through communication cables for data communication. The invention has the advantages of simple structure, high efficiency of the calibration process, capability of effectively improving the operation precision of the industrial robot and the working efficiency of the production line, and the like.

Description

Arc welding robot tool coordinate system on-line quick calibration system and method thereof
Technical Field
The invention belongs to the technical field of robot tool calibration, and particularly relates to a system and a method for quickly calibrating a tool coordinate system of an arc welding robot on line.
Background
With the continuous improvement of the industrial automation level and the development of the robot technology, the industrial robot is widely applied in various industries. When applied to different production lines, the end of an industrial robot usually needs to be equipped with different tools, such as a spray gun, a clamping jaw, a welding gun, etc. The welding robot is taken as one of industrial robots, the proportion of the welding robot is about 50%, and the welding robot is very wide in application.
Generally, a Tool Center Point (TCP) of a welding robot is a manual calibration method with a single constraint point, and after long-time work, the TCP of the welding robot generates a certain pose error, thereby directly affecting the stability of welding quality. Therefore, the TCP calibration of the welding robot needs to be performed again. The existing TCP calibration method is mainly a single-constraint point calibration method, and the method has the main defects that manual operation is needed, the calibration precision depends on manual operation experience, large errors easily occur, a production line is required to be completely stopped, and the production efficiency of an automatic production line is seriously influenced. There are currently a few calibration systems based on external measurements, but such systems are generally expensive to manufacture.
Therefore, a device and a method for rapidly calibrating a TCP of a welding robot on line, which have a compact structure and a low price, are urgently needed to be provided. The system needs to be capable of guaranteeing the operation precision of the welding robot and improving the working efficiency.
Disclosure of Invention
The invention provides an on-line rapid calibration system and method for a tool coordinate system of an arc welding robot, which can realize 5-degree-of-freedom calibration of a TCP (transmission control protocol) of the welding robot so as to overcome the defects of the prior art.
In order to achieve the above object, the present invention provides a system for rapidly calibrating a tool coordinate system of an arc welding robot on line, which has the following characteristics: the system comprises a robot control cabinet, an industrial robot provided with a welding gun and a TCP calibration device; the welding gun is arranged on a flange plate at the tail end of the industrial robot; the TCP calibration device comprises a support, a device body and two-dimensional laser sensors; the device body is fixed on the support, is in a vertical bending shape and is provided with two inner side walls which are vertical to each other; the two-dimensional laser sensors are respectively and fixedly arranged on two mutually vertical inner side walls of the device body, coordinate systems of the two-dimensional laser sensors are positioned on the same plane, and central axes of laser ranges emitted by the two-dimensional laser sensors are mutually vertical; the plane where the lasers emitted by the two-dimensional laser sensors are located is a detection plane of the TCP calibration device, and the region where the lasers emitted by the two-dimensional laser sensors are overlapped is a detection region of the TCP calibration device; the TCP calibration device is placed on one side of the industrial robot, and a detection plane of the TCP calibration device is parallel to an XOY plane of a base coordinate system of the industrial robot; the robot control cabinet is respectively connected with the industrial robot and the TCP calibration device through communication cables for data communication.
The invention also provides a calibration method of the arc welding robot tool coordinate system on-line quick calibration system, which is characterized in that: before the industrial robot works, initialization calibration is firstly carried out, and then after the industrial robot works, a TCP calibration program is periodically executed according to the initialization calibration.
Further, the invention provides a calibration method for an on-line rapid calibration system of an arc welding robot tool coordinate system, which can also have the following characteristics: the initialization calibration comprises the following steps:
step one, manually calibrating a TCP coordinate system of a welding gun at the tail end of an industrial robot;
secondly, controlling a Z axis of a TCP coordinate system of a welding gun at the tail end of the industrial robot to be vertical to an XOY plane of a base coordinate system of the industrial robot, and controlling the tail end of the welding gun of the industrial robot to move above a detection area of a TCP calibration device;
step three, controlling the industrial robot to descend along the Z axis of the industrial robot base coordinate system, and recording the TCP position coordinate P1(x1, y1 and Z1) in the current robot controller when the two-dimensional laser sensor of the TCP calibration device detects that the tail end of the welding gun contacts a detection area;
and step four, controlling the industrial robot to continuously descend along the Z axis of the industrial robot base coordinate system, and when the industrial robot moves to the welding gun cylindrical position H, calculating and obtaining the position coordinate P2(x2, y2) of the cylindrical center point at the welding gun cylindrical position H in the TCP calibration device measuring coordinate system according to the feedback data of the two-dimensional laser sensors.
Further, the invention provides a calibration method for an on-line rapid calibration system of an arc welding robot tool coordinate system, which can also have the following characteristics: the TCP calibration program comprises the following steps:
adjusting a Z axis of a TCP coordinate system of a welding gun at the tail end of the industrial robot, controlling the Z axis of the TCP coordinate system to be adjusted and changed in the second step of repeated initialization calibration, and controlling the tail end of the welding gun of the industrial robot to move above a detection area of a TCP calibration device;
secondly, controlling the industrial robot to descend along the Z axis of the industrial robot base coordinate system, and when the industrial robot moves to the middle position of the welding gun cylinder, calculating and obtaining a position coordinate P3(x3, y3) of the cylinder center point of the middle position of the welding gun cylinder in the measurement coordinate system of the TCP calibration device according to the feedback data of the two-dimensional laser sensors;
then keeping the current posture, controlling the industrial robot to continuously descend for a distance L along the Z axis of the industrial robot base coordinate system, and calculating and obtaining a position coordinate P4(x4, y4) of the cylinder center point of the position of the welding gun cylinder in the TCP calibration device measuring coordinate system according to the feedback data of the two-dimensional laser sensors;
recording coordinates of a point P3 as (X3, Y3, 0), coordinates of a point P4 as (X4, Y4, -L), and direction vectors as (X3-X4, Y3-Y4, L), calculating an included angle beta between the vector and a projection of the vector on a plane of a coordinate system YOZ measured by a TCP calibration device, and an included angle alpha between a projection of the vector on the plane of the coordinate system YOZ measured by the TCP calibration device and a Z axis, wherein alpha and beta are angle errors of the TCP coordinate system on the X axis and the Y axis respectively, and controlling the industrial robot to compensate the angle errors of the TCP coordinate system on the X axis and the Y axis;
step three, keeping the current posture, and controlling the tail end of the welding gun of the industrial robot to move above the detection area of the TCP calibration device;
controlling the industrial robot to descend along the Z axis of the industrial robot base coordinate system, and recording the current TCP position coordinate P5(x5, y5 and Z5) in the robot controller when the two-dimensional laser sensor of the TCP calibration device detects that the tail end of the welding gun contacts the detection area;
according to TCP position coordinates P1(x1, y1 and Z1) obtained in the initialization calibration step III, calculating to obtain a position error delta Z of a Z axis of a TCP coordinate system, wherein the delta Z is Z5-Z1;
step four, controlling the industrial robot to continuously descend along the Z axis of the industrial robot base coordinate system, and when the industrial robot moves to the welding gun cylindrical position H, calculating and obtaining a position coordinate P6(x6, y6) of the cylindrical center point of the welding gun cylindrical position H in the measurement coordinate system of the TCP calibration device according to the feedback data of the two-dimensional laser sensors;
according to the position coordinates P2(X2, Y2) of the measurement coordinate system obtained in the fourth initialization calibration step, position errors delta X and delta Y of the X axis and the Y axis of the TCP coordinate system are calculated, wherein the position errors delta X are X6-X2, and the position errors delta Y are Y6-Y2;
and controlling the industrial robot to compensate the position errors of the X axis, the Y axis and the Z axis of the TCP coordinate system.
Further, the invention provides a calibration method for an on-line rapid calibration system of an arc welding robot tool coordinate system, which can also have the following characteristics: in the steps three and four of initializing the calibration and the steps two, three and four of the TCP calibration program, the descending process of the industrial robot along the Z axis of the base coordinate system is descending at the lowest speed of the industrial robot at a constant speed.
Further, the invention provides a calibration method for an on-line rapid calibration system of an arc welding robot tool coordinate system, which can also have the following characteristics: in the step four of initializing the calibration, and in the step two and the step four of the TCP calibration program, the method for obtaining the position coordinate of the current welding gun cylindrical center point in the measurement coordinate system according to the feedback data of the two-dimensional laser sensor comprises the following steps of: recording feedback data of the two current two-dimensional laser sensors, calculating projection coordinates of the edge of the welding gun cylinder on an X axis and a Y axis of a measurement coordinate system of a TCP calibration device according to the feedback data, and calculating coordinates of the position of a center point of the welding gun cylinder by taking the mean value of coordinates at two ends.
Further, the invention provides a calibration method for an on-line rapid calibration system of an arc welding robot tool coordinate system, which can also have the following characteristics: in the first step of initialization calibration, a TCP coordinate system of an industrial robot end welding gun is calibrated manually through a single constraint point method.
The invention has the beneficial effects that:
firstly, the operation precision of the industrial robot can be effectively improved through the arc welding robot tool coordinate system online quick calibration system and the method thereof.
Compared with the existing calibration methods such as manual calibration and the like, the system and the method can quickly calibrate the tool coordinate system, thereby reducing the shutdown maintenance time of the industrial robot and improving the efficiency and the productivity of an industrial production line.
And thirdly, the TCP calibration device is simple in structure, and the robot calibration operation is less.
Drawings
FIG. 1 is a schematic diagram of the structure of an arc welder robot tool coordinate system on-line fast calibration system.
Fig. 2 is a perspective view of a TCP calibration apparatus.
Fig. 3 is a top view of a TCP calibration device.
Fig. 4 is a schematic view of a circular cross section of an industrial robot gun in the detection area of a TCP calibration device without an error.
Fig. 5 is a schematic diagram of the torch tip continuing to move down to the torch cylindrical position H after contacting the detection area.
Fig. 6 is a schematic diagram of an elliptical cross-section of an industrial robot torch within the detection area of a TCP calibration device when the torch has an error.
Fig. 7 is a schematic diagram of error calculation of the TCP calibration apparatus of the present invention.
Detailed Description
The following describes embodiments of the present invention with reference to the drawings.
As shown in figures 1-3, the invention provides an arc welding robot tool coordinate system on-line quick calibration system, which comprises a robot control cabinet 1, a TCP calibration device 2 and an industrial robot 3 provided with a welding gun 31.
The welding gun 31 is mounted on the end flange of the industrial robot 3.
The TCP calibration apparatus 2 includes a support 21, an apparatus body 22, and two-dimensional laser sensors 23.
The device body 22 is fixed on the support 21, is bent vertically, and has two inner side walls 221 perpendicular to each other.
The two-dimensional laser sensors 23 are fixedly mounted on two inner side walls 221 of the apparatus body 22, which are perpendicular to each other. The coordinate systems of the two-dimensional laser sensors 23 are located on the same plane, and the central axes of the laser ranges emitted by the two-dimensional laser sensors 23 are perpendicular to each other.
The plane where the two-dimensional laser sensors 23 emit laser is the detection plane of the TCP calibration device 2, and the overlapping area of the two-dimensional laser sensors 23 emitting laser is the detection area of the TCP calibration device 2.
The TCP calibration device 2 is placed at one side of the industrial robot 3, and the detection plane of the TCP calibration device 2 is parallel to the XOY plane of the industrial robot 3 base coordinate system.
The robot control cabinet 1 is respectively connected with the industrial robot 3 and the TCP calibration device 2 through a communication cable 4, performs data communication, and calculates and controls the industrial robot 3.
The calibration method of the arc welding robot tool coordinate system on-line quick calibration system comprises the following steps: before the industrial robot works, initial calibration is firstly carried out. And then after the industrial robot continuously works for a period of time, periodically executing a TCP calibration program according to the initial calibration.
The initialization calibration comprises the following steps:
step one, manually calibrating a TCP coordinate system of a welding gun at the tail end of the industrial robot by a single constraint point method (the tail end of the welding gun is an O point of the TCP coordinate system, and an extension line of a bending tail section of the welding gun is a Z axis of the TCP coordinate system), wherein the TCP coordinate system of the welding gun has no error, and the section of the TCP coordinate system in a detection area detected by a TCP calibration device is circular, as shown in figure 4.
And secondly, controlling the Z axis of a TCP coordinate system of the welding gun at the tail end of the industrial robot to be vertical to an XOY plane of a base coordinate system of the industrial robot, and controlling the tail end of the welding gun of the industrial robot to move to a position above the middle position of a detection area of the TCP calibration device.
And step three, controlling the industrial robot (including the welding gun, and the tail end welding gun synchronously moving along with the industrial robot) to descend at the lowest speed at a constant speed along the Z axis of the industrial robot base coordinate system, and recording the TCP position coordinate P1(x1, y1 and Z1) in the current robot controller when the two-dimensional laser sensor of the TCP calibration device detects that the tail end of the welding gun contacts the detection area.
And fourthly, controlling the industrial robot to continuously descend at a constant speed along the Z axis of the industrial robot base coordinate system at the lowest speed, when the industrial robot moves to the welding gun cylinder position H (at the moment, the tail end of the welding gun is positioned below the detection area of the TCP calibration device, H refers to the distance from the position of the welding gun cylinder where the detection plane A is positioned to the tail end of the welding gun, as shown in figure 5), recording feedback data of the two current two-dimensional laser sensors by the robot control cabinet, calculating projection coordinates of the welding gun cylinder edge on the X axis and the Y axis of the TCP calibration device measurement coordinate system according to the feedback data, and calculating a coordinate P2(X2, Y2) of the welding gun cylinder center point position by taking the average value of coordinates of the two ends, namely, calculating the position coordinate of the cylinder center point at the welding gun cylinder. The specific method comprises the following steps: one of the two-dimensional laser sensors measures a profile arc of a circle (the cross section of the welding gun in the measuring area), the average value of two projection coordinates of the arc on the Y axis of the TCP measuring coordinate system is Y2, and the other two-dimensional laser sensor measures a profile arc of a circle, the average value of two projection coordinates of the arc on the X axis of the TCP measuring coordinate system is X2.
The measurement coordinate system of the TCP calibration device is a reference coordinate system defined by fusion calculation of measurement data of the two-dimensional laser sensors, the measurement coordinate system XOY of the TCP calibration device is coplanar with the detection planes of the two-dimensional laser sensors, the coordinate axis of the measurement coordinate system XOY is the same as that of one two-dimensional laser sensor, and the conversion relation between the measurement coordinate system XOY and the coordinate systems of the two-dimensional laser sensors can be known according to design parameters.
After the industrial robot works continuously for a period of time, the TCP coordinate system of the welding gun has an error, and the cross section of the welding gun in the detection area of the TCP calibration device is elliptical, as shown in fig. 6. Therefore, TCP calibration needs to be performed periodically. The TCP calibration procedure comprises the following steps:
and step one, adjusting a Z axis of a TCP coordinate system of the industrial robot tail end welding gun, controlling the adjustment change of the Z axis of the TCP coordinate system in the repeated initialization calibration step two, and controlling the tail end of the industrial robot welding gun to move to a position above the middle position of a detection area of the TCP calibration device.
And secondly, controlling the industrial robot to descend at a constant speed along the Z axis of the industrial robot base coordinate system at the lowest speed, recording feedback data of the two current two-dimensional laser sensors by the robot control cabinet when the industrial robot moves to the middle position of the welding gun cylinder, calculating projection coordinates of the edge of the welding gun cylinder on the X axis and the Y axis of the measurement coordinate system of the TCP calibration device according to the feedback data, and calculating a coordinate P3(X3, Y3) of the center point position of the welding gun cylinder by taking the average value of coordinates at two ends, namely the position coordinate of the center point of the cylinder at the middle position of the welding gun cylinder in the measurement coordinate system of the TCP calibration device. The specific method comprises the following steps: one of the two-dimensional laser sensors measures a profile arc of an ellipse (a section of the welding gun in the detection area), the projection coordinates of the arc on the Y axis of the TCP measurement coordinate system are q1 and q2, and the other two-dimensional laser sensor measures a profile arc of an ellipse, the projection coordinates of the arc on the X axis of the TCP measurement coordinate system are q3 and q4, so that X3 is (q3+ q4)/2, and Y3 is (q1+ q2)/2, as shown in (1) in fig. 7.
And then keeping the current posture, controlling the industrial robot to continuously descend at a constant speed for a distance L along the Z axis of the industrial robot base coordinate system at the lowest speed, recording feedback data of the two current two-dimensional laser sensors by the robot control cabinet, calculating projection coordinates of the edge of the welding gun cylinder on the X axis and the Y axis of the TCP calibration device measurement coordinate system according to the feedback data, and calculating a coordinate P4(X4, Y4) of the position of the welding gun cylinder center point by taking the average value of the coordinates of the two ends, namely the position coordinate of the cylinder center point of the welding gun cylinder on the position of the TCP calibration device measurement coordinate system. The specific method comprises the following steps: one of the two-dimensional laser sensors measures a section of the contour arc of the ellipse, the projection coordinates of the arc on the Y axis of the TCP measurement coordinate system are q5 and q6, and the other two-dimensional laser sensor measures a section of the contour arc of the ellipse, the projection coordinates of the arc on the X axis of the TCP measurement coordinate system are q7 and q8, then X4 is (q7+ q8)/2, and Y4 is (q5+ q6)/2, as shown in (2) in fig. 7.
The robot control cabinet calculates the angle error: the coordinates of a point P3 are (X3, Y3, 0), the coordinates of a point P4 are (X4, Y4, -L), a direction vector is (X3-X4, Y3-Y4, L), an included angle beta between the vector and a projection plane of a measured coordinate system YOZ of the TCP calibration device is calculated, an included angle alpha between the projection plane of the vector and the Z axis of the measured coordinate system YOZ of the TCP calibration device is calculated, alpha and beta are angle errors of the TCP coordinate system in the X axis and the Y axis respectively, and the robot control cabinet controls the industrial robot to compensate the angle errors of the TCP coordinate system in the X axis and the Y axis.
And step three, keeping the current posture, and controlling the tail end of the welding gun of the industrial robot to move to the position above the middle position of the detection area of the TCP calibration device.
And controlling the industrial robot to descend at a constant speed along the Z axis of the industrial robot base coordinate system at the lowest speed, and recording TCP position coordinates P5(x5, y5 and Z5) in the current robot controller when a two-dimensional laser sensor of the TCP calibration device detects that the tail end of the welding gun contacts a detection area, namely when a welding wire with a smaller tail end diameter of the welding gun is detected, the diameter of a contour circle of the welding wire is smaller, as shown in (4) in FIG. 7.
And (3) calculating a position error delta Z of a Z axis of a TCP coordinate system according to the TCP position coordinate P1(x1, y1 and Z1) obtained in the initialization calibration step III by the robot control cabinet, wherein the delta Z is Z5-Z1.
And fourthly, controlling the industrial robot to continuously descend at a constant speed along the Z axis of the industrial robot base coordinate system at the lowest speed, recording feedback data of the two current two-dimensional laser sensors when the industrial robot moves to the welding gun cylinder position H, calculating projection coordinates of the welding gun cylinder edge on the X axis and the Y axis of the TCP calibration device measurement coordinate system according to the feedback data, and calculating a coordinate P6(X6, Y6) of the welding gun cylinder center point position by taking the average value of coordinates at two ends, namely the position coordinate of the cylinder center point at the welding gun cylinder position H in the TCP calibration device measurement coordinate system. The specific method comprises the following steps: one of the two-dimensional laser sensors measures a contour arc of a circle (the plane cross section of the welding gun cylinder in the detection area after compensating the angle error is a circle), the projection coordinates of the arc on the Y axis of the TCP measurement coordinate system are q9 and q10, the other two-dimensional laser sensor measures a contour arc of a circle, the projection coordinates of the arc on the X axis of the TCP measurement coordinate system are q11 and q11, then X6 is (q11+ q12)/2, and Y7 is (q9+ q10)/2, as shown in (3) in FIG. 7.
And the robot control cabinet calculates position errors delta X and delta Y of an X axis and a Y axis of the TCP coordinate system according to the position coordinates P2(X2 and Y2) of the measurement coordinate system obtained in the fourth initialization calibration step, wherein the position errors delta X are X6-X2, and the position errors delta Y are Y6-Y2.
And the robot control cabinet controls the industrial robot to compensate the position errors of the X axis, the Y axis and the Z axis of the TCP coordinate system.

Claims (4)

1. The utility model provides an arc welding robot tool coordinate system is at quick calbiration system of line which characterized in that:
the system comprises a robot control cabinet, an industrial robot provided with a welding gun and a TCP calibration device;
the welding gun is arranged on a flange plate at the tail end of the industrial robot;
the TCP calibration device comprises a support, a device body and two-dimensional laser sensors;
the device body is fixed on the support, is in a vertical bending shape and is provided with two inner side walls which are vertical to each other;
the two-dimensional laser sensors are respectively and fixedly arranged on two mutually vertical inner side walls of the device body, coordinate systems of the two-dimensional laser sensors are positioned on the same plane, and central axes of laser ranges emitted by the two-dimensional laser sensors are mutually vertical;
the plane where the lasers emitted by the two-dimensional laser sensors are located is a detection plane of the TCP calibration device, and the region where the lasers emitted by the two-dimensional laser sensors are overlapped is a detection region of the TCP calibration device;
the TCP calibration device is placed on one side of the industrial robot, and a detection plane of the TCP calibration device is parallel to an XOY plane of a base coordinate system of the industrial robot;
the robot control cabinet is respectively connected with the industrial robot and the TCP calibration device through communication cables for data communication;
before the industrial robot works, firstly carrying out initialization calibration, and then after the industrial robot works, periodically executing a TCP calibration program according to the initialization calibration;
wherein, the initialization calibration comprises the following steps:
step one, manually calibrating a TCP coordinate system of a welding gun at the tail end of an industrial robot;
secondly, controlling a Z axis of a TCP coordinate system of a welding gun at the tail end of the industrial robot to be vertical to an XOY plane of a base coordinate system of the industrial robot, and controlling the tail end of the welding gun of the industrial robot to move above a detection area of a TCP calibration device;
step three, controlling the industrial robot to descend along the Z axis of the industrial robot base coordinate system, and recording the TCP position coordinate P1(x1, y1 and Z1) in the current robot controller when the two-dimensional laser sensor of the TCP calibration device detects that the tail end of the welding gun contacts a detection area;
step four, controlling the industrial robot to continuously descend along the Z axis of the industrial robot base coordinate system, and when the industrial robot moves to the welding gun cylindrical position H, calculating and obtaining a position coordinate P2(x2, y2) of the cylindrical center point of the welding gun cylindrical position H in the measurement coordinate system of the TCP calibration device according to the feedback data of the two-dimensional laser sensors;
the TCP calibration program comprises the following steps:
adjusting a Z axis of a TCP coordinate system of a welding gun at the tail end of the industrial robot, controlling the Z axis of the TCP coordinate system to be adjusted and changed in the second step of repeated initialization calibration, and controlling the tail end of the welding gun of the industrial robot to move above a detection area of a TCP calibration device;
secondly, controlling the industrial robot to descend along the Z axis of the industrial robot base coordinate system, and when the industrial robot moves to the middle position of the welding gun cylinder, calculating and obtaining a position coordinate P3(x3, y3) of the cylinder center point of the middle position of the welding gun cylinder in the measurement coordinate system of the TCP calibration device according to the feedback data of the two-dimensional laser sensors;
then keeping the current posture, controlling the industrial robot to continuously descend for a distance L along the Z axis of the industrial robot base coordinate system, and calculating and obtaining a position coordinate P4(x4, y4) of the cylinder center point of the position of the welding gun cylinder in the TCP calibration device measuring coordinate system according to the feedback data of the two-dimensional laser sensors;
recording coordinates of a point P3 as (X3, Y3, 0), coordinates of a point P4 as (X4, Y4, -L), and direction vectors as (X3-X4, Y3-Y4, L), calculating an included angle beta between the vector and a projection of the vector on a plane of a coordinate system YOZ measured by a TCP calibration device, and an included angle alpha between a projection of the vector on the plane of the coordinate system YOZ measured by the TCP calibration device and a Z axis, wherein alpha and beta are angle errors of the TCP coordinate system on the X axis and the Y axis respectively, and controlling the industrial robot to compensate the angle errors of the TCP coordinate system on the X axis and the Y axis;
step three, keeping the current posture, and controlling the tail end of the welding gun of the industrial robot to move above the detection area of the TCP calibration device;
controlling the industrial robot to descend along the Z axis of the industrial robot base coordinate system, and recording the current TCP position coordinate P5(x5, y5 and Z5) in the robot controller when the two-dimensional laser sensor of the TCP calibration device detects that the tail end of the welding gun contacts the detection area;
according to TCP position coordinates P1(x1, y1 and Z1) obtained in the initialization calibration step III, calculating to obtain a position error delta Z of a Z axis of a TCP coordinate system, wherein the delta Z is Z5-Z1;
step four, controlling the industrial robot to continuously descend along the Z axis of the industrial robot base coordinate system, and when the industrial robot moves to the welding gun cylindrical position H, calculating and obtaining a position coordinate P6(x6, y6) of the cylindrical center point of the welding gun cylindrical position H in the measurement coordinate system of the TCP calibration device according to the feedback data of the two-dimensional laser sensors;
according to the position coordinates P2(X2, Y2) of the measurement coordinate system obtained in the fourth initialization calibration step, position errors delta X and delta Y of the X axis and the Y axis of the TCP coordinate system are calculated, wherein the position errors delta X are X6-X2, and the position errors delta Y are Y6-Y2;
and controlling the industrial robot to compensate the position errors of the X axis, the Y axis and the Z axis of the TCP coordinate system.
2. The method of calibrating an on-line rapid calibration system for an arc welder robotic tool coordinate system as defined in claim 1, wherein:
in the steps three and four of initializing the calibration and the steps two, three and four of the TCP calibration program, the descending process of the industrial robot along the Z axis of the base coordinate system is descending at the lowest speed of the industrial robot at a constant speed.
3. The method of calibrating an on-line rapid calibration system for an arc welder robotic tool coordinate system as defined in claim 1, wherein:
in the step four of initializing the calibration, and in the step two and the step four of the TCP calibration procedure, the method for obtaining the position coordinate of the current welding gun cylinder center point in the measurement coordinate system according to the feedback data of the two-dimensional laser sensor comprises the following steps: recording feedback data of the two current two-dimensional laser sensors, calculating projection coordinates of the edge of the welding gun cylinder on an X axis and a Y axis of a measurement coordinate system of a TCP calibration device according to the feedback data, and calculating coordinates of the position of a center point of the welding gun cylinder by taking the mean value of coordinates at two ends.
4. The method of calibrating an on-line rapid calibration system for an arc welder robotic tool coordinate system as defined in claim 1, wherein:
in the first step of initialization calibration, a TCP coordinate system of an industrial robot end welding gun is calibrated manually through a single constraint point method.
CN202010316233.8A 2020-04-21 2020-04-21 Arc welding robot tool coordinate system on-line quick calibration system and method thereof Active CN111347136B (en)

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