CN117600714A - Flexible welding system and welding method for wire feeding frame robot - Google Patents
Flexible welding system and welding method for wire feeding frame robot Download PDFInfo
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- CN117600714A CN117600714A CN202311666971.5A CN202311666971A CN117600714A CN 117600714 A CN117600714 A CN 117600714A CN 202311666971 A CN202311666971 A CN 202311666971A CN 117600714 A CN117600714 A CN 117600714A
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- 238000003466 welding Methods 0.000 title claims abstract description 249
- 238000000034 method Methods 0.000 title claims abstract description 28
- 238000012546 transfer Methods 0.000 claims abstract description 65
- 238000004519 manufacturing process Methods 0.000 claims abstract description 57
- 239000002184 metal Substances 0.000 claims abstract description 36
- 238000005452 bending Methods 0.000 claims abstract description 30
- 238000007689 inspection Methods 0.000 claims description 69
- 239000011324 bead Substances 0.000 claims description 32
- 238000007599 discharging Methods 0.000 claims description 22
- 239000000428 dust Substances 0.000 claims description 16
- 230000008569 process Effects 0.000 claims description 12
- 230000008439 repair process Effects 0.000 claims description 5
- 238000010586 diagram Methods 0.000 description 10
- 238000004590 computer program Methods 0.000 description 7
- 230000006870 function Effects 0.000 description 5
- 230000007547 defect Effects 0.000 description 4
- 239000000463 material Substances 0.000 description 4
- 238000012545 processing Methods 0.000 description 4
- 230000000694 effects Effects 0.000 description 3
- 238000003860 storage Methods 0.000 description 3
- 230000006978 adaptation Effects 0.000 description 2
- 230000008859 change Effects 0.000 description 2
- 238000012790 confirmation Methods 0.000 description 2
- 238000012986 modification Methods 0.000 description 2
- 230000004048 modification Effects 0.000 description 2
- 238000010923 batch production Methods 0.000 description 1
- 238000010009 beating Methods 0.000 description 1
- 230000009286 beneficial effect Effects 0.000 description 1
- 238000001514 detection method Methods 0.000 description 1
- 238000005516 engineering process Methods 0.000 description 1
- 230000006872 improvement Effects 0.000 description 1
- 239000013072 incoming material Substances 0.000 description 1
- 230000005389 magnetism Effects 0.000 description 1
- 230000003287 optical effect Effects 0.000 description 1
- 230000001681 protective effect Effects 0.000 description 1
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
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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
- B23K31/00—Processes relevant to this subclass, specially adapted for particular articles or purposes, but not covered by only one of the preceding main groups
- B23K31/02—Processes relevant to this subclass, specially adapted for particular articles or purposes, but not covered by only one of the preceding main groups relating to soldering or welding
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- 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 a flexible welding system and a welding method of a wire feeding rack robot, wherein the flexible welding system comprises the following steps: sheet metal part skip, straight pipe skip, welding bench, PLC control module and by automatic skip of going up of AGV, 3D camera, first transfer robot, automatic bending machine, second transfer robot and the welding robot of PLC control module control. Under the control of the PLC control module, on one hand, the first carrying robot, the second carrying robot and the welding robot are used for carrying out coordinated welding, and the clamp-free welding is adopted, so that the clamp replacement time and the clamp manufacturing cost are saved to a great extent, and the flexible welding is realized; on the other hand, through the cooperation of 3D camera and second transfer robot, saved the time of special location work piece frock and extra work piece of putting, realized the flexible production.
Description
Technical Field
The invention relates to a flexible welding system and a flexible welding method for a wire feeding frame robot, and belongs to the technical field of flexible welding of wire feeding frames.
Background
With the improvement of the industrial automation level, the manual welding of a wire feeding rack and a single robot workstation cannot meet the actual production, and particularly, the problems of multiple product types, small production batch are solved, the corresponding fixture is required to be replaced frequently, the workload is large, the period is long, the cost is high, and the user frequently switches the fixture of a new product, so that the precision is easy to reduce, the production is poor, multiple special feeding fixtures are generally required in the common robot automation workstation, the cost is high, the switching is complicated, and the device is not suitable for the quick update of the new product. In addition, after the welding of a common robot in a common robot automation workstation is finished, the quality of welding seams is required to be checked manually one by one, the number of welding points is too large, the checking work load is large, the labor cost is high, the checking quality of the welding seams is unstable, and the welding quality cannot be ensured.
The information disclosed in this background section is only for enhancement of understanding of the general background of the invention and should not be taken as an acknowledgement or any form of suggestion that this information forms the prior art already known to a person of ordinary skill in the art.
Disclosure of Invention
The invention aims to overcome the defects in the prior art, and provides a flexible welding system and a flexible welding method for a wire feeding rack robot, which are controlled by a PLC control module, on one hand, the flexible welding is realized by adopting a first carrying robot, a second carrying robot and a welding robot to carry out coordinated welding and adopting clamp-free welding, so that the clamp replacement time and the clamp manufacturing cost are saved to a great extent; on the other hand, through the cooperation of 3D camera and second transfer robot, saved the time of special location work piece frock and extra work piece of putting, realized the flexible production.
In order to achieve the above purpose, the invention is realized by adopting the following technical scheme:
in one aspect, the invention discloses a wire-feed gantry robot flexible welding system comprising: sheet metal part skip, straight pipe skip, welding bench, PLC control module and by PLC control module control:
the AGV is used for automatically feeding and discharging the sheet metal part skip car and the straight pipe skip car;
the 3D camera is used for identifying the workpiece and the corresponding position on the sheet metal part skip to obtain corresponding workpiece position data;
the first transfer robot is used for grabbing the straight pipe on the straight pipe skip car to the automatic pipe bending machine; according to the workpiece position data, grabbing the corresponding workpiece on the sheet metal part skip to a welding workbench;
the automatic pipe bending machine is used for performing pipe bending operation on the straight pipe to obtain a bent pipe;
the second carrying robot is used for grabbing the bent pipe on the automatic pipe bending machine to the welding workbench;
and the welding robot is used for welding the workpiece and the bent pipe on the welding workbench under the control of the coordination group of the first transfer robot and the second transfer robot to obtain a finished product of the wire feeding frame.
Further, the device also comprises a finished product skip, a repair skip and a bead laser welding seam inspection device controlled by the PLC control module,
the second transfer robot is further used for transferring the finished product of the wire feeding frame from the welding workbench to the bead laser welding seam inspection device;
the bead laser weld inspection device is used for inspecting weld appearances of good products and AI (advanced technology) of the finished product of the wire feeding frame respectively to obtain an inspection result of the finished product of the wire feeding frame;
the second transfer robot is further used for transferring finished products of the wire feeding frame, which are qualified in inspection result, from the bead laser welding seam inspection device to the finished product skip; conveying the finished product of the wire feeding frame with unqualified inspection results from the loadeye laser welding seam inspection device to the repairing skip car;
the AGV is used for automatically feeding and discharging the skip and is also used for discharging the finished skip and the repairing skip.
Further, in the weld appearance inspection of the bead laser weld inspection device, if the weld appearance inspection of the good product and the AI of the finished product of the wire feeding frame is judged to be qualified, the inspection result of the finished product of the wire feeding frame is qualified, otherwise, the inspection result of the finished product of the wire feeding frame is not qualified.
Further, the device also comprises a fence, wherein the PLC control module is arranged outside the fence; the sheet metal part skip, the straight pipe skip, the welding workbench, the first carrying robot, the automatic pipe bending machine, the second carrying robot, the welding robot, the finished product skip, the repairing skip and the bead laser welding seam inspection device are all arranged in the fence;
the 3D camera is arranged on the fence through a travelling device; and a plurality of doors which are convenient for the AGV to automatically feed and discharge the material in and out are also arranged on the fence.
Further, the PLC control module is respectively connected with the AGV automatic feeding and discharging vehicle, the 3D camera, the first transfer robot, the automatic pipe bending machine, the second transfer robot, the welding robot and the bead laser weld inspection device through Ethernet and TCP/IP protocols.
Further, a welding gun and an arcey laser sensor are arranged on the welding robot;
on a welding workbench, the first carrying robot performs cooperative assembly on the grabbed workpiece and the bent pipe grabbed by the second carrying robot to obtain an unwelded assembly;
the arceye laser sensor is used for scanning the unwelded assembly to obtain a welding seam position;
the welding robot is used for controlling the welding gun to weld the non-welded assembly according to the welding seam position under the coordinated control of the first carrying robot and the second carrying robot;
the arceye laser sensor is also used for laser scanning during welding to control welding deformation.
Furthermore, the head of the welding gun is also provided with dust removing equipment, and the dust removing equipment is used for carrying out dust removing work in the welding process.
Further, the first transfer robot and the second transfer robot are respectively provided with a magnetic attraction type gripper and an adjustable pneumatic clamping type gripper.
Further, the wire feeding machine further comprises an IOT welding management module, wherein the IOT welding management module is used for acquiring a production order of the wire feeding machine frame, and sending an order instruction to the PLC control module according to the production order;
and the PLC control module is used for sending a control instruction to the outside according to the order instruction to finish welding of the wire feeding frame.
On the other hand, the invention discloses a flexible welding method of a wire feeding frame robot, wherein a PLC control module controls the operation of an AGV automatic feeding and discharging vehicle, a 3D camera, a first carrying robot, an automatic pipe bending machine, a second carrying robot and a welding robot to finish welding of the wire feeding frame, and the flexible welding method comprises the following steps:
the sheet metal part skip car and the straight pipe skip car are fed by controlling the AGV to automatically feed and discharge the skip car;
the method comprises the steps of grabbing a straight pipe on a straight pipe skip car to an automatic pipe bending machine by controlling a first carrying robot; the pipe bending operation is carried out on the straight pipe by controlling the automatic pipe bending machine, so as to obtain a bent pipe; grabbing the bent pipe on the automatic pipe bending machine to a welding workbench by controlling a second carrying robot;
identifying a workpiece and a corresponding position on the sheet metal part skip through a 3D camera to obtain a corresponding workpiece position; grabbing a corresponding workpiece on the sheet metal part skip to a welding workbench according to the position of the workpiece by controlling a first carrying robot;
and under the coordinated assembly control of the first transfer robot and the second transfer robot, the welding robot is controlled to weld the workpiece and the bent pipe on the welding workbench, so that a finished product of the wire feeding frame is obtained.
Compared with the prior art, the invention has the beneficial effects that:
the invention adopts the first carrying robot, the second carrying robot and the welding robot to coordinate welding, saves a plurality of clamps for workpieces of various small batches in the process, saves the production cost, improves the production efficiency, achieves the purpose of flexible welding suitable for the production of various small batches, adopts the non-clamp welding, saves the clamp replacement time and the clamp manufacturing cost to a great extent, and realizes flexible welding;
according to the invention, workpieces in the sheet metal part skip are not required to be placed in a strict sequence, multiple types of workpieces and positions thereof are accurately identified and distinguished through the 3D camera, intelligent sensing is realized, and the workpieces are grasped through the second transfer robot, so that the sheet metal part skip is stable and reliable, special workpiece positioning tools and extra workpiece placing time are saved, and flexible production is realized.
According to the invention, through the cooperation of the bead laser weld inspection device and the second transfer robot, intelligent inspection and classification of the appearance quality of the weld are realized; automatic feeding and discharging of the whole welding process is achieved through intelligent control of the AGV by the PLC control module, the requirement of flexible welding of the wire feeding machine frame robot is met, unmanned, flexible and intelligent production of the production process suitable for multiple varieties of small-batch wire feeding machine frames is achieved, welding quality and production efficiency are improved, and production cost is reduced.
The invention is also provided with an IOT welding management module which is used for acquiring the production order of the wire feeding rack so that the PLC control module can complete full-automatic welding of the products of the subsequent orders until the welding of the finished products is completed. In the welding production process, the PLC control module responds rapidly through real-time accurate information to deal with the change, so that the production activity without added value is reduced, and the production efficiency is improved.
Drawings
FIG. 1 is a schematic structural view of a wire feeder frame robot flexible welding system;
FIG. 2 is a top view of a wire feeder frame robotic flexible welding system;
FIG. 3 is a schematic view of the sheet metal part skip;
FIG. 4 is a schematic view of the structure of a straight pipe skip;
FIG. 5 is a schematic view of the structure of the finished skip;
FIG. 6 is a schematic diagram of a 3D camera and walking device;
FIG. 7 is a flow chart of a welding method of the wire-feed frame robotic flexible welding system;
FIG. 8 is an inspection logic diagram of a bead laser weld inspection apparatus;
FIG. 9 is an electrical control flow diagram of a wire-feed frame robotic flexible welding system;
FIG. 10 is a schematic circuit diagram of a wire feeder frame robot flexible welding system;
in the figure: 1. a 3D camera; 2. sheet metal part skip car; 3. a welding robot; 4. a finished product skip; 5. a second transfer robot; 6. repairing the skip car; 7. automatic pipe bending machine; 8. a fence; 9. the bead laser welding line inspection device; 10. a welding workbench; 11. a straight pipe skip car; 12. a man-machine interface management module; 13. a PLC control module; 14. a first transfer robot; 15. a dust removal control box; 16. an IOT welding management module; 17. an air source control box; 18. AGVs automatically load and unload the vehicle; 19. and a walking device.
Detailed Description
The invention is further described below with reference to the accompanying drawings. The following examples are only for more clearly illustrating the technical aspects of the present invention, and are not intended to limit the scope of the present invention.
Example 1.
Embodiment 1 provides a wire-feed gantry robot flexible welding system, as shown in fig. 1-6, comprising: sheet metal part skip 2, straight pipe skip 11, welding bench 10, PLC control module 13 and by PLC control module 13 control:
the AGV automatic feeding and discharging vehicle 18 is used for feeding the sheet metal part skip 2 and the straight pipe skip 11;
the 3D camera 1 is used for identifying the workpiece and the corresponding position on the sheet metal part skip 2 to obtain corresponding workpiece position data;
the first carrying robot 14 is used for grabbing the straight pipe on the straight pipe skip car 11 to the automatic pipe bending machine 7; according to the workpiece position data, grabbing the corresponding workpiece on the sheet metal part skip 2 to a welding workbench 10;
the automatic pipe bending machine 7 is used for performing pipe bending operation on the straight pipe to obtain a bent pipe;
the second carrying robot 5 is used for grabbing the bent pipe on the automatic pipe bending machine 7 to the welding workbench 10;
and the welding robot 3 is used for welding the workpiece and the bent pipe on the welding workbench 10 under the control of the coordination group of the first transfer robot 14 and the second transfer robot 5 to obtain a finished product of the wire feeding frame.
The technical conception of the invention is as follows: on the one hand, the first transfer robot 14, the second transfer robot 5 and the welding robot 3 are adopted for coordination welding, a plurality of clamps for workpieces of various types in small batches are omitted in the process, the production cost is saved, the production efficiency is improved, the purpose of flexible welding suitable for the production of various types in small batches is achieved, and the clamp-free welding is adopted, so that the clamp replacement time and the clamp manufacturing cost are saved to a great extent, and therefore flexible welding is realized. On the other hand, the workpieces of various varieties and the positions thereof are accurately identified and distinguished through the 3D camera 1, intelligent sensing is realized, and the workpieces are grasped through the second carrying robot 5, so that the device is stable and reliable, and the special workpiece positioning tool and the additional workpiece placing time are saved, thereby realizing flexible production.
The flexible welding system of the wire feeding frame robot in the embodiment also comprises a finished product skip 4, a repair skip 6 and a bead laser welding seam inspection device 9 controlled by a PLC control module 13,
the second transfer robot 5 is further used for transferring the finished product of the wire feeding frame from the welding workbench 10 to the bead laser welding seam inspection device 9;
the bead laser weld inspection device 9 is used for respectively inspecting the weld appearance of the good products and AI of the finished product of the wire feeding frame to obtain an inspection result of the finished product of the wire feeding frame;
the second carrying robot 5 is further used for carrying the finished product of the wire feeding frame, which is qualified in the inspection result, from the bead laser welding seam inspection device 9 to the finished product skip 4; conveying the finished product of the wire feeding frame with unqualified inspection results from the loadeye laser welding seam inspection device 9 to the repairing skip 6;
the AGV automatically loads and unloads the skip 18 and is also used for discharging the finished skip 4 and the repairing skip 6.
The device 9 for inspecting the laser welding seam of the bead comprises a bead laser scanning head, a bead laser controller and a bead display device.
As shown in fig. 1, in the wire feeding frame robot flexible welding system, a sheet metal part skip 2, a straight pipe skip 11, a welding workbench 10, a first transfer robot 14, an automatic pipe bender 7, a second transfer robot 5, a welding robot 3, a finished product skip 4, a repairing skip 6 and a bead laser weld inspection device 9 are all arranged in a fence 8 so as to facilitate safety management. Meanwhile, a plurality of doors which are convenient for the AGV to automatically feed and discharge the skip 18 in and out are further arranged on the fence 8.
The 3D camera 1 is arranged on the fence 8 through the travelling device 19, so that the movement identification of the 3D camera 1 is facilitated.
The outside of the fence 8 is provided with a PLC control module 13, an IOT welding management module 16, a dust removal control box 15, an air source control box 17 and a man-machine management interface 12. The IOT welding management module 16 is connected with the PLC control module 13 through the Fbox, the PLC control module 13 is connected with the man-machine management interface 12, the man-machine management interface 12 is used for displaying production orders, after the on-site condition is confirmed to allow production by an operator, one-key confirmation is carried out, the system can automatically weld production, and meanwhile production conditions of the orders can be monitored.
The purpose of the air source control box 17 is to provide a protective air source for welding and automatically detect whether the flow pressure of the air source is qualified or not, and in addition, provide a compressed air source for the pneumatic device of the whole system and automatically detect the air supply pressure and automatically alarm when the pressure is insufficient.
Specifically, the IOT welding management module 16 is configured to obtain a production order of the wire feeding frame, and send an order instruction to the PLC control module 13 according to the production order; and the PLC control module 13 is used for sending a control instruction to the outside according to the order instruction to finish welding of the wire feeding frame.
The PLC control module 13 is respectively connected with an AGV automatic feeding and discharging vehicle 18, a 3D camera 1, a first transfer robot 14, an automatic pipe bender 7, a second transfer robot 5, a welding robot 3 and a bead laser weld inspection device 9 through Ethernet and TCP/IP protocols.
The first transfer robot 14 and the second transfer robot 5 are respectively provided with a magnetic attraction type gripper and an adjustable pneumatic clamping type gripper, and the grippers are switched through a quick-change disc according to actual working conditions. Wherein, the magnetism is inhaled tongs more suitable for snatching the panel beating work piece, and adjustable pneumatic clamp type tongs more is applicable to snatch the straight tube.
A welding gun and an arceye laser sensor are arranged on the welding robot 3; the arceye laser sensor is used for scanning the unwelded assembly to obtain a welding line position; the arceye laser sensor is also used to perform laser scanning during welding to control welding deformation. The head of the welding gun is also provided with dust removing equipment which is used for carrying out dust removing work in the welding process. The dust removal control box 15 and the dust removal equipment attached to the welding gun of the welding robot 3 form a dust removal system, when the dust removal system is automatically opened before welding, the dust removal system is automatically closed after welding is finished, and energy is saved. The arcey welding seam laser sensor comprises an arcey laser scanning head, an arcey laser controller and an arcey display device. As shown in fig. 7-10, the workflow of the wire-feed gantry robot flexible welding system is as follows:
1. the IOT welding management module 16 issues an order to the PLC control module 13 according to the acquired production order of the wire feeding frame. The PLC control module 13 receives the order instruction and synchronizes the order instruction to the man-machine management interface 12, and after an operator confirms one key on the man-machine management interface 12, the PLC control module 13 sends a control instruction to the outside according to the order instruction so that the welding system starts automatic production.
One wire feeding frame in this embodiment assumes that the required parts are workpiece a, workpiece B, workpiece C, and 1 straight tube.
2. The PLC control module 13 controls the AGV to automatically charge and discharge the skip 18, and the charging of the sheet metal part skip 2 and the straight pipe skip 11 is realized.
3. After the sheet metal part skip 2 and the straight pipe skip 11 are fed, the PLC control module 13 sends the model of the required workpiece A and the straight pipe.
Recognizing the workpiece and the corresponding position on the sheet metal part skip 2 through the 3D camera 1, obtaining workpiece position data corresponding to the workpiece A and sending the workpiece position data to the first transfer robot 14;
the first transfer robot 14 adopts an adjustable pneumatic clamping type gripper to grasp the straight pipe on the straight pipe skip car 11 to the automatic pipe bender 7; bending the straight pipe through an automatic pipe bending machine 7 to obtain a bent pipe; the second transfer robot 5 grabs the bent pipe on the automatic pipe bender 7 to a designated position of the welding table 10.
The first transfer robot 14 uses a magnetic gripper to grasp the corresponding workpiece a on the sheet metal part carriage 2 to the designated position of the welding table 10 according to the workpiece position data of the workpiece a.
4. The first transfer robot 14 performs cooperative pairing control on the gripped workpiece A and the bent pipe gripped by the second transfer robot 5 to obtain an unwelded assembly A;
the welding robot 3 scans the unwelded assembly a by means of an arceye laser sensor carried by itself, accurately determines the weld position and transmits it to the welding robot 3.
At this time, the welding robot 3 automatically opens the dust removing device of the head of the welding gun, and controls the welding gun to weld the unwelded assembly A according to the position of the welding seam, so as to obtain the welded assembly A. The arceye laser sensor tracks and scans the welding position in real time in the welding process and rectifies the welding position at any time so as to realize the purpose of controlling welding deformation in the welding process.
5. The PLC control module 13 again transmits the model numbers of the desired workpiece B and workpiece C.
Recognizing the workpiece and the corresponding position on the sheet metal part skip 2 through the 3D camera 1, obtaining workpiece position data corresponding to the workpiece B and the workpiece C, and sending the workpiece position data to the first transfer robot 14;
the first transfer robot 14 adopts a magnetic gripper to respectively grasp the corresponding workpiece B and the workpiece C on the sheet metal part skip 2 to the appointed position of the welding workbench 10 according to the workpiece position data of the workpiece B and the workpiece C, and performs group pairing work with the welding assembly A grasped by the second transfer robot 5 to obtain an unwelded assembly B;
the welding robot 3 scans the unwelded assembly B by means of an arceye laser sensor carried by itself, accurately determines the weld position, and transmits the weld position to the welding robot 3.
And the welding robot 3 automatically opens dust removing equipment of the head part of the welding gun, and controls the welding gun to weld the unwelded assembly B according to the welding seam position, so that a finished product of the wire feeding frame is obtained. The arceye laser sensor tracks and scans the welding position in real time in the welding process and rectifies the welding position at any time so as to realize the purpose of controlling welding deformation in the welding process.
6. The second carrying robot 5 grabs the finished product of the wire feeding frame in the step 5, and sends the finished product to the bead laser welding seam inspection device 9 for welding seam appearance inspection, and meanwhile, inspection work of two logics, namely good product comparison and AI inspection, is carried out.
By learning the shape of the defect with AI and judging the type and position of the defect, a minute defect can be inspected very simply. The bead laser weld inspection device 9 adopts two logics of good product comparison and AI inspection to inspect weld quality, provides guarantee for the stability of workpiece welding quality,
as shown in fig. 8, if both the good product of the wire feeding frame finished product and the weld appearance inspection of AI are judged to be qualified, the inspection result of the wire feeding frame finished product is qualified, otherwise, the inspection result of the wire feeding frame finished product is not qualified.
Since the inspection result is saved in the GI variable of the bead laser welding inspection apparatus 9, the inspection result can be output as an external signal to the PLC control module 13 by the bead laser welding inspection apparatus 9.
The PLC control module 13 controls the second transfer robot 5 to transfer the qualified wire feeding frame finished product from the bead laser welding seam inspection device 9 to the finished product skip 4; conveying the finished product of the wire feeding frame with unqualified inspection results from the loadeye laser welding seam inspection device 9 to the repairing skip 6;
after the finished product skip 4 or the repairing skip 6 is full, the PLC control module 13 controls the AGV to automatically feed and discharge the skip 18 to realize the discharging of the finished product skip 4 and the repairing skip 6, and the next cycle is performed.
In the automatic production process, a mode of combining a counting algorithm with sensor detection is adopted to judge whether a feeding unit, namely the sheet metal part skip 2 and the straight pipe skip 11 are in a material shortage state or whether the finished product skip 4/the repair skip 6 are full. After the material shortage is confirmed, the system sends a feeding request through the PLC control module 13, and the PLC control module 13 calls an AGV automatic feeding and discharging vehicle 18 to feed materials to a workstation. Before the finished product skip 4/repair skip 6 is full, the corresponding signal can be sent to the production management system in advance according to the production beat workstation, the PLC control module 13 calls the AGV trolley to transport an empty skip, the empty skip is automatically replaced after the transfer robot is full of the skip, the workstation is temporarily suspended during skip replacement, the utilization rate of equipment is improved to the greatest extent, and the welding system automatically starts to continue production after skip replacement is completed. When the set order yield arrives, the system stops production, sends an order completion signal to the PLC control module 13, informs the manager that the production is completed, and can place a new order.
The system adopts multi-robot cooperation, adopts one welding robot 3 and two transfer robots to coordinate welding, and after the two transfer robots grasp workpieces and assemble, the welding robot 3 coordinates welding, so that a plurality of clamps for multiple varieties of small batch workpieces are omitted in the process, the production cost is saved, the production efficiency is improved, and the purpose of flexible welding suitable for the multiple varieties of small batch production is achieved by adopting the method.
The system adopts the 3D camera 1 to accurately identify and distinguish various parts of the workpieces, and provides guarantee for the variety expansion of the workpieces to be welded subsequently through an intelligent learning function. By adopting the bedey laser welding seam inspection device, the welding seam appearance inspection of a welding finished product is realized, the humanization is saved, the inspection work of the welding seam of the workpiece finished product is efficiently and accurately completed, and the intelligent sensing is realized.
The system adopts plc as core control, and connects the 3D intelligent camera, the welding robot 3, the transfer robot, the welding seam appearance inspection device and various sensing devices through Ethernet and TCP/IP, without human intervention, the intelligent machine can be independently driven to realize intelligent control of workpiece photographing identification, transfer robot feeding and discharging and workpiece assembly, transfer robot and welding robot 3 coordination welding, finished welding seam appearance inspection, calling AGV automatic feeding and discharging vehicle 18 and the like.
The system adopts the IOT welding management module 16, the product order is sent to the automatic welding system of the wire feeding rack, and after one-key confirmation, a person on duty can start full-automatic welding of the product corresponding to the order until the welding of the finished product is completed, and the management module plays a role in transmitting information to optimize production activities. In the welding production process, the IOT welding management module 16 responds quickly to the change by real-time accurate information, thereby reducing the production activity without added value and improving the production efficiency.
In the embodiment, the intelligent sensing of the 3D intelligent camera and the bead-eye laser weld inspection device is used for realizing the accurate identification of incoming materials and the intelligent inspection of the appearance quality of the weld; digital informatization is realized through the IOT welding management module 16; meanwhile, automatic feeding and discharging of the AGV is realized through the PLC control module 13, and the requirement of flexible welding of a wire feeding rack robot is met, so that unmanned, flexible and intelligent production in the production process suitable for multiple varieties of small-batch wire feeding racks is achieved, the welding quality and the production efficiency are improved, and the production cost is reduced;
the flexibility of the flexible welding system of the wire feeding rack robot is mainly embodied in the production condition corresponding to multiple varieties in small batches, and the flexible welding is realized by adopting the clamp-free welding, namely the coordinated welding between the first carrying robot 14 and the second carrying robot 5 and the coordination welding between the welding robot 3 and the carrying robot, so that the clamp replacement time and the clamp manufacturing cost are saved to a great extent. Secondly, the 3D camera 1 recognizes workpiece feeding, workpieces do not need to be placed in a strict sequence, and the 3D camera 1 can recognize the coordinates of the workpieces which can be grasped at the uppermost layer as long as the workpieces are placed in a certain range, and the coordinates are sent to the transfer robot for grasping, so that the device is stable and reliable, and the special workpiece fixture positioning and additional workpiece placing time is saved, so that flexible production is realized.
Example 2.
The embodiment 2 provides a flexible welding method of a wire feeding frame robot, wherein a PLC control module 13 controls the operation of an automatic feeding and discharging carriage 18, a 3D camera 1, a first transfer robot 14, an automatic pipe bender 7, a second transfer robot 5 and a welding robot 3 of an AGV to complete the welding of the wire feeding frame, and the method comprises the following steps:
the feeding of the sheet metal part skip 2 and the straight pipe skip 11 is realized by controlling the operation of the AGV automatic feeding and discharging skip 18;
the first transfer robot 14 is controlled to grasp the straight pipe on the straight pipe skip car 11 to the automatic pipe bending machine 7; the automatic pipe bending machine 7 is controlled to bend the straight pipe, so as to obtain a bent pipe; grabbing the bent pipe on the automatic pipe bending machine 7 to a welding workbench 10 by controlling a second carrying robot 5;
identifying a workpiece and a corresponding position on the sheet metal part skip 2 through the 3D camera 1 to obtain a corresponding workpiece position; the first transfer robot 14 is controlled to grasp the corresponding workpiece on the sheet metal part skip 2 to the welding workbench 10 according to the position of the workpiece;
under the coordinated pairing control of the first transfer robot 14 and the second transfer robot 5, the welding robot 3 is controlled to weld the workpiece and the bent pipe on the welding workbench 10, and the finished product of the wire feeding frame is obtained.
It will be appreciated by those skilled in the art that embodiments of the present application may be provided as a method, system, or computer program product. Accordingly, the present application may take the form of an entirely hardware embodiment, an entirely software embodiment, or an embodiment combining software and hardware aspects. Furthermore, the present application may take the form of a computer program product embodied on one or more computer-usable storage media (including, but not limited to, disk storage, CD-ROM, optical storage, and the like) having computer-usable program code embodied therein.
The present application is described with reference to flowchart illustrations and/or block diagrams of methods, apparatus (systems) and computer program products according to embodiments of the application. It will be understood that each flow and/or block of the flowchart illustrations and/or block diagrams, and combinations of flows and/or blocks in the flowchart illustrations and/or block diagrams, can be implemented by computer program instructions. These computer program instructions may be provided to a processor of a general purpose computer, special purpose computer, embedded processor, or other programmable data processing apparatus to produce a machine, such that the instructions, which execute via the processor of the computer or other programmable data processing apparatus, create means for implementing the functions specified in the flowchart flow or flows and/or block diagram block or blocks.
These computer program instructions may also be stored in a computer-readable memory that can direct a computer or other programmable data processing apparatus to function in a particular manner, such that the instructions stored in the computer-readable memory produce an article of manufacture including instruction means which implement the function specified in the flowchart flow or flows and/or block diagram block or blocks.
These computer program instructions may also be loaded onto a computer or other programmable data processing apparatus to cause a series of operational steps to be performed on the computer or other programmable apparatus to produce a computer implemented process such that the instructions which execute on the computer or other programmable apparatus provide steps for implementing the functions specified in the flowchart flow or flows and/or block diagram block or blocks.
The foregoing is only a preferred embodiment of the invention, it being noted that: it will be apparent to those skilled in the art that various modifications and adaptations can be made without departing from the principles of the present invention, and such modifications and adaptations are intended to be comprehended within the scope of the invention.
Claims (10)
1. Wire feeding frame robot flexible welding system, characterized by includes: sheet metal part skip (2), straight tube skip (11), welding table (10), PLC control module (13) and by PLC control module (13) control:
the AGV automatic feeding and discharging vehicle (18) is used for feeding the sheet metal part skip (2) and the straight pipe skip (11);
the 3D camera (1) is used for identifying the workpiece and the corresponding position on the sheet metal part skip (2) to obtain corresponding workpiece position data;
the first carrying robot (14) is used for grabbing the straight pipe on the straight pipe skip car (11) to the automatic pipe bending machine (7); according to the workpiece position data, grabbing a corresponding workpiece on the sheet metal part skip (2) to a welding workbench (10);
the automatic pipe bending machine (7) is used for performing pipe bending operation on the straight pipe to obtain a bent pipe;
the second carrying robot (5) is used for grabbing the bent pipe on the automatic pipe bending machine (7) to the welding workbench (10);
and the welding robot (3) is used for welding the workpiece and the bent pipe on the welding workbench (10) under the coordinated assembly control of the first transfer robot (14) and the second transfer robot (5) to obtain a finished product of the wire feeding frame.
2. The flexible welding system of a wire feeding frame robot according to claim 1, further comprising a finished product skip (4), a repair skip (6) and a bead laser weld inspection device (9) controlled by the PLC control module (13),
the second transfer robot (5) is further used for transferring the finished product of the wire feeding frame from the welding workbench (10) to the bead laser welding seam inspection device (9);
the bead laser weld inspection device (9) is used for performing weld appearance inspection of good products and AI on the finished product of the wire feeding frame respectively to obtain an inspection result of the finished product of the wire feeding frame;
the second transfer robot (5) is further used for transferring finished products of the wire feeding frame, which are qualified in inspection result, from the bead laser welding seam inspection device (9) to the finished product skip (4); conveying the finished product of the wire feeding frame with unqualified inspection results from a bead laser welding seam inspection device (9) to a repairing skip car (6);
the AGV is used for automatically feeding and discharging the skip (18) and is also used for discharging the finished skip (4) and the repairing skip (6).
3. The flexible welding system of the wire feeding machine frame robot according to claim 2, wherein in the welding appearance inspection of the bead laser welding inspection device (9), if the welding appearance inspection of the good product and the AI of the wire feeding machine frame product is judged to be qualified, the inspection result of the wire feeding machine frame product is judged to be qualified, otherwise, the inspection result of the wire feeding machine frame product is judged to be unqualified.
4. The wire-feed gantry robot flexible welding system of claim 2, further comprising a fence (8), wherein the PLC control module (13) is disposed outside the fence (8); the sheet metal part skip (2), the straight pipe skip (11), the welding workbench (10), the first carrying robot (14), the automatic pipe bending machine (7), the second carrying robot (5), the welding robot (3), the finished product skip (4), the repairing skip (6) and the bead laser welding seam inspection device (9) are all arranged in the fence (8);
the 3D camera (1) is arranged on the fence (8) through a traveling device (19); and a plurality of doors which are convenient for the AGV to automatically feed and discharge the skip (18) in and out and feed and discharge are further arranged on the fence (8).
5. The flexible welding system of a wire feeding frame robot according to claim 2, wherein the PLC control module (13) is respectively connected with an AGV automatic feeding and discharging carriage (18), a 3D camera (1), a first transfer robot (14), an automatic pipe bender (7), a second transfer robot (5), a welding robot (3) and a loadeye laser weld inspection device (9) through ethernet and TCP/IP protocols.
6. The wire-feed gantry robot flexible welding system of claim 1, wherein a welding gun and an arceye laser sensor are provided on the welding robot (3);
on a welding workbench (10), the first carrying robot (14) performs cooperative assembly on the grabbed workpiece and the bent pipe grabbed by the second carrying robot (5) to obtain an unwelded assembly;
the arceye laser sensor is used for scanning the unwelded assembly to obtain a welding seam position;
the welding robot (3) is used for controlling a welding gun to weld the non-welded assembly according to the welding seam position under the coordinated control of the first carrying robot (14) and the second carrying robot (5);
the arceye laser sensor is also used for laser scanning during welding to control welding deformation.
7. The flexible welding system of a wire-feed gantry robot of claim 6, wherein the head of the welding gun is further provided with a dust removal device for performing dust removal during the welding process.
8. The wire-feeding frame robot flexible welding system according to claim 1, wherein the first transfer robot (14) and the second transfer robot (5) are provided with a magnetic gripper and an adjustable pneumatic clamping gripper.
9. The wire-feed frame robot flexible welding system of claim 1, further comprising an IOT welding management module (16), wherein the IOT welding management module (16) is configured to obtain a production order of the wire-feed frame, and issue an order instruction to the PLC control module (13) according to the production order;
and the PLC control module (13) is used for sending a control instruction to the outside according to the order instruction to finish welding of the wire feeding frame.
10. The flexible welding method of the wire feeding frame robot is characterized in that a PLC control module (13) controls the operation of an AGV automatic feeding and discharging vehicle (18), a 3D camera (1), a first carrying robot (14), an automatic pipe bending machine (7), a second carrying robot (5) and a welding robot (3) to finish the welding of the wire feeding frame, and the flexible welding method comprises the following steps:
the feeding of the sheet metal part skip (2) and the straight pipe skip (11) is realized by controlling the running of the AGV automatic feeding and discharging skip (18);
the straight pipe on the straight pipe skip car (11) is grabbed to the automatic pipe bender (7) by controlling the first carrying robot (14); the automatic pipe bending machine (7) is controlled to bend the straight pipe, so that a bent pipe is obtained; grabbing the bent pipe on the automatic pipe bending machine (7) to a welding workbench (10) by controlling a second carrying robot (5);
identifying a workpiece and a corresponding position on the sheet metal part skip (2) through a 3D camera (1) to obtain a corresponding workpiece position; the first transfer robot (14) is controlled to grasp the corresponding workpiece on the sheet metal part skip (2) to the welding workbench (10) according to the position of the workpiece;
under the coordinated assembly control of the first transfer robot (14) and the second transfer robot (5), the welding robot (3) is controlled to weld the workpiece and the bent pipe on the welding workbench (10) to obtain a finished product of the wire feeding frame.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN202311666971.5A CN117600714A (en) | 2023-12-06 | 2023-12-06 | Flexible welding system and welding method for wire feeding frame robot |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN202311666971.5A CN117600714A (en) | 2023-12-06 | 2023-12-06 | Flexible welding system and welding method for wire feeding frame robot |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CN117600714A true CN117600714A (en) | 2024-02-27 |
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| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CN202311666971.5A Pending CN117600714A (en) | 2023-12-06 | 2023-12-06 | Flexible welding system and welding method for wire feeding frame robot |
Country Status (1)
| Country | Link |
|---|---|
| CN (1) | CN117600714A (en) |
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2023
- 2023-12-06 CN CN202311666971.5A patent/CN117600714A/en active Pending
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