CN101774065B - Robot welding line tracking deviation compensation method - Google Patents
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Abstract
The invention relates to a robot welding line deviation compensation method based on arc oscillation welding line tracking, comprising the steps of: 1, detecting a welding current, sampling, filtering collected welding current data; 2, extracting deviation of the filtered current data, fitting a deviation direction, extracting according to an integral differential method, obtaining a compensationdosage and a transverse deviation value of a height deviation direction; 3, storing the transverse deviation value, adjusting the sensitivity; 4, computing a compensation dosage of the deviation by combining with the transverse deviation value and the sensitivity; 5, updating and accumulating deviation compensation dosages along the height direction and the transverse direction; 6, converting a three-dimensional compensation dosage into interpolation points of x axis, y axis and z axis; and 7, sending the compensated interpolation points to a control part of the robot. The invention can not generate jump change aiming at the compensation dosages, can ensure the stability of the system at a certain degree, and has better molding of a welding line subjected to the deviation compensation andtracking error of generally within +/-mm.
Description
Technical field
The present invention relates to a kind of robot welding line tracking deviation compensation method.
Background technology
Weld joint tracking is the prerequisite and the important assurance of Automation of Welding, and for the robot welding system, weld joint tracking plays a part very big for improving welding quality undoubtedly.Arc welding robot weld joint tracking process is the complication system of a multi-parameter influence; Wherein exist the influence of a large amount of uncertain factors, the weldment distortion that causes like the heat in the machining accuracy of welding work pieces groove, assembly precision, the welding process, arc force, arc blow etc., the accuracy of robot teaching, repeatable accuracy of robot or the like.Because welding process is non-linear, the modeling work of welding process is much more complicated, tired much more difficult than linear system.Though Recent study personnel utilize the whole bag of tricks to set up some comparatively precise analytic model, computational process need spend the long time, and differs and satisfy the requirement of control in real time surely.Therefore, be that classical control theory and the modern control theory of design basis all run into serious challenge in the control automatically in welding process with the mathematical models.
Summary of the invention
The object of the present invention is to provide the adjustable welding line tracking deviation compensation method of compensate for sensitivity under a kind of plant model uncertain condition.
In order to reach above purpose, the scheme that the present invention adopts is:
A kind of robot trajectory's deviation compensation method of following the tracks of based on the arc oscillation welding seam; This robot has weld tracker; Described weld tracker comprises arc sensor, signal processing module, weld seam correction module; Described arc sensor is used to detect welding current, and the trajector deviation that described weld seam correction module is used for butt welded seam compensates, and described deviation compensation method may further comprise the steps:
Step 1: in welding process, at first with the current welding current of the instant detection of described arc sensor, described signal processing module is sampled to the detected welding current of arc sensor, and the welding current data of gathering are carried out filtering;
Step 2: the welding current data of filtering are carried out deviation information extract; The match bias direction judges whether the welding current data of gathering exist deviation, and the deviation information here extracts and extracts according to the integration differential method; The concrete grammar of described integration differential method is: when electric arc scans the bevel for welding both sides; Welding current signal i (t) to and arranged on left and right sides carries out integration respectively, with the integrated value sum of and arranged on left and right sides welding current signal i (t) as the welding and assembling height signal, through current altitude signal; Reference quantity with short transverse compares again, obtains the compensation rate of height tolerance direction; With the difference of the integrated value of and arranged on left and right sides welding current signal i (t) lateral deviation signal as the welding gun disalignment; After the integration differential that obtains and arranged on left and right sides welding current signal i (t), can calculate the transversal discrepancy that welding gun departs from axis of a weld according to the relation of this integration differential and deviation;
Step 3: preserve this transversal discrepancy, and compare, when transversal discrepancy increases than the transversal discrepancy of last time, then strengthen compensate for sensitivity with the transversal discrepancy of last time; When transversal discrepancy reduces than the transversal discrepancy of last time, then reduce compensate for sensitivity; When transversal discrepancy did not change, compensate for sensitivity was constant;
Step 4: the transversal discrepancy that combination is preserved and the compensation rate of this deviation of sensitivity calculations;
Step 5: upgrade and accumulative total short transverse and horizontal deviation compensation amount: this deviation compensation amount that calculates is added in the deviation compensation amount of accumulative total last time, obtain new Accumulated deviation compensation rate;
Step 6: combine short transverse and horizontal Accumulated deviation compensation rate to form the three-dimensional compensation rate in the space, three-dimensional compensation rate is converted into the interpolated point of three of x, y, z;
Step 7: revised interpolated point is issued the ROBOT CONTROL part.
Above-mentioned technical scheme can be preferably, and described step 1 pair image data is carried out deviation when extracting, and is provided with the dead band band, when the departure of extracting in the band of described dead band, looking departure is 0; When the departure of extracting exceeds described dead band band, compensate.
Above-mentioned technical scheme also can be preferably, the adjustable-speed of described step 2 pair deviation compensation, and when the deviation variation tendency increased, deviation compensation speeded up; When the deviation variation tendency reduced, deviation compensation speed reduced.
The present invention compared with prior art has following advantage:
1, the compensation rate that the present invention is directed to can not produce to jump and change, and can on certain degree, guarantee the stability of system.
2, through good through the appearance of weld behind the deviation compensation, tracking error is generally in ± 1mm.
Description of drawings
Accompanying drawing 1 is a deviation compensation flow chart of the present invention;
Accompanying drawing 2 has added the robot welding line tracking flow chart of deviation compensation for the present invention;
Accompanying drawing 3 is a deviation compensation scheme sketch map of the present invention;
Accompanying drawing 4 is a compensation rate decomposing schematic representation of the present invention;
Integration differential figure when accompanying drawing 5 is welding gun of the present invention and weld seam center;
Accompanying drawing 6 is welding gun of the present invention and the integration differential figure of weld seam center to taking back;
Accompanying drawing 7 is welding gun of the present invention and the integration differential figure of weld seam center to taking over.
The specific embodiment
Describe concrete structure of the present invention below with reference to accompanying drawings in detail:
A kind of robot welding line tracking device comprises arc sensor, signal processing module, weld seam correction module, and arc sensor is used to detect welding current, and the trajector deviation that weld seam correction module is used for butt welded seam compensates.Wherein, the trajector deviation compensation method may further comprise the steps:
Like accompanying drawing 1, shown in 2: step 1: start welding, arc sensor detects current welding current immediately, and signal processing module is sampled to the detected welding current of arc sensor, and the welding current data of gathering are carried out filtering.In the present embodiment, through experimental design the digital filters that combine of local mean value filtering and two kinds of methods of improved slip medium filtering.Experiment shows, this wave filter is the interfering signal in the filtering welding current preferably, satisfies actual needs.
Step 2: the welding current data of filtering are carried out deviation information extract, the match bias direction judges whether the welding current data of gathering exist deviation.The deviation information here extracts and extracts according to the integration differential method.
The concrete grammar of integration differential method is: when electric arc scans the bevel for welding both sides; Welding current signal i (t) to and arranged on left and right sides carries out integration respectively; With the integrated value sum of and arranged on left and right sides welding current signal i (t) as the welding and assembling height signal; Through current altitude signal, the reference quantity with short transverse compares again, obtains the compensation rate of height tolerance direction; With the difference of the integrated value of and arranged on left and right sides welding current signal i (t) lateral deviation signal as the welding gun disalignment.Like S in the accompanying drawing 5～7
L, S
RIf, welding gun and weld seam center, then current integration value in both sides is equal basically, and difference approaches 0; If welding gun phase butt welded seam center takes back, then left side current integration value is greater than right side current integration value, and difference is one greater than 0 value; If welding gun phase butt welded seam center takes over, then left side current integration value is less than the right side, and difference is one less than 0 value.Relation according to integration differential and deviation can obtain the transversal discrepancy that welding gun departs from axis of a weld so again.S wherein
L, S
RAccount form following:
Because actual current sampling data disperses, therefore should adopt the mode of numerical integration to calculate S
LAnd S
RSet higher sample rate in the experiment simultaneously, caused the step-length between the sampled point less, therefore can adopt the trapezoidal integration formula to calculate S
LAnd S
RAnd can guarantee higher computational accuracy.The actual calculating formula that adopts is:
H is an integration step in the formula, h=2 π V/L; V is a speed of welding; L is the distance that the torch swinging one-period advances; N is counting of sampling in the one-period.
Be referred from the PID backoff algorithm (ratio P, integration I and differential D in deviation calculate) in band dead band; When carrying out the deviation compensation algorithm, present embodiment has also designed a dead band band, when the departure of extracting is in this dead band band; Do not compensate, directly looking departure is 0; Only, the deviation of extracting just carries out deviation compensation when having exceeded this dead band band.
Relation is shown in accompanying drawing 3 between the deviation e ' of compensation tache and the uncompensated deviation e.The figure bend is e '=e line.When deviate changed for the forward augment direction, OaM compensated along curve; When deviate for just and when reducing direction and change, bO compensates along curve M; When deviate is to bear and when reducing the variation of (absolute value increase) direction, compensate along curve OdN; When deviate is to bear and when increasing the variation of (absolute value reduces) direction, compensate along curve N cO; E ' when deviate does not change=e.This compensation way, when the deviation change direction changed, compensation rate can not produce to jump and change, and can on certain degree, guarantee the stability of system.
Step 3: preserve this transversal discrepancy, and compare with the transversal discrepancy of last time.Because the variation of deviation is non-linear, so, must the departure of this preservation and the departure of last time be compared according to actual conditions in compensation process, when transversal discrepancy increases than the transversal discrepancy of last time, then strengthen compensate for sensitivity; When transversal discrepancy reduces than the transversal discrepancy of last time, then reduce compensate for sensitivity; When transversal discrepancy did not change, compensate for sensitivity was constant.
In addition, extract deviation and compensate, and actual compensation rate is tried to achieve through compensation speed as judging compensation direction and whether needing.Consider that again weld joint tracking has certain time lag,, regulate according to being the rate of change of deviation so that compensation speed is designed to is adjustable.When the deviation variation tendency increased, deviation compensation speeded up; When the deviation variation tendency reduced, deviation compensation speed reduced.Can satisfy progressively compensation like this, the purpose of tenacious tracking, it is disconnected on certain degree, to carry out anticipation to deviation again, precompensation.
Step 4: the transversal discrepancy that combination is preserved and the compensation rate of this deviation of sensitivity calculations.
At first, carry out the correction on the lateral deviation direction earlier, shown in accompanying drawing 4, the track when supposing robot teaching is straight line P
0P
e, and actual weld seam is centered close to P
0P
e'.Suppose that welded piece is positioned at the xoy plane of robot basis coordinates system, extract deviation at every turn after, the form that the compensation rate s of each lateral deviation direction is decomposed into the vector sum under the basis coordinates system of robot is suc as formula shown in (1.2):
s＝K
p·e (1.1)
Wherein, K
pBe sensitivity,
Be respectively compensation rate
Corresponding reference axis component:
Δx＝s·sinα (1.3)
Δy＝s·cosα (1.4)
The compensation rate h ' of height tolerance direction utilizes this compensation rate to get final product the interpolated point correction of z direction to the robot pre-planning.
h′＝H-h_ref (1.7)
Δz＝h′ (1.8)
Step 5: upgrade and accumulative total short transverse and horizontal deviation compensation amount: this deviation compensation amount that calculates is added in the deviation compensation amount of accumulative total last time, obtain new Accumulated deviation compensation rate;
Step 6: combine short transverse and horizontal Accumulated deviation compensation rate to form the three-dimensional compensation rate in the space, three-dimensional compensation rate is converted into the interpolated point of three of x, y, z;
Step 7: the PMAC (multi-axis motion controller) that revised interpolated point is issued robot.
Can be in view of the above the interpolated point of robot pre-planning be carried out the correction on x, y, three directions of z, to accomplish the weld joint tracking task.
At present should correction algorithm modular applications among arc oscillation welding seam tracking system, under 10 ° situation, realized effective tracking at V-butt banjo fixing butt jointing and T shape corner joint end offset amount, appearance of weld is good, tracking error is in ± 1mm.Simultaneously, tracking error is analyzed, provided the scope of application of sensor.
The foregoing description only is explanation technical conceive of the present invention and characteristics; Its purpose is to let the personage that is familiar with this technology can understand content of the present invention and implements; Can not limit protection scope of the present invention with this; All equivalences that spirit is done according to the present invention change or modify, and all should be encompassed in protection scope of the present invention.
Claims (2)
1. robot trajectory's deviation compensation method of following the tracks of based on arc oscillation welding seam; This robot has weld tracker; Described weld tracker comprises arc sensor, signal processing module, weld seam correction module; Described arc sensor is used to detect welding current, and the trajector deviation that described weld seam correction module is used for butt welded seam compensates, and it is characterized in that: described deviation compensation method may further comprise the steps:
Step 1: in welding process, at first with the current welding current of the instant detection of described arc sensor, described signal processing module is sampled to the detected welding current of arc sensor, and the welding current data of gathering are carried out filtering;
Step 2: the welding current data of filtering are carried out deviation information extract; The match bias direction judges whether the welding current data of gathering exist deviation, and the deviation information here extracts and extracts according to the integration differential method; The concrete grammar of described integration differential method is: when electric arc scans the bevel for welding both sides; Welding current signal i (t) to and arranged on left and right sides carries out integration respectively, with the integrated value sum of and arranged on left and right sides welding current signal i (t) as the welding and assembling height signal, through current altitude signal; Reference quantity with short transverse compares again, obtains the compensation rate of height tolerance direction; With the difference of the integrated value of and arranged on left and right sides welding current signal i (t) lateral deviation signal as the welding gun disalignment; After the integration differential that obtains and arranged on left and right sides welding current signal i (t), can calculate the transversal discrepancy that welding gun departs from axis of a weld according to the relation of this integration differential and deviation;
Step 3: preserve this transversal discrepancy, and compare, when transversal discrepancy increases than the transversal discrepancy of last time, then strengthen compensate for sensitivity with the transversal discrepancy of last time; When transversal discrepancy reduces than the transversal discrepancy of last time, then reduce compensate for sensitivity; When transversal discrepancy did not change, compensate for sensitivity was constant;
Step 4: the transversal discrepancy that combination is preserved and the compensation rate of this deviation of sensitivity calculations;
Step 5: upgrade and accumulative total short transverse and horizontal deviation compensation amount: this deviation compensation amount that calculates is added in the deviation compensation amount of accumulative total last time, obtain new Accumulated deviation compensation rate;
Step 6: combine short transverse and horizontal Accumulated deviation compensation rate to form the three-dimensional compensation rate in the space, three-dimensional compensation rate is converted into the interpolated point of three of x, y, z;
Step 7: revised interpolated point is issued the ROBOT CONTROL part.
2. robot trajectory's deviation compensation method of following the tracks of based on the arc oscillation welding seam according to claim 1; It is characterized in that: when described step 2 pair image data is carried out the deviation extraction; Be provided with the dead band band, when the departure of extracting in the band of described dead band, looking departure is 0; When the departure of extracting exceeds described dead band band, compensate.
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Address after: 215300, No. 15, 1504-4 floor, 1699 South Gate Road, Yushan Town, Kunshan, Jiangsu Patentee after: Kunshan Hua Heng robot Co., Ltd. Address before: 215347 No. 1588, doctor Road, Ba Town, Jiangsu, Kunshan Patentee before: Industrial Robot Research Co., Ltd. Of Kunshan Industrial Technology Research Institute |