CN102601493B - Embedded multi-device real-time control welding robot system and control method - Google Patents

Embedded multi-device real-time control welding robot system and control method Download PDF

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CN102601493B
CN102601493B CN201210087867.6A CN201210087867A CN102601493B CN 102601493 B CN102601493 B CN 102601493B CN 201210087867 A CN201210087867 A CN 201210087867A CN 102601493 B CN102601493 B CN 102601493B
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welding
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CN102601493A (en
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石永华
郑泽培
段锦程
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South China University of Technology SCUT
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Abstract

The invention provides an embedded multi-device real-time control welding robot system and a control method. The system comprises a welding robot, a robot control cabinet, a robot teaching box, a handheld embedded real-time controller, a two-dimensional movement platform, a wire feeder and an arc welding power source, wherein the handheld embedded real-time controller serves as a control core and is electrically connected with the robot control cabinet, the two-dimensional movement platform, the wire feeder and the arc welding power source. The control method is used for realizing the functions of rectifying deviation of welding tracks, adjusting and displaying welding parameters and controlling start and stop of the wire feeder and on and off of the arc welding power source in real time. By the aid of the system and the control method, teaching of welding paths of the welding robot before welding, setting of the welding parameters, real-time control of the position of a welding gun during welding and real-time adjustment of the welding parameters can be combined.

Description

Welding robot system and control method that a kind of embedded many equipment is controlled in real time
Technical field
The present invention relates to Technology of Welding Robot field, be specifically related to welding robot system and control method that a kind of embedded many equipment is controlled in real time.
Background technology
In welding field, in the irregular situation of baroque weldment, particularly weld seam (such as parabola, S curve, cylinder is used to line mutually), often adopt teach programming mode, by butt welding machine device people's teaching, reproduction, complete the TRAJECTORY CONTROL of welding process.But in welding process, weldment often produces relative motion because temperature distortion causes welding gun and weldment.Welding gun often shows as blow-out and welding wild effect with respect to the vertical up-or-down movement on weldment surface; Welding gun often shows as welding gun substantial deviation weld seam with respect to the horizontal movement on weldment surface.Tracing it to its cause, is the uncertainty that in welding process, the temperature distortion of workpiece has caused the relative position of welding gun and weld seam.Solution is on the basis of welding robot teaching, and the movement locus of welding gun in welding process is carried out to real-time deviation correcting.This external welding is a complicated process, needs to adjust in real time the parameters such as weldingvoltage, welding current and speed of welding according to welding situation, and can under abnormal conditions, stop in time weld job running in welding process.Therefore, need to be a set of easy to operate, can control in real time welding track and adjust welding parameter in welding process, and can control Arc Welding Power, the welder of the multiple devices such as wire-feed motor simultaneously.
Chinese invention patent application " is controlled the method and apparatus of welding robot ", application number is 98125934.0, the main feature of this invention is in welding process, obtain the temperature of weldment by temperature sensor, with predetermined reference temperature contrast, thereby in the situation that not stopping weld job, adjust weldingvoltage, welding current and speed of welding value.The weak point of its control method is mainly: 1. can not be in welding process carry out real-time deviation correcting.The welding gun producing for a certain reason in welding process is departed to weld seam problem, only adopt temperature sensor not detect, also just cannot make the side-to-side movement of controller control welding gun phase butt welded seam.2. can not dynamically adjust welding gun height.In the time causing welding gun too high or too low from the distance of weldment due to welding temperature distortion in welding process, can cause easy blow-out or electric arc wild effect.Only cannot be from improving in essence welding quality by adjusting weldingvoltage, welding current and speed of welding.
Existing application for a patent for invention " welding robot system ", application number is 99111556.2, its application is also welding robot control.The main feature of this invention is in welding process by the welding robot system of main PC control welding robot mobile route.Its PC is by vision sensor way to acquire deviation in welding process, and the correction that sends order control welding gun is moved.The weak point of this system is mainly: 1. the problem of welding gun height can not be dynamically adjusted in same existence in welding process.2. in welding process, can not adjust the welding parameter of weldingvoltage, welding current, speed of welding.3. system is used vision sensor and PC, has improved the cost of system.4. use PC expansion trouble, inconvenience is controlled many welding equipments (as Arc Welding Power, wire-feed motor etc.) simultaneously.
Existing application for a patent for invention " for man-machine interaction method and the device for carrying out said of welding robot ", application number is 201110023122.9, its application is also welding robot control.
The main feature of this invention is by human-computer interaction interface, and control information is transferred to welding robot controller, completes the front setting of weldering by welding robot controller, and when weldering, adjustment waits operation.The weak point of this device mainly exists: 1. under man-machine interaction meeting main window, multiple subwindows are set, subwindow respectively has its function, and the mobile adjustment function of controlling function and welding parameter of for example welding gun adheres to different subwindows separately.In welding process, need the frequent subwindow that switches to send different control informations, inconvenient operation.2. welding process moves and changes welding parameter according to welding situation control welding gun, and General Requirements real-time is higher, adopts this kind of control method to be difficult to meet the demands.In the time pressing touch-screen, need to touch screen controller and receive touch information from touch point detection device, and convert it to contact coordinate, send order by serial ports, thereby receive order by welding robot controller again and judge which control is pressed, final order of just sending control welding robot, the larger time overhead of this process need cost, is not suitable for parameter modification frequently or the higher occasion of weld job requirement of real-time.
Summary of the invention
The object of the invention is to overcome prior art above shortcomings, be provided as welding robot system and control method that a kind of embedded many equipment is controlled in real time, its maximum feature is that this system is taking hand-held embedded real-time controller as control core, hand-held embedded real-time controller is electrically connected with robot control cabinet, two-dimension moving platform, wire-feed motor and Arc Welding Power, has the function of cut-offfing of correction welding track, adjustment welding parameter, demonstration welding parameter, the start and stop of controlling in real time wire-feed motor and Arc Welding Power.Can realize path of welding teaching, the welding parameter of the front welding robot of welding and set and combine with the real-time control of welding torch position in welding process, the real-time adjustment of welding parameter, concrete technical scheme is as follows.
The welding robot system that a kind of embedded many equipment is controlled in real time, comprise: welding robot, robot control cabinet, robot teach box, hand-held embedded real-time controller, two-dimension moving platform, wire-feed motor and Arc Welding Power, wherein, two-dimension moving platform is installed on the end of welding robot, and two-dimension moving platform is provided with welding gun; Hand-held embedded real-time controller is electrically connected with two-dimension moving platform, robot control cabinet, wire-feed motor and Arc Welding Power respectively; Robot teach box is connected with robot control cabinet, carries out teaching for butt welding machine device people; Hand-held embedded real-time controller is for controlling the start and stop of wire-feed motor and cut-offfing of Arc Welding Power, control two-dimension moving platform and drive welding gun motion, send order and move to robot control cabinet and by robot control cabinet control welding robot, in welding process, adjust in real time the voltage and current of Arc Welding Power output.
In the welding robot system that above-mentioned embedded many equipment is controlled in real time, described robot control cabinet comprises for receiving the order that hand-held embedded real-time controller sends and controlling the CPU of welding robot motion and for storing the position of welding process welding robot and the RAM of velocity information.
In the welding robot system that above-mentioned embedded many equipment is controlled in real time, described hand-held embedded real-time controller comprises single-chip microcomputer and the power supply being connected with described single-chip microcomputer respectively and reset circuit, clock oscillation circuit, electromagnetic relay module, RS-232 interface, independent key-press module, A/D modular converter, stepper motor driving circuit, LCD MODULE, wherein, electromagnetic relay module is connected with wire-feed motor and Arc Welding Power, for controlling the start and stop of wire-feed motor and cut-offfing of Arc Welding Power; RS-232 interface is connected with robot control cabinet, for realizing the serial communication between hand-held embedded real-time controller and robot control cabinet; On hand-held embedded real-time controller, be also provided with the knob for regulating Arc Welding Power electric current and voltage; A/D modular converter is connected by described knob with Arc Welding Power, for detection of the electric current and voltage of Arc Welding Power output; Stepper motor driving circuit is connected with the stepper motor on two-dimension moving platform, for Driving Stepping Motor; LCD MODULE is used for showing welding parameter; Described independent key-press module includes for the welding track of rectifying a deviation, adjusts welding parameter, start and stop wire-feed motor, cut-offs each button of Arc Welding Power.
In the welding robot system that above-mentioned embedded many equipment is controlled in real time, two-dimension moving platform comprises X platform and Y platform, drives ball screw to drive by stepper motor by shaft coupling; Y platform is installed on X platform, and described welding gun is arranged on Y platform.
The control method of the welding robot system that above-mentioned embedded many equipment is controlled in real time, comprises the real-time control of welding torch position and the real-time adjustment of welding parameter in the path of welding teaching of welding robot and welding process, specifically comprises the steps:
Before welding, carry out the movement locus teaching of welding robot by robot teach box, use hand-held embedded real-time controller to set welding parameter;
Use hand-held embedded real-time controller to open Arc Welding Power and wire-feed motor, weld job starts;
In welding process, observe on-the-spot welding situation, when welding gun, to depart from weld seam, welding gun excessive or when too small to the distance of weldment, drive welding gun phase butt-welding fitting level or vertically move by hand-held embedded real-time controller control welding robot or two-dimension moving platform, rectifying a deviation; When arc voltage, welding current, speed of welding are excessive or when too small, adjust in real time weldingvoltage electric current, and control speed of welding by controlling welding robot by hand-held embedded real-time controller, realize the control of welding energy input;
In the time that welding occurs that abnormal or weld job completes, close wire-feed motor and Arc Welding Power by hand-held embedded real-time controller.
In above-mentioned control method, hand-held embedded real-time controller sends control command by RS-232 interface, controls the motion of welding robot in welding process; Hand-held embedded real-time controller sends instruction, obtain current position and the speed parameter of welding robot in robot control cabinet RAM by robot control cabinet by internal robot instruction, send current position and speed parameter to RS-232 again, after hand-held embedded real-time controller is received data, show in real time by LCD MODULE.
In above-mentioned control method, drive X platform and Y platform by the stepper motor on hand-held embedded real-time controller control two-dimension moving platform, in welding process, drive welding gun to carry out the adjustment of X, Y direction, realize in real time and controlling.
In above-mentioned control method, before welding, carry out teaching by robot teach box butt welding machine device people, and weldingvoltage and welding current parameter are set and open Arc Welding Power and wire-feed motor with hand-held embedded real-time controller.In welding process, according to on-the-spot welding situation, send the mobile route of order correction welding robot by hand-held embedded real-time controller, carry out real-time deviation correcting and adjust welding gun height, avoiding in welding process due to the weldment welding gun substantial deviation weld seam that causes and the problem such as welding is unstable of deforming of being heated.Can adjust in real time the parameters such as speed of welding, weldingvoltage, welding current by hand-held embedded real-time controller, further improve welding quality simultaneously.In the time running into abnormal conditions or need weld job to stop, button that can directly pressing above hand-held embedded real-time controller stops weld job in time, ensures safety.Between welding robot robot end and welding gun, two-dimension moving platform is installed, thereby can make hand-held embedded real-time controller in welding process, directly control two-dimension moving platform and drive the welding gun control of rectifying a deviation, needn't send order indirectly by robot control cabinet control welding robot by serial communication, adapt to the higher occasion of requirement of real-time.
Compared with prior art, tool of the present invention has the following advantages and technique effect: 1, hand-held embedded real-time controller energy real-time deviation correcting welding track and adjustment welding gun height.2, hand-held embedded real-time controller can be adjusted weldingvoltage, welding current, speed of welding in real time, realizes the control of welding energy input.3, the expansion of the welding robot system taking hand-held embedded real-time controller as control core easily, is conveniently controlled many welding equipments (as Arc Welding Power, wire-feed motor, welding robot) in real time.4, two-dimension moving platform is installed on the end of welding robot, two-dimension moving platform install welding gun, thereby hand-held embedded real-time controller can directly control two-dimension moving platform drive welding gun rectify a deviation control and welding gun height adjustment, real-time is high.5, the hand-held embedded real-time controller adopting adopts button, processing ease, and cost is low.
Brief description of the drawings
Fig. 1 is that embedded many equipment of the present invention is controlled welding robot system schematic diagram in real time.
Fig. 2 is hand-held embedded real-time controller theory diagram of the present invention.
Fig. 3 is two-dimension moving platform X-Y scheme of the present invention.
Fig. 4 is workflow diagram of the present invention.
Detailed description of the invention
Below in conjunction with drawings and Examples, the present invention is described in more detail, but the invention is not restricted to these embodiment.
embodiment 1
As shown in Figure 1, this embedded many equipment is controlled in real time welding robot system and is mainly comprised welding robot 7, robot control cabinet 4, robot teach box 3, hand-held embedded real-time controller 2, two-dimension moving platform 1, wire-feed motor 6 and Arc Welding Power 5.Wherein, system, taking hand-held embedded real-time controller 2 as core, is connected with Arc Welding Power 5, wire-feed motor 6, two-dimension moving platform 1, the equal live wire of robot control cabinet 4.
Robot control cabinet 4 is the motion control core of welding robot 7, has the CPU of oneself, can receive the motion of order control welding robot 7.In welding process, the position of welding robot 7 and velocity information are stored in the RAM of robot control cabinet 4.
Robot teach box 3 is connected with robot control cabinet 4, carries out teaching for operating personnel's butt welding machine device people 7.Tutorial program is explained by the CPU of robot control cabinet 4 and is operated welding robot 7 and moves.
As shown in Figure 2, hand-held embedded real-time controller is taking single-chip microcomputer as core, and peripheral circuit and module comprise: power supply and reset circuit, clock oscillation circuit, electromagnetic relay module, RS-232 interface, independent key-press module, A/D modular converter, stepper motor driving circuit, LCD MODULE.
Power supply and reset circuit, clock oscillation circuit form single-chip minimum system together with single-chip microcomputer.
Electromagnetic relay module is for starting and stop Arc Welding Power 5 and wire-feed motor 6, only just can control multiple welding equipments by the button on hand-held embedded real-time controller 2 simultaneously, easy to operate, safe and reliable, when in welding process when unusual circumstance, can close in time Arc Welding Power and stop welding.
RS-232 interface is realized the serial communication between hand-held embedded real-time controller 2 and robot control cabinet 4.On the one hand, hand-held embedded real-time controller 2 sends control command by RS-232, and the CPU of robot control cabinet 4 receives after data, controls welding robot 7 and moves.Meet real-time deviation correcting motion and welding gun height adjustment in welding process.On the other hand, hand-held embedded real-time controller 2 sends instruction, obtained the current parameter such as position and speed of welding robot 7 in the RAM of robot control cabinet 4 by internal robot instruction by robot control cabinet 4, send data to RS-232 again, after hand-held embedded real-time controller 2 is received data, show in real time by LCD MODULE.
Independent key-press module, except controlling the start and stop of Arc Welding Power 5 and wire-feed motor 6, is mainly used in transmission correction in welding process and orders the motion of controlling welding robot, carries out real-time deviation correcting, adjustment welding gun height and speed of welding.The CPU of hand-held embedded real-time controller 2 obtains the state of each independent button by timing inquiry mode, judge butt welding machine device people 7 is sent to which kind of order, comprise " on welding gun, moving ", " welding gun moves down ", " fast, moving ", " moving down fast " " welding gun moves to left ", " welding gun moves to right ", " moving to left fast ", " moving to right fast ", " acceleration ", " deceleration " " two times of acceleration ", " two times of decelerations ".
A/D modular converter is connected with the rheostat knob on hand-held embedded real-time controller 2.Rheostat is connected with the internal circuit of arc-welding voltage, for adjusting weldingvoltage current value.In the time adjusting weldingvoltage and welding current by knob, the CPU of hand-held embedded real-time controller 2 obtains the electric current and voltage value corresponding with knob position by A/D modular converter, then shows current voltage current value by LCDs.
embodiment 2
In embodiment 1, the real-time deviation correcting function in welding process and the adjustment of welding gun height are that hand-held embedded real-time controller 2 carries out serial communication realization by RS-232 interface and robot control cabinet 4.This process comprises: on hand-held embedded real-time controller 2 button press, the CPU of hand-held embedded real-time controller 2 detect button press and judge, CPU response that hand-held embedded real-time controller 2 sends order data, robot control cabinet 4 by serial ports interrupts, robot control cabinet 4 receives data deal with data, robot control cabinet 4 sends and drives order control welding robot 7 to move.This process has spent more time overhead.The present embodiment, on the basis of embodiment 1, increases two-dimension moving platform 1.As shown in Figure 3, this two-dimension moving platform 1 comprises X platform d and Y platform e, moves by drive lead screw b band moving platform by stepper motor a.The X platform d of two-dimension moving platform is installed on welding robot c end, and it is upper that Y platform e is installed on X platform d, and welding gun f is installed on Y platform.Can drive X platform d and Y platform e by the stepper motor a on hand-held embedded real-time controller control two-dimension moving platform, in welding process, directly drive welding gun f to carry out the adjustment of X, Y direction, thereby carry out welding track correction, adjust the distance of welding gun to workpiece, be applicable to the occasion that requirement of real-time is higher.In addition, in the programming of hand-held embedded real-time controller 2, also need not relate to calling of welding robot movement function, realize more simple and convenient.
As shown in Figure 3, before welding, according to the concrete condition of weld seam, by robot teach box, 3 butt welding machine device people 7 carry out teaching, by hand-held embedded real-time controller 2, weldingvoltage and welding current parameter are set.In welding process, technical staff observes welding situation.Generally, weldment all can be heated and produce distortion, particularly thin plate weldment.Now the hand-held embedded real-time controller 2 of solder technology librarian use is controlled in real time, for example, in the time that welding gun track departs from weld seam, " welding gun moves to left ", " welding gun moves to right " button that can press on hand-held embedded real-time controller 2 are adjusted in real time, if depart from when larger, can press " moving to left fast ", " moving to right fast " button.In the time causing the vertical range of welding gun and weldment to change due to the distortion of workpiece, can press " on welding gun, moving ", " welding gun moves down " button is adjusted in real time, there is equally " fast, moving ", " moving down fast " button.In the time of welding gun process circular arc or irregular curve, can pass through again " acceleration ", " deceleration " " two times of acceleration ", " two times of decelerations " by key control speed of welding, ensure welding quality.In the time observing weldment groove and fill out discontented or groove and pile up, the electric current and voltage knob that can operate on hand-held embedded real-time controller 2 carries out the adjustment of electric current and voltage.In the time that welding appearance is abnormal, close in time Arc Welding Power 5 and wire-feed motor 6 by the button on hand-held embedded real-time controller 2, stop welding operation, ensure safety.

Claims (3)

1. the welding robot system that embedded many equipment is controlled in real time, it is characterized in that comprising: welding robot, robot control cabinet, robot teach box, hand-held embedded real-time controller, two-dimension moving platform, wire-feed motor and Arc Welding Power, wherein, two-dimension moving platform is installed on the end of welding robot, and two-dimension moving platform is provided with welding gun; Hand-held embedded real-time controller is electrically connected with two-dimension moving platform, robot control cabinet, wire-feed motor and Arc Welding Power respectively; Robot teach box is connected with robot control cabinet, carries out teaching for butt welding machine device people; Hand-held embedded real-time controller is for controlling the start and stop of wire-feed motor and cut-offfing of Arc Welding Power, control two-dimension moving platform and drive welding gun motion, send order and move to robot control cabinet and by robot control cabinet control welding robot, in welding process, adjust in real time the voltage and current of Arc Welding Power output;
Described hand-held embedded real-time controller comprises single-chip microcomputer and the power supply being connected with described single-chip microcomputer respectively and reset circuit, clock oscillation circuit, electromagnetic relay module, RS-232 interface, independent key-press module, A/D modular converter, stepper motor driving circuit, LCD MODULE, wherein, electromagnetic relay module is connected with wire-feed motor and Arc Welding Power, for controlling the start and stop of wire-feed motor and cut-offfing of Arc Welding Power; RS-232 interface is connected with robot control cabinet, for realizing the serial communication between hand-held embedded real-time controller and robot control cabinet; On hand-held embedded real-time controller, be also provided with the knob for regulating Arc Welding Power electric current and voltage; A/D modular converter is connected by described knob with Arc Welding Power, for detection of the electric current and voltage of Arc Welding Power output; Stepper motor driving circuit is connected with the stepper motor on two-dimension moving platform, for Driving Stepping Motor; LCD MODULE is used for showing welding parameter; Described independent key-press module includes for the welding track of rectifying a deviation, adjusts welding parameter, start and stop wire-feed motor, cut-offs each button of Arc Welding Power; Two-dimension moving platform comprises X platform and Y platform, drives ball screw to drive by stepper motor by shaft coupling; Y platform is installed on X platform, and described welding gun is arranged on Y platform.
2. the welding robot system that embedded many equipment according to claim 1 is controlled in real time, is characterized in that described robot control cabinet comprises for receiving the order that hand-held embedded real-time controller sends and controlling the CPU of welding robot motion and for storing the position of welding process welding robot and the RAM of velocity information.
3. the control method of the welding robot system that described in claim 1, embedded many equipment is controlled in real time, it is characterized in that comprising the real-time control of welding torch position and the real-time adjustment of welding parameter in the path of welding teaching of welding robot and welding process, specifically comprise the steps:
Before welding, carry out the movement locus teaching of welding robot by robot teach box, use hand-held embedded real-time controller to set welding parameter;
Use hand-held embedded real-time controller to open Arc Welding Power and wire-feed motor, weld job starts;
In welding process, observe on-the-spot welding situation, when welding gun, to depart from weld seam, welding gun excessive or when too small to the distance of weldment, drive welding gun phase butt-welding fitting level or vertically move by hand-held embedded real-time controller control welding robot or two-dimension moving platform, rectifying a deviation; When arc voltage, welding current, speed of welding are excessive or when too small, adjust in real time weldingvoltage electric current, and control speed of welding by controlling welding robot by hand-held embedded real-time controller, realize the control of welding energy input;
In the time that welding occurs that abnormal or weld job completes, close wire-feed motor and Arc Welding Power by hand-held embedded real-time controller;
Described hand-held embedded real-time controller sends control command by RS-232 interface, controls the motion of welding robot in welding process; Hand-held embedded real-time controller sends instruction, obtain current position and the speed parameter of welding robot in robot control cabinet RAM by robot control cabinet by internal robot instruction, send current position and speed parameter to RS-232 again, after hand-held embedded real-time controller is received data, show in real time by LCD MODULE; Drive X platform and Y platform by the stepper motor on hand-held embedded real-time controller control two-dimension moving platform, in welding process, drive welding gun to carry out the adjustment of X, Y direction, realize in real time and controlling.
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CN105302062A (en) * 2015-10-15 2016-02-03 东南大学 Task decoupling-based multi-robot collaboration welding path generation method
CN105302062B (en) * 2015-10-15 2017-10-03 东南大学 A kind of generation method of the multi-robot Cooperation path of welding of task based access control decoupling

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