CN102689085B - Autonomous mobile dithering hot wire tungsten-inert-gas (TIG) welding robot system for welding large-sized precision equipment - Google Patents
Autonomous mobile dithering hot wire tungsten-inert-gas (TIG) welding robot system for welding large-sized precision equipment Download PDFInfo
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- 238000003466 welding Methods 0.000 title claims abstract description 252
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Abstract
The invention belongs to the technical field of welding of robots, and in particular relates to an autonomous mobile dithering hot wire tungsten-inert-gas (TIG) welding robot system for welding large-sized precision equipment. The system comprises a robot body, a control system and a dithering hot wire TIG welding system, wherein the robot body comprises a crawling mechanism and an operating mechanism; the control system comprises a sensing system, a robot body control box and a robot master control system; and the dithering hot wire TIG welding system comprises a dithering hot wire TIG welding gun, a dithering hot wire TIG welding power supply, a wire feeding machine, shielding gas and a weld cooling system. The system has the advantages that a contact type magnet-wheel adsorption and non-contact type clearance adsorption composite mode and a three-wheel full-drive wheel type movement mode are systematically used by the crawling mechanism, so that a robot can autonomously and flexibly move at all positions on the surface of a large-sized steel structure, can be reliably adsorbed and can perform dithering hot wire TIG all-position welding operation, and the system is high in comprehensive performance.
Description
Technical field
The invention belongs to robotic welding technology field, is a kind of autonomous formula shake hot wire TIG welding robot system for large-scale precision equipment welding specifically.
Background technology
TIG refers to pure tungsten or activates tungsten (thorium tungsten, cerium tungsten, zirconium tungsten, lanthanum tungsten) as the Heliarc welding of nonconsumable electrode; welding for precision equipment; the welding of shake heating wire TIG can improve welding efficiency and welding quality; but the structure of large-scale precision equipment is no longer applicable to welder's manual operations, need exploitation for the robot system of the welding of autonomous formula.The welding of shake heating wire TIG is suitable for large scale structure thick plates, and the disposable through welding 25mm of energy also can reduce welding sermon while being applied to multi-layer multi-pass welding.For large scale structure, this body structure of parts, weight impact are not suitable for rotation or rotate, and existing special for automatic welding tractor need to be laid track mostly, and track flexibility is limited in scope, and laying operation is loaded down with trivial details; On the other hand, the shake heating wire TIG of large-scale component welding automation cannot be applied stationary machine hand.
Welding robot system is generally by welding load carrier, welding system, composition of the control system.Load carrier is divided into again fixed industry mechanical arm, rail mounted dolly, autonomous formula mechanism; Welding system is comprised of the source of welding current, welding gun, protection gas, wire feeder etc.; Control system is responsible for motion, tracking, welding quality control of load carrier etc.
That be usually used at present large-scale precision structure welding is rail mounted robot welding system, this system is comprised of robot orbit, robot and welding system, during use, need to carry out in advance track laying, be only applicable to lay the straight weld of track, and the flexibility of track within the specific limits, cannot adapt to the conversion of weld seam form.
If number of patent application is 201010180754.1, the applying date is on May 14th, 2010, name is called the patent of invention of " welding setting device, welding robot system and welding establishing method ", its main technical schemes is: a kind of while multiple-bead deposit setting device, possess: lamination pattern determination portion, it determines the lamination pattern of the welding bead corresponding with the joint of object based on each input data and lamination pattern data base value; Individual operation welding bead determination portion, it is in the lamination pattern of two joints of object, when the difference of the area of section of deposited metal amount when expression is combined welding bead surpasses predetermined threshold value, after getting rid of with welding bead the large side's of the area of section welding bead as individual operation, determine the combination of welding simultaneously; Weld all condition determination portions, its definite each welding bead welding condition of giving the corresponding current value of speed and seam formation position with the welding wire of calculating based on input welding condition that comprises; Operation program generating unit, it generates the robot motion programs of the welding condition based on definite, and is set in robot controller.The welding robot system of above-mentioned patent adopts rail mounted to arrange, cannot realize soldering joint automatic tracking identification and autonomous function, and this welding system is applicable to the welding of streamline form and is not suitable for large-scale steel structure members to carry out autonomous welding, weld seam type difference is larger.
And for example number of patent application is 201019063009.6, the applying date is on February 5th, 2010, name is called the patent of invention of " a kind of welding robot workstation system for injection molding machine frame ", comprise welding robot, welder, robot Mobile Slide, welding gun cooling device, intelligent locating tracking means and robot control cabinet, welding robot is arranged on robot Mobile Slide; Welder is connected with welding gun cooling device with welding robot respectively; Robot control cabinet is connected with welding robot, robot Mobile Slide, welder and intelligent locating tracking means respectively, for controlling movement and the welding of welding robot.The welding robot system of above-mentioned patent adopts rail mounted robot welding system, cannot realize that robot body automatic tracking welding seam moves freely and complete welding and this robot welds for injection molding machine frame, and weld seam type scope is very limited.
Tsing-Hua University has developed the attached autonomous welding robot of crawler type magnetic, and crawler type absorption travel mechanism absorption reliability is good but steering behaviour is poor, causes robot motion's very flexible, job position to adjust difficulty.Beijing Institute of Petrochemical Technology has developed magnetic wheel type autonomous welding robot, and magnetic wheel type absorption travel mechanism kinematic dexterity is good but adsorption capacity is poor, and robot absorption reliability is low.So problem that existing autonomous formula welding robot exists kinematic dexterity and adsorption capacity not to have concurrently.
Summary of the invention
The problem that exists kinematic dexterity and adsorption capacity not to have concurrently in order to overcome existing shake heating wire TIG robot, now special proposition can meet large-scale precision equipment welding, have flexibility and adsorption capacity concurrently, a kind of autonomous formula shake hot wire TIG welding robot system for large-scale precision equipment welding of high-effect high-quality Intelligent welding.
For achieving the above object, technical scheme of the present invention is as follows:
An autonomous formula shake hot wire TIG welding robot system for large-scale precision equipment welding, comprises robot body, control system and shake hot wire TIG welding welding system, it is characterized in that:
Robot body comprises climbing mechanism and operating mechanism: described climbing mechanism comprises the front-wheel module, the trailing wheel module that adopts permanent magnetism gap adsorbent equipment that adopt to drive steering integrated magnet-wheel, is connected the vehicle frame of front and back wheel and is arranged on the motor drive controller on vehicle frame; Described operating mechanism comprises crosshead shoe and swing mechanism, swing mechanism front end clamping shake heating wire TIG welding gun, the crosshead shoe that the free degree of horizontal and vertical directions is combined by two lead screw guide rails assembled units is realized, and swing mechanism adopts stepper motor collocation worm type of reduction gearing;
Control system comprises sensor-based system, robot body control cabinet and robot master control system;
Shake hot wire TIG welding welding system comprises shake heating wire TIG welding gun, shake heating wire TIG welding power supply, wire-feed motor, protection gas and welding cooling system;
It is obviously different that annexation between shake heating wire TIG welding gun, shake heating wire TIG welding power supply and shake hot wire TIG welding welding system and the annexation of welding gun, the source of welding current and the welding system of other welding systems exist, but above-mentioned difference and concrete how connection are that those skilled in the art know.
Robot body, control system and shake hot wire TIG welding welding system three are connected by cable.
Described front-wheel module and trailing wheel module are arranged on respectively vehicle frame two ends, and in trailing wheel module, place is provided with trailing wheel chassis, and trailing wheel is provided with permanent magnet on chassis;
Front-wheel module, for driving steering integrated magnet-wheel, comprises permanent magnet and wheel, and the permanent magnet of front-wheel adopts the magnetized annular permanent magnet of through-thickness; Trailing wheel module adopts permanent magnetism gap suction type, comprises
permanent magnetism gap adsorbent equipmentand wheel,
permanent magnetism gap adsorbent equipment comprisesaround wheel, be arranged on the permanent magnet on trailing wheel chassis, permanent magnetism gap adsorbent equipment is arranged on chassis around trailing wheel, between described permanent magnetism gap adsorbent equipment and magnetic conduction wall, be non-contacting, by regulating the distance between chassis and magnetic conduction wall to set the air gap between permanent magnetic adhesion device and magnetic conduction wall;
Described climbing mechanism adopts tricycle structure, and each wheel is driving wheel, relies on the differential of two trailing wheels and the controlled steering angle of front-wheel to realize turning to and rectilinear motion on magnetic conduction wall.
Described operating mechanism comprises crosshead shoe transverse axis, the crosshead shoe longitudinal axis, linking arm, weld seam tracking sensor connector and wig-wag connector, crosshead shoe transverse axis and the crosshead shoe longitudinal axis are to comprise respectively stepper motor and precision ball screw guide rail, weld seam tracking sensor is arranged on the front end of connector, wig-wag connector is arranged on the end of linking arm, swing mechanism is arranged on wig-wag connector, swing mechanism front end clamping shake heating wire TIG welding gun, the clamping of shake heating wire TIG welding gun and attitude-adjusting system.
Described sensor-based system comprises laser tracking transducer, environmental monitoring sensor and molten bath monitoring sensor, operating mechanism and environmental monitoring installation of sensors are on climbing mechanism, operating mechanism end is installed laser tracking transducer, molten bath monitoring sensor and shake heating wire TIG welding gun, robot body control cabinet is arranged on climbing mechanism, and robot control cabinet is connected by cable with master control system; Described welding system shake heating wire TIG welding power supply, wire-feed motor, protection gas are connected by cable with the welding gun of part on machine.
The working method of described robot control system is: operator utilizes remote control handheld box control to move near starting the arc position, by robot sensing's control system, completed again the adjustment of initial point position, finally by autonomous classification tracking weld seam, realizing weld groove center position follows the tracks of, robot control system adopts PCC or Industrial PC as master control system, the groove central point deviation signal control body that laser Method Seam Tracking Sensing System gathers and operating mechanism motion; The control of shake hot wire TIG welding welding system comprises switching value control, technological parameter setting.
Described robot control system adopts multiple degrees of freedom The Cloud Terrace to realize the monitoring of macroscopical welding surroundings, completes the front starting point macrotechnique of weldering; Adopt molten bath monitoring sensor to realize the attitude adjustment of microcosmic shake heating wire TIG welding gun, the molten bath monitoring of welding process.
Described robot system main control system carries out communication by Device net and the source of welding current, by host computer control interface, completes welding parameter setting and welding parameter is adjusted online, controls welding and starts and stop.
The steering integrated magnet-wheel concrete structure of described driving is: roll rotating shaft one end and be arranged on car body fixed frame, other end turntable lower supporting plate connects, turntable upper backup pad, turret supports column is connected with turntable lower supporting plate, turntable cover plate is connected with turntable upper backup pad, taper roll bearing is arranged in two gripper shoes, steering spindle is bearing on taper roll bearing, steering spindle is connected with 60 tooth straight-tooth gears, angular transducer power shaft and steering spindle are affixed, angular transducer support bar is connected with turntable upper backup pad, angular transducer is connected with angular transducer support bar, steer motor installing plate is connected with turntable upper backup pad, turn to reducing motor to be connected with steer motor installing plate, 20 tooth straight bevel gears are fixed in and turn on reducing motor output shaft, the 40 tooth straight bevel gears that are meshed are with it mounted on bevel gear shaft, bevel gear shaft is supported by the first deep groove ball bearing that is arranged on turntable upper backup pad, the opposite side of bevel gear shaft connects by flat key with 19 tooth straight-tooth gears, 19 tooth straight-tooth gears and the engagement of 60 tooth straight-tooth gears, the lower end of steering spindle is connected with turning to substrate, wheel left side installing plate, wheel right side installing plate, drive motors installing plate is connected with turning to substrate, drive reducing motor to be connected with drive motors installing plate, small synchronous pulley axle is affixed with the output shaft of driving reducing motor, small synchronous pulley is connected and is arranged on small synchronous pulley axle by flat key, front-wheel module permanent magnet and wheel yoke are connected and are arranged on axletree by flat key, axletree is bearing between wheel left side installing plate and wheel right side installing plate by the first deep groove ball bearing and the second deep groove ball bearing, large synchronous pulley connects the opposite side that is arranged on axletree by flat key, between large synchronous pulley and small synchronous pulley, by Timing Belt, connected, between tensioning running roller and tensioning running roller support bar, be connected by screw, tensioning running roller support bar is arranged on the installing plate of wheel left side by screw, drive between reducing motor and axletree and pass through toothed belt transmission, steering driving mechanism also comprises steering spindle, steering spindle bottom is provided with drive mechanism for wheel and roller, described steer axis and wheel axis perpendicular quadrature.
The invention has the advantages that:
1, climbing mechanism system of the present invention adopts complex method and the full drive-type move mode of three-wheel of the absorption of contact magnet-wheel and non-contact gap absorption, robot can move, reliably adsorb and implement shake heating wire TIG all-position welding operation in large-scale steel structure table surface all-position independent and flexible, and overall system performance is good.
2, the present invention adopts the control mode of " macroscopical remote control, microcosmic autonomous ", can autonomous classification follow the tracks of weld seam, possesses the setting of remote welding parameter and adjusts online function; Adopt multiple degrees of freedom The Cloud Terrace to realize workpiece environmental monitoring, complete the front starting point macrotechnique of weldering; Adopt molten bath monitoring sensor to realize the attitude adjustment of shake heating wire TIG rifle, the molten bath monitoring of welding process.Possess macroscopical welding surroundings monitoring function, realized intelligent welding.
3, shake hot wire TIG welding welding robot can adapt to all position welding seam form of large-scale steel structure, adopt absorption type climbing mechanism, motion flexibly, adopt laser seam tracking sensor, possess macro environment and monitor and molten bath monitoring system, when large slab all-position welding, can meet and swing requirement, control requirement and motion requirement.
4, operation of the present invention and swing mechanism are applicable to creeping-type welding robot, crosshead shoe by operating mechanism provides Y-axis and two frees degree of Z axis, and the shake heating wire TIG welding gun that is leading portion clamping by swing mechanism provides a rotary freedom around X-axis to realize oscillating function.Crosshead shoe adopts high precision ball lead screw guide rails to coordinate stepper motor combination to form, and positioning precision can reach 0.02mm, to guarantee the craft precision requirement of welding gun tracking weld seam.Swing mechanism provides rotary freedom by worm and gear collocation stepper motor for welding gun, and output torque is not less than 10Nm, can make welding gun realize centered by any swing angle to swing to weld.
5, the linking arm arm of operating mechanism of the present invention exhibition can manual adjustments, and maximum arm exhibition can reach 450mm.The clamping device clip position of weld seam tracking sensor can manual adjustments, X-axis adjustable extent 120mm, the maximum adjustable extent 350mm of Y-axis, Z axis adjustable extent 100mm, larger adjustable space scope guarantees that under multiple welding procedure, weld seam tracking sensor position can adapt to the various attitude demands of shaking heating wire TIG welding gun.
6, drive between reducing motor and axletree and pass through toothed belt transmission, by regulating transmission centre-to-centre spacing can obtain larger installing space, thereby the driving reducing motor of installation relatively high power improves driving moment.
7, be provided with and independently turn to the free degree and make steer axis and wheel axis perpendicular quadrature, can realize the independent steering of wheel, improve climbing robot kinematic dexterity.
8, be provided with passive banking degree of freedom and by rolling confinement block constrained side tilt angle in positive and negative 10 degree, make climbing robot there is good curved surface adaptive capacity.
9, roll confinement block and by mechanical position limitation, realize the function of constrained side degree of tilt.
10, described steering structure and wheel rolling are all provided with independently driving mechanism.
11, autonomous formula robot and the shake heating wire TIG welding gun advantage of being combined are that whole welding robot system can realize shake heating wire TIG and weld in autonomous, on the basis of common TIG weldering, welding wire is carried out to preheating, improve heat input, increase burn-off rate, thereby improved speed of welding.Compare with TIG weldering, shake heating wire TIG welding gun has obviously improved speed of welding, be suitable for welding the Welding Structure of intermediate gauge, the feature again with TIG weldering high-quality weld seam simultaneously, owing to shaking hot wire TIG welding's wire feed rate, be independent of welding current, therefore can control better appearance of weld, for bevelled weld seam, its sidewall amalgamation welds than MIG.
Accompanying drawing explanation
Fig. 1 is structure chart of the present invention.
Fig. 2 is robot body figure of the present invention.
Fig. 3 is climbing mechanism structural representation of the present invention.
Fig. 4 is climbing mechanism trailing wheel module diagram of the present invention.
Fig. 5 is operating mechanism schematic diagram of the present invention.
Fig. 6 is system construction drawing of the present invention.
Fig. 7 is permanent magnetism gap adsorbent equipment structural representation.
Fig. 8 is for driving steering integrated magnet-wheel structural representation.
Fig. 9 is the cutaway view that front-wheel is crossed steering spindle and bevel gear shaft.
Figure 10 is magnet-wheel cutaway view.
1 operating mechanism in accompanying drawing, 2 molten bath monitoring sensors, 3 shake heating wire TIG welding guns; 4 laser tracking transducers, 5 weld seams, 6 climbing mechanisms; 7 multiple degrees of freedom The Cloud Terraces, 8 robot body control cabinets, 9 cables; 10 welding objects, 11 wire-feed motor, 12 shake heating wire TIG welding power supplys; 13 protection gas; 14 welding cooling systems, 15 robot master control systems, 16 remote control operation boxes.
17 front-wheel modules, 18 vehicle frames, 19 motor drive controllers, 20 trailing wheel modules.
21 permanent magnets, 22 chassis, 23 wheels, 24 turbine and worm decelerators, 25 planetary reducers, 26 motors.
27 Timing Belts, 28 decelerators, 29 turn to soleplate, 30 .20 tooth straight bevel gears.
31 steering spindles, 32.60 tooth roller gears, 33.19 tooth roller gears, 34 bevel gear shafts, 35.40 tooth straight bevel gears.
36 front-wheel module permanent magnets, 37 yokes.
41 crosshead shoe transverse axis, the 42 crosshead shoe longitudinal axis, 43 linking arms, 44 weld seam tracking sensor connectors, 45 wig-wag connectors, 46 swing mechanisms, 47 welding guns, 48 weld seam tracking sensors.
The specific embodiment
An autonomous formula shake hot wire TIG welding robot system for large-scale precision equipment welding, comprises robot body, control system and shake hot wire TIG welding welding system, it is characterized in that:
Robot body comprises climbing mechanism and operating mechanism: described climbing mechanism comprises the front-wheel module, the trailing wheel module that adopts permanent magnetism gap adsorbent equipment that adopt to drive steering integrated magnet-wheel, is connected the vehicle frame of front and back wheel and is arranged on the motor drive controller on vehicle frame; Described operating mechanism comprises crosshead shoe and swing mechanism, swing mechanism front end clamping shake heating wire TIG welding gun, the crosshead shoe that the free degree of horizontal and vertical directions is combined by two lead screw guide rails assembled units is realized, and swing mechanism adopts stepper motor collocation worm type of reduction gearing;
Control system comprises sensor-based system, robot body control cabinet and robot master control system;
Shake hot wire TIG welding welding system comprises shake heating wire TIG welding gun, shake heating wire TIG welding power supply, wire-feed motor, protection gas and welding cooling system;
Robot body, control system and shake hot wire TIG welding welding system three are connected by cable.
Described front-wheel module and trailing wheel module are arranged on respectively vehicle frame two ends, and in trailing wheel module, place is provided with trailing wheel chassis, and trailing wheel is provided with permanent magnet on chassis;
Front-wheel module, for driving steering integrated magnet-wheel, comprises permanent magnet and wheel, and the permanent magnet of front-wheel adopts the magnetized annular permanent magnet of through-thickness; Trailing wheel module adopts permanent magnetism gap suction type, comprises
permanent magnetism gap adsorbent equipmentand wheel,
permanent magnetism gap adsorbent equipment comprisesaround wheel, be arranged on the permanent magnet on trailing wheel chassis, permanent magnetism gap adsorbent equipment is arranged on chassis around trailing wheel, between described permanent magnetism gap adsorbent equipment and magnetic conduction wall, be non-contacting, by regulating the distance between chassis and magnetic conduction wall to set the air gap between permanent magnetic adhesion device and magnetic conduction wall;
Described climbing mechanism adopts tricycle structure, and each wheel is driving wheel, relies on the differential of two trailing wheels and the controlled steering angle of front-wheel to realize turning to and rectilinear motion on magnetic conduction wall.
Described operating mechanism comprises crosshead shoe transverse axis, the crosshead shoe longitudinal axis, linking arm, weld seam tracking sensor connector and wig-wag connector, crosshead shoe transverse axis and the crosshead shoe longitudinal axis are to comprise respectively stepper motor and precision ball screw guide rail, weld seam tracking sensor is arranged on the front end of connector, wig-wag connector is arranged on the end of linking arm, swing mechanism is arranged on wig-wag connector, swing mechanism front end clamping shake heating wire TIG welding gun, the clamping of shake heating wire TIG welding gun and attitude-adjusting system.
Described sensor-based system comprises laser tracking transducer, environmental monitoring sensor and molten bath monitoring sensor, operating mechanism and environmental monitoring installation of sensors are on climbing mechanism, operating mechanism end is installed laser tracking transducer, molten bath monitoring sensor and shake heating wire TIG welding gun, robot body control cabinet is arranged on climbing mechanism, and robot control cabinet is connected by cable with master control system; Described welding system shake heating wire TIG welding power supply, wire-feed motor, protection gas are connected by cable with the welding gun of part on machine.
The working method of described robot control system is: operator utilizes remote control handheld box control to move near starting the arc position, by robot sensing's control system, completed again the adjustment of initial point position, finally by autonomous classification tracking weld seam, realizing weld groove center position follows the tracks of, robot control system adopts PCC or Industrial PC as master control system, the groove central point deviation signal control body that laser Method Seam Tracking Sensing System gathers and operating mechanism motion; The control of shake hot wire TIG welding welding system comprises switching value control, technological parameter setting.
Described robot control system adopts multiple degrees of freedom The Cloud Terrace to realize the monitoring of macroscopical welding surroundings, completes the front starting point macrotechnique of weldering; Adopt molten bath monitoring sensor to realize the attitude adjustment of microcosmic shake heating wire TIG welding gun, the molten bath monitoring of welding process.
Described robot system main control system carries out communication by Device net and the source of welding current, by host computer control interface, completes welding parameter setting and welding parameter is adjusted online, controls welding and starts and stop.
Below in conjunction with accompanying drawing, the present invention will be further described.
As shown in Figure 1, shake heating wire TIG welding autonomous formula robot system is comprised of robot body, control system, shake hot wire TIG welding welding system.Robot body comprises operating mechanism and climbing mechanism; control system comprises sensor-based system (multiple degrees of freedom The Cloud Terrace, laser tracking transducer and molten bath monitoring sensor), robot body control cabinet and robot master control system, and shake hot wire TIG welding welding system comprises welding cooling system, shake heating wire TIG welding power supply, wire-feed motor, protection gas.
Robot system can be divided into " part on machine " of walking on operation workpiece and be installed on " part under machine " outside operation workpiece from space.Machine top is divided and is comprised robot body (operating mechanism, climbing mechanism), robot body control cabinet, sensor-based system, welding gun, and sensor-based system is mainly comprised of laser tracking transducer, environmental monitoring sensor and molten bath monitoring sensor.Operating mechanism and environmental monitoring installation of sensors are on climbing mechanism, and operating mechanism end is installed laser tracking transducer, molten bath monitoring sensor and welding gun, and robot body control cabinet is arranged on climbing mechanism.Robot system machine bottom is divided and is comprised main control system, straighforward operation, the source of welding current, wire-feed motor, protection gas.On machine, the robot control cabinet of part is connected by cable with the main control system of part under machine, and the source of welding current, wire-feed motor, protection gas are connected by cable with the welding gun of part on machine.Cable comprises fulgurite, tracheae and holding wire.Operating mechanism end is with oscillator of welding gun, and shake heating wire TIG welding gun clamps and attitude-adjusting system.
Part on machine: comprise robot body (operating mechanism, climbing mechanism), robot body control cabinet, sensor-based system (multiple degrees of freedom The Cloud Terrace), laser tracking transducer and molten bath monitoring sensor), welding gun.Operating mechanism and multiple degrees of freedom The Cloud Terrace are arranged on climbing mechanism, and operating mechanism end is installed laser tracking transducer, molten bath monitoring sensor, welding gun, and robot body control cabinet is arranged on climbing mechanism.Wherein climbing mechanism is collectively referred to as robot body with the operating mechanism being arranged on climbing mechanism.
Part under machine: comprise robot master control system, straighforward operation, shake heating wire TIG welding power supply, Plasma Welding power supply, wire-feed motor, protection gas.On machine, the robot body control cabinet of part is connected by cable with the robot master control system of part under machine, and shake heating wire TIG welding power supply, welding cooling system, wire-feed motor, protection gas are connected by cable with the welding gun of part on machine.Cable comprises fulgurite, water pipe, tracheae and holding wire.
As shown in Figure 2, robot body comprises climbing mechanism and operating mechanism.
As shown in Figures 3 and 4, climbing mechanism comprises that employing drives the front-wheel module of steering integrated magnet-wheel, adopt the trailing wheel module of permanent magnetism gap adsorbent equipment, connect the vehicle frame of front and back wheel and be arranged on the motor drive controller on vehicle frame.Wherein, trailing wheel chassis adopts mild steel (as Q235) manufacture, except as supporting the function of rear-wheel structure, also as yoke, forms a part for magnetic circuit be arranged on the permanent magnet on trailing wheel chassis around wheel together with.After motor, connect two stage reducer band motor car wheel, the first order is planetary reducer, and the second level is turbine and worm decelerator, and turbine and worm decelerator is connected by screw and is arranged on trailing wheel chassis.Magnet-wheel consists of 1 permanent magnet and 2 yokes.Described permanent magnet adopts the magnetized annular permanent magnet of through-thickness, and permanent magnet can adopt high performance permanent magnetic materials as manufactures such as NdFeB, and yoke adopts mild steel (as Q235 etc.) to manufacture.
As shown in Figure 5, operating mechanism is mainly comprised of crosshead shoe transverse axis, the crosshead shoe longitudinal axis, linking arm, weld seam tracking sensor connector, wig-wag connector.Crosshead shoe transverse axis and the crosshead shoe longitudinal axis are stepper motor and precision ball screw guide rail, to consist of respectively.Transverse axis is arranged on mobile platform by support, and the longitudinal axis is arranged on transverse axis slide block.Transverse axis provides the Y-axis free degree, working range 90mm; The longitudinal axis provides the Z axis free degree, working range 75mm.Crosshead shoe single shaft positioning precision 0.02mm.Linking arm is arranged on longitudinal axis slide block by fixture block, the maximum arm exhibition of linking arm 450mm, and can be by regulating fixture block clip position to carry out manual adjustments.Weld seam tracking sensor connector is clamped on linking arm, and the clip position of manual adjustments connector can provide for weld seam tracking sensor the position range of 350mm.Weld seam tracking sensor is arranged on the front end of connector, during work, to weld seam Emission Lasers bundle and scan weld seam, instructs the action of crosshead shoe and mobile platform.Wig-wag connector is arranged on the end of linking arm, and the height of connector can manual adjustments, for swing mechanism provides the adjusting range of Z-axis direction 80mm.Swing mechanism is arranged on connector, front end clamping welding gun.
Figure 6 shows that robot control system sequential chart.Control system adopts PCC or other Industrial PC as master control system, and each function plate is modularized design.Utilize the FEEDBACK CONTROL robot body climbing mechanism of laser tracking transducer and the motion of operating mechanism; Utilize switching value to control the actions such as welding starts, stops; Possess the setting of remote welding parameter and adjust online function; Tool adopts multiple degrees of freedom The Cloud Terrace to realize the monitoring of macroscopical welding surroundings, adopts molten bath monitoring sensor to realize the monitoring of microcosmic welding pool; ; During operation, first start Plasma Welding power supply, after the 2S of interval, restart shake heating wire TIG welding power supply, and open robot feed motion; Receive in arc process, Plasma Welding power supply, shake heating wire TIG welding power supply, robot system are closed simultaneously.
Control system adopts PCC or other Industrial PC as master control system, and each function plate is modularized design.Utilize the FEEDBACK CONTROL robot body climbing mechanism of laser tracking transducer and the motion of operating mechanism; Utilize switching value to control the actions such as welding starts, stops; Possess the setting of remote welding parameter and adjust online function; Tool adopts multiple degrees of freedom The Cloud Terrace to realize the monitoring of macroscopical welding surroundings, adopts molten bath monitoring sensor to realize the monitoring of microcosmic welding pool; Possesses handheld box remote control robot systemic-function.
Supervisory control comuter by Ethernet 1. connection 2. the parameter of programmed computer controller is set, and accept the video data of video server.3. programmable computer controller is connected with handheld box, driver by CAN bus.Driver control the executing agency of creeping, 4. operation executing agency programmable computer controller carries out the setting of welding machine adapter by RS485 bus, by RS232 bus, 9. 7. reads with IO the status information that laser is followed sensor and position switch.Video server is by the 8. 10. video information of environment of accepting monitoring head, environmental monitoring video camera, molten bath CCTV camera of video interface.
The shake heated filament source of welding current connects with control system by Devicenet, utilizes distinctive jittering device and heated filament wire-feed motor to weld.
Supervisory control comuter adopts PC104 industrial computer to realize, and wherein has 2 Ethernet interfaces: one for being connected with programmable computer controller, one for being connected with video server.
Environmental monitoring video camera adopts SONY The Cloud Terrace CCTV camera, profile that can be to workpiece, and robot is monitored.The optical filter that operation field CCTV camera has been equipped with speciality completes in welding process, the monitoring in molten bath.
The climbing mechanism drive system of robot has adopted two MAXON direct current generators, and operating structure is crosshead shoe, and drive motors is selected stepper motor.Motor driver adopts ELMO driver.
Robot alignment sensor adopts laser seam tracking sensor, carries out determining of welding seam position information.Operation adapter is source of welding current adapter, by adapter can control welding electric current, voltage, start, stop.Limit switch is arranged on crosshead shoe, completes limit function.
While welding, laser seam tracking sensor passes to programmable computer controller in real time by welding seam position information, and programmable computer controller first carries out signal filtering, and according to position deviation, crosshead shoe can be followed the tracks of accurately.And programmable computer controller utilizes filtered positional information to carry out the location estimation of robot crawling mechanism, according to position deviation, climbing mechanism carries out rough tracking.
Permanent magnetism gap adsorbent equipment as shown in Figure 7, the Nd-Fe-B permanent magnet being magnetized by 12 thickness directions forms, each trailing wheel is respectively arranged 6 permanent magnets, the N utmost point and the S utmost point formation magnetic circuit that is staggered, around trailing wheel, be arranged on chassis, between described permanent magnetism gap adsorbent equipment and magnetic conduction wall, be non-contacting, by regulating the distance between chassis and magnetic conduction wall to set the air gap between described permanent magnetic adhesion device and magnetic conduction wall.
Fig. 8 is the three-dimensional model diagram of front-wheel, and Fig. 9 is the cutaway view that front-wheel is crossed steering spindle and bevel gear shaft, and Figure 10 was the cutaway view of front-wheel axletree.Wherein, DC brushless motor and planetary reducer drive bevel gear shaft rotation through 20 tooth straight bevel gears and 40 tooth Straight Bevel Gear Drive, bevel gear shaft drives steering spindle to rotate by 19 tooth roller gears and 60 tooth column gear transmission again, steering spindle with turn to soleplate to fix by screw attachment.Front-wheel drive motor and decelerator adopt brush direct current motor and planetary reducer, by toothed belt transmission, drive front-wheel.Front-wheel is magnet-wheel, and structure is shown in Figure 10.Magnet-wheel consists of 1 front-wheel module permanent magnet and 2 yokes.Described permanent magnet adopts the magnetized annular permanent magnet of through-thickness, and permanent magnet can adopt high performance permanent magnetic materials as manufactures such as NdFeB, and yoke adopts mild steel (as Q235 etc.) to manufacture.
Drive a kind of embodiment of steering integrated magnet-wheel to be, roll rotating shaft one end by the sliding supported condition being arranged on car body fixed frame, the other end and turntable lower supporting plate are affixed by thread connection, turntable upper backup pad, turret supports column and turntable lower supporting plate are connected by screw, turntable cover plate and turntable upper backup pad are connected by screw, two taper roll bearings are arranged in two gripper shoes face-to-face, steering spindle is bearing on these two taper roll bearings, steering spindle is connected by flat key with 60 tooth straight-tooth gears, angular transducer power shaft and steering spindle are affixed, angular transducer support bar and turntable upper backup pad are connected by screw, angular transducer and angular transducer support bar are connected by screw, steer motor installing plate and turntable upper backup pad are connected by screw, turn to reducing motor and steer motor installing plate to be connected by screw, 20 tooth straight bevel gears are fixed in and turn on reducing motor output shaft, the 40 tooth straight bevel gears that are meshed are with it connected and are arranged on bevel gear shaft by flat key, bevel gear shaft is supported by the first deep groove ball bearing that is arranged on turntable upper backup pad, the opposite side of bevel gear shaft connects by flat key with 19 tooth straight-tooth gears, 19 tooth straight-tooth gears and the engagement of 60 tooth straight-tooth gears, the lower end of steering spindle with turn to substrate to be connected by screw, wheel left side installing plate, wheel right side installing plate, drive motors installing plate with turn to substrate to be connected by screw, drive reducing motor and drive motors installing plate to be connected by screw, small synchronous pulley axle is affixed with the output shaft of driving reducing motor, small synchronous pulley is connected and is arranged on small synchronous pulley axle by flat key, front-wheel module permanent magnet and wheel yoke are connected and are arranged on axletree by flat key, axletree is bearing between wheel left side installing plate and wheel right side installing plate by the first deep groove ball bearing and the second deep groove ball bearing, large synchronous pulley connects the opposite side that is arranged on axletree by flat key, between large synchronous pulley and small synchronous pulley, by Timing Belt, connected, between tensioning running roller and tensioning running roller support bar, be connected by screw, tensioning running roller support bar is arranged on the installing plate of wheel left side by screw.Magnet-wheel comprises front-wheel module permanent magnet and wheel yoke.
Programmable computer controller, is called for short PCC(programmable computer controller), be a kind of programmable computer controller of new generation.
Devicenet is grow up the mid-90 a kind of based on CAN(Controller Area Network) style of opening of technology, the low cost that meets global industrial standard, high performance communication network, at first by U.S. Rockwell company Application and Development.Devicenet has now become international standard IEC62026-3 < < low voltage switch equipment and control appliance Control Unit Device Interface > >, and be listed in European standard, be also the facility network standard in actual Asia and America.
Shake heating wire TIG welding gun in the application refers to that the welding gun that can realize shake heating wire TIG welding method in prior art all can.
Claims (7)
1. for an autonomous formula shake hot wire TIG welding robot system for large-scale precision equipment welding, comprise robot body, control system and shake hot wire TIG welding welding system, it is characterized in that:
Robot body comprises climbing mechanism (6) and operating mechanism (1): described climbing mechanism (6) comprises the front-wheel module (17), the trailing wheel module (20) that adopts permanent magnetism gap adsorbent equipment that adopt to drive steering integrated magnet-wheel, is connected the vehicle frame (18) of front and back wheel and is arranged on the motor drive controller (19) on vehicle frame (18); Described operating mechanism (1) comprises crosshead shoe and swing mechanism (46), swing mechanism (46) front end clamping shake heating wire TIG welding gun (3), the crosshead shoe that the free degree of horizontal and vertical directions is combined by two lead screw guide rails assembled units is realized, and swing mechanism (46) adopts stepper motor collocation worm type of reduction gearing (28);
Control system comprises sensor-based system, robot body control cabinet (8) and robot master control system (15);
Shake hot wire TIG welding welding system comprises shake heating wire TIG welding gun (3), shake heating wire TIG welding power supply (12), wire-feed motor (11), protection gas (13) and welding cooling system (14);
Robot body, control system and shake hot wire TIG welding welding system three are connected by cable (9);
Described front-wheel module (17) and trailing wheel module (20) are arranged on respectively vehicle frame (18) two ends, in trailing wheel module (20), locate to be provided with chassis (22), are provided with permanent magnet (21) on chassis (22);
Front-wheel module (17), for driving steering integrated magnet-wheel, comprises permanent magnet (21) and wheel (23), and the permanent magnet of front-wheel (21) adopts the magnetized annular permanent magnet of through-thickness; Trailing wheel module (20) adopts permanent magnetism gap suction type, comprise permanent magnetism gap adsorbent equipment and wheel (23), permanent magnetism gap adsorbent equipment comprises around wheel (23) and is arranged on the permanent magnet (21) on chassis (22), permanent magnetism gap adsorbent equipment is arranged on chassis (22) around trailing wheel, between described permanent magnetism gap adsorbent equipment and magnetic conduction wall, be non-contacting, by regulating the distance between chassis (22) and magnetic conduction wall to set the air gap between permanent magnetic adhesion device and magnetic conduction wall;
Described climbing mechanism (6) adopts tricycle structure, and each wheel (23) is driving wheel, relies on the differential of two trailing wheels and the controlled steering angle of front-wheel to realize turning to and rectilinear motion on magnetic conduction wall.
2. a kind of autonomous formula for large-scale precision equipment welding according to claim 1 is shaken hot wire TIG welding's robot system, it is characterized in that: described operating mechanism (1) comprises crosshead shoe transverse axis (41), the crosshead shoe longitudinal axis (42), linking arm (43), weld seam tracking sensor connector (44) and wig-wag connector (45), crosshead shoe transverse axis (41) is to comprise respectively stepper motor and precision ball screw guide rail with the crosshead shoe longitudinal axis (42), weld seam tracking sensor (48) is arranged on the front end of weld seam tracking sensor connector (44), wig-wag connector (45) is arranged on the end of linking arm (43), swing mechanism (46) is arranged on wig-wag connector (45), swing mechanism (46) front end clamping shake heating wire TIG welding gun (3), shake heating wire TIG welding gun (3) clamping attitude-adjusting system.
3. a kind of autonomous formula for large-scale precision equipment welding according to claim 2 is shaken hot wire TIG welding's robot system, it is characterized in that: described sensor-based system comprises laser tracking transducer (4), environmental monitoring sensor and molten bath monitoring sensor (2), operating mechanism (1) and environmental monitoring installation of sensors are on climbing mechanism (6), operating mechanism (1) end is installed laser tracking transducer (4), molten bath monitoring sensor (2) and shake heating wire TIG welding gun (3), robot body control cabinet (8) is arranged on climbing mechanism (6), robot control cabinet is connected by cable with master control system, described welding system shake heating wire TIG welding power supply (12), wire-feed motor (11), protection gas (13) are connected by cable (9) with the welding gun of part on machine.
4. a kind of autonomous formula for large-scale precision equipment welding according to claim 3 is shaken hot wire TIG welding's robot system, it is characterized in that: the working method of described robot control system is: operator utilizes remote control handheld box control to move near starting the arc position, by robot sensing's control system, completed again the adjustment of initial point position, finally by autonomous classification tracking weld seam, realizing weld groove center position follows the tracks of, robot control system adopts PCC or Industrial PC as master control system, the groove central point deviation signal control body that laser Method Seam Tracking Sensing System gathers and operating mechanism motion, the control of shake hot wire TIG welding welding system comprises switching value control, technological parameter setting.
5. a kind of autonomous formula for large-scale precision equipment welding according to claim 3 is shaken hot wire TIG welding's robot system, it is characterized in that: described robot control system adopts multiple degrees of freedom The Cloud Terrace (7) to realize the monitoring of macroscopical welding surroundings, complete the front starting point macrotechnique of weldering; Adopt molten bath monitoring sensor (2) to realize the attitude adjustment of microcosmic shake heating wire TIG welding gun (3), the molten bath monitoring of welding process.
6. a kind of autonomous formula for large-scale precision equipment welding according to claim 5 is shaken hot wire TIG welding's robot system, it is characterized in that: robot system main control system carries out communication by Device net and the source of welding current, by host computer control interface, complete welding parameter setting and welding parameter is adjusted online, control welding and start and stop.
7. a kind of autonomous formula for large-scale precision equipment welding according to claim 1 is shaken hot wire TIG welding's robot system, it is characterized in that: the steering integrated magnet-wheel concrete structure of described driving is: roll rotating shaft one end and be arranged on car body fixed frame, the other end is connected with turntable lower supporting plate, turntable upper backup pad, turret supports column is connected with turntable lower supporting plate, turntable cover plate is connected with turntable upper backup pad, taper roll bearing is arranged in two gripper shoes, steering spindle (31) is bearing on taper roll bearing, steering spindle (31) is connected with 60 tooth straight-tooth gears, angular transducer power shaft and steering spindle (31) are affixed, angular transducer support bar is connected with turntable upper backup pad, angular transducer is connected with angular transducer support bar, steer motor installing plate is connected with turntable upper backup pad, turn to reducing motor to be connected with steer motor installing plate, 20 tooth straight bevel gears (30) are fixed in and turn on reducing motor output shaft, the 40 tooth straight bevel gears (35) that are meshed are with it mounted on bevel gear shaft (34), bevel gear shaft (34) is supported by the first deep groove ball bearing that is arranged on turntable upper backup pad, the opposite side of bevel gear shaft (34) connects by flat key with 19 tooth straight-tooth gears, 19 tooth straight-tooth gears and the engagement of 60 tooth straight-tooth gears, the lower end of steering spindle (31) is connected with turning to substrate, wheel left side installing plate, wheel right side installing plate, drive motors installing plate is connected with turning to substrate, drive reducing motor to be connected with drive motors installing plate, small synchronous pulley axle is affixed with the output shaft of driving reducing motor, small synchronous pulley is connected and is arranged on small synchronous pulley axle by flat key, front-wheel module permanent magnet (21) and wheel yoke (37) are connected and are arranged on axletree by flat key, axletree is bearing between wheel left side installing plate and wheel right side installing plate by the first deep groove ball bearing and the second deep groove ball bearing, large synchronous pulley connects the opposite side that is arranged on axletree by flat key, between large synchronous pulley and small synchronous pulley, by Timing Belt (27), connected, between tensioning running roller and tensioning running roller support bar, be connected by screw, tensioning running roller support bar is arranged on the installing plate of wheel left side by screw, drive between reducing motor and axletree by Timing Belt (27) transmission, steering driving mechanism also comprises steering spindle (31), steering spindle (31) bottom is provided with drive mechanism for wheel and roller, described steering spindle (31) line and wheel axis perpendicular quadrature.
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| CN201210185599.1A CN102689085B (en) | 2012-06-07 | 2012-06-07 | Autonomous mobile dithering hot wire tungsten-inert-gas (TIG) welding robot system for welding large-sized precision equipment |
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Effective date of registration: 20180425 Address after: 610000 18 West core road, hi-tech West District, Chengdu, Sichuan Patentee after: Dongfang Electric Co., Ltd. Address before: 610036 Shu Han Road, Jinniu District, Chengdu, Sichuan Province, No. 333 Patentee before: Dongfang Electric Corporation |