CN102689100A - Autonomous mobile robot system for plasma metal-inert-gas (MIG) composite welding - Google Patents
Autonomous mobile robot system for plasma metal-inert-gas (MIG) composite welding Download PDFInfo
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Abstract
The invention belongs to the technical field of welding of robots, and in particular relates to an autonomous mobile robot system for plasma metal-inert-gas (MIG) composite welding. The system comprises a robot body, a control system and a plasma MIG composite 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 plasma MIG composite welding system comprises a digitized MIG welding power supply, a plasma power supply, a wire feeding machine, shielding gas, a plasma welding gun and an MIG welding gun. The system has the advantages that a plasma MIG composite welding robot can adapt to an all-position welding mode of a large-sized steel structure; due to the adoption of an adsorption type crawling mechanism, the system can flexibly move; and due to the adoption of a laser welding seam tracking sensor and the arrangement of a macro-environment monitoring and molten pool monitoring system, the system can meet swinging requirements, control requirements and movement requirements in the all-position welding process of large thick plates.
Description
Technical field
The invention belongs to the robotic welding technology field, is a kind of autonomous mobile robot system that is used for plasma MIG composite welding specifically.
Background technology
The MIG weldering is meant metal inert gas arc welding; This welding method is to utilize the electric arc that burns between the welding wire sent to continuously and the workpiece to make thermal source; Protect the protective gas of the common usefulness of melting pole gas shielded arc welding that electric arc welds that argon gas is arranged by the gas of welding torch nib ejection; Helium, carbon dioxide gas or these mist.Be called metal inert gas arc welding (being called the MIG weldering in the world) when serving as protection gas with argon gas or helium; The major advantage of melting pole gas shielded arc welding is to carry out the welding of all places easily, and it is very fast also to have speed of welding simultaneously, the deposition rate advantage of higher.
Welding for large scale structure; Plasma MIG composite welding can improve welding efficiency and welding quality; But, need exploitation be used for the robot system that plasma MIG welding connects because the weight and volume of plasma MIG welding rifle after compound no longer is fit to welder's manual operations.Plasma MIG welding connects and is suitable for the large scale structure thick plates, can disposable through welding 25mm, also can reduce the welding sermon when being applied to multi-pass welding and connecing.For large scale structure, this body structure of parts, weight influence are not suitable for rotation or rotate, and existing Special Automaticization welding tractor need be laid track mostly, and the track flexibility is limited in scope, and the laying operation is loaded down with trivial details; On the other hand, the plasma MIG welding of large-scale component connect automation can't application of fixed formula manipulator.
Welding robot system generally is made up of welding load carrier, welding system, control system.Load carrier is divided into fixed industry mechanical arm, rail mounted dolly, autonomous portable mechanism again; Welding system is made up of the source of welding current, welding gun, protection gas, wire feeder etc.; The control system is responsible for motion, tracking, welding Quality control of load carrier etc.That be usually used in the large-scale steel structure welding at present is the rail mounted robot welding system; This system is made up of robot orbit, robot and welding system; Need carry out track laying in advance during use; Be only applicable to lay the straight weld of track, and the flexibility of track within the specific limits, can't adapt to the conversion of weld seam form.
Like 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 ", and its main technical schemes is: a kind of while multiple-bead deposit setting device, and possess: lamination pattern is confirmed portion; It confirms 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 is confirmed portion with welding bead; It is in the lamination pattern of two joints of object; When the difference of the area of section of the deposited metal amount when expression is made up welding bead surpasses predetermined threshold value; The side's that the area of section is big welding bead is confirmed the combination of welding simultaneously after getting rid of with welding bead as individual operation; The all conditions of welding are confirmed portion, and it confirms to comprise each welding bead welding condition of giving corresponding current value of speed and seam formation position with the welding wire of calculating based on the input welding condition; Operation program generation portion, it generates the robot motion programs based on the welding condition of confirming, and is set in the robot controller.The welding robot system of above-mentioned patent adopts rail mounted to arrange; Can't realize soldering joint automatic tracking identification and autonomous locomotive function; And this welding system is fit to the welding of streamline form and is not suitable for large-scale steel structure members is carried out autonomous welding, and the difference of weld seam type is bigger.
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 that is used 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 installed on the robot Mobile Slide; Welder is connected with the welding gun cooling device with welding robot respectively; The robot control cabinet links to each other with welding robot, robot Mobile Slide, welder and intelligent locating tracking means respectively; Be used to control moving and welding of welding robot; The welding robot system of above-mentioned patent adopts the rail mounted robot welding system; Can't realize that robot body follows the tracks of weld seam automatically and move freely and accomplish welding and this robot to injection molding machine frame welding, weld seam type scope is very limited.
Tsing-Hua University has developed the crawler type magnetic and has attached autonomous mobile welding robot, and crawler type absorption travel mechanism absorption reliability is good but steering behaviour is poor, causes robot motion's very flexible, job position adjustment difficulty.The Beijing Institute of Petrochemical Technology has developed the autonomous mobile welding robot of magnetic wheel type, and magnetic wheel type absorption travel mechanism kinematic dexterity is good but adsorption capacity is poor, can't use for the big heavy duty soldering gun of plasma MIG.So problem that existing plasma MIG welding welding robot exists kinematic dexterity and adsorption capacity not to have concurrently.
Summary of the invention
In order to overcome the problem that the existing autonomous mobile robot who is used for plasma MIG composite welding exists kinematic dexterity and adsorption capacity not to have concurrently, now special proposition can satisfy the large-scale steel structure vertical position welding, have flexibility and adsorption capacity concurrently, a kind of autonomous mobile robot system that is used for plasma MIG composite welding of efficient high-quality intelligence welding.
For realizing above-mentioned purpose, technical scheme of the present invention is following:
A kind of autonomous mobile robot system that is used for plasma MIG composite welding comprises robot body, control system and plasma MIG composite welding system, it is characterized in that:
Robot body comprises climbing mechanism and operating mechanism: said climbing mechanism comprises that employing drives the trailing wheel module of the front-wheel module of steering integrated magnet-wheel, employing permanent magnetism gap adsorbent equipment, is connected the vehicle frame of front and back wheel and is installed in the motor drive controller on the vehicle frame; Described operating mechanism comprises crosshead shoe and swing mechanism; The compound welding gun of swing mechanism front end clamping plasma MIG; The free degree of level and vertical both direction is realized that by the crosshead shoe that two lead screw guide rails assembled units combine swing mechanism adopts stepper motor collocation worm type of reduction gearing;
Said control system comprises sensor-based system, robot body control cabinet and robot master control system;
Said plasma MIG composite welding system comprises the digitlization MIG source of welding current, plasma power supply, wire-feed motor, protection gas, plasma gun and MIG welding gun;
Annexation between MIG welding gun, plasma gun, the MIG source of welding current, plasma power supply and the plasma MIG composite welding system and the annexation of welding gun, the source of welding current and the welding system of other welding systems exist obviously different, but above-mentioned difference and specifically how connecting is that then those skilled in the art knew.
Robot body, control system and the plasma MIG composite welding three of system are connected through cable.
Said front-wheel module and trailing wheel module are installed in the vehicle frame two ends respectively, and the place is provided with the trailing wheel chassis in the trailing wheel module, and the trailing wheel chassis is provided with permanent magnet;
The front-wheel module comprises permanent magnet and wheel for driving steering integrated magnet-wheel, and the permanent magnet of front-wheel adopts along the magnetized annular permanent magnet of thickness direction; The trailing wheel module adopts permanent magnetism gap suction type; Comprise permanent magnetism gap adsorbent equipment and wheel; Permanent magnetism gap adsorbent equipment comprises around wheel and is installed in the permanent magnet on the trailing wheel chassis; Permanent magnetism gap adsorbent equipment is installed on the chassis around trailing wheel, is noncontact between said permanent magnetism gap adsorbent equipment and magnetic conduction wall, sets the air gap between permanent magnetic adhesion device and magnetic conduction wall through the distance of regulating between chassis and the magnetic conduction wall;
Said 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 be implemented in turning to and rectilinear motion on the magnetic conduction wall.
Described operating mechanism comprises crosshead shoe transverse axis, the crosshead shoe longitudinal axis, linking arm, weld seam tracking sensor connector, welding gun connector; The crosshead shoe transverse axis and the crosshead shoe longitudinal axis are to be made up of stepper motor and precision ball screw guide rail respectively; Weld seam tracking sensor is installed in the front end of weld joint tracking connector, and the welding gun connector is installed in the end of linking arm.
Said sensor-based system comprises Laser Tracking sensor, environmental monitoring sensor and molten bath monitoring sensor; Operating mechanism and environmental monitoring sensor are installed on the climbing mechanism; Terminal Laser Tracking sensor, molten bath monitoring sensor and the compound welding gun of plasma MIG installed of operating mechanism; The robot body control cabinet is installed on the climbing mechanism; The robot body control cabinet links to each other through cable with the robot master control system, and the source of welding current, wire-feed motor, protection gas link to each other through cable with the compound welding gun of plasma MIG.
The working method of described robot control system is: the operator utilizes remote control hand behaviour box control robot to move near the starting the arc position; Accomplish the adjustment of initial point position again by robot sensing's control system; Follow the tracks of weld seam by autonomous classification at last and realize the tracking of weld groove center position; Robot control system adopts PCC or other Industrial PC as master control system, groove central point deviation signal control robot body that the Laser Tracking sensor-based system is gathered and operating mechanism motion; The control of plasma MIG composite welding system comprises switching value control, technological parameter setting, plasma arc and the starting the arc of MIG arc and receives arc coordination control.
Described robot control system adopts the multiple degrees of freedom The Cloud Terrace to realize the monitoring of macroscopical welding surroundings, accomplishes the preceding starting point macrotechnique of weldering; Adopt the molten bath monitoring sensor to realize the attitude adjustment of microcosmic plasma gun and MIG rifle, the molten bath monitoring of welding process, The Cloud Terrace belongs to sensor-based system.
Plasma gun and MIG rifle are arranged along the weld groove direction; Plasma gun is in the place ahead of welding traffic direction; The MIG rifle is at the plasma gun rear; The compound welding gun of plasma MIG is that plasma gun head and MIG rifle head are integrated on the welding gun, and plasma MIG composite welding robot control system utilizes X20DI9371 input module, X20DO9322 output module to be connected with plasma welding power supply, the MIG source of welding current; MIG source of welding current external interface is a relay, and after relay closes, the MIG source of welding current begins welding, and after relay broke off, the MIG source of welding current stopped welding; In the welding process, control, it is characterized in that in the starting the arc process, start plasma welding machine earlier, behind the 2S, restart the MIG source of welding current at interval, and open the robot feed motion according to set logical sequence; Receive in the arc process, plasma is welded power supply, the MIG source of welding current, robot close simultaneously.
Described plasma MIG composite welding system, the robot system main control system carries out communication through the RS485 and the MIG source of welding current, accomplishes welding parameter setting and the online adjustment of welding parameter through the host computer control interface, and welding starts and stops.
The steering integrated magnet-wheel concrete structure of said driving is: inclination rotating shaft one end is installed on the car body fixed frame, and other end turntable lower supporting plate connects, and turntable upper backup pad, turret supports column and turntable lower supporting plate are connected; The turntable cover plate is connected with the turntable upper backup pad, and taper roll bearing is installed on two gripper shoes, and steering spindle is bearing on the taper roll bearing; Steering spindle is connected with 60 tooth straight-tooth gears, and angular transducer power shaft and steering spindle are affixed, and the angular transducer support bar is connected with the turntable upper backup pad; Angular transducer is connected with the angular transducer support bar, and the steer motor installing plate is connected with the turntable upper backup pad, turns to reducing motor to be connected with the steer motor installing plate; 20 tooth straight bevel gears are fixed in and turn on the reducing motor output shaft; The 40 tooth straight bevel gears that are meshed with it are mounted on the bevel gear shaft, and bevel gear shaft is by first deep groove ball bearing supporting that is installed in the turntable upper backup pad, and the opposite side of bevel gear shaft connects through 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, and wheel left side installing plate, wheel right side installing plate, drive motors installing plate are connected with turning to substrate, drive reducing motor and are connected with the drive motors installing plate; The small synchronous pulley axle is affixed with the output shaft that drives reducing motor; Small synchronous pulley is installed on the small synchronous pulley axle through the flat key connection, and wheel permanent-magnet body and wheel yoke are installed on the axletree through the flat key connection, and axletree is bearing between wheel left side installing plate and the wheel right side installing plate through first deep groove ball bearing and second deep groove ball bearing; Big synchronous pulley connects the opposite side that is installed in axletree through flat key; Connected by synchronous band between big synchronous pulley and the small synchronous pulley, be connected through screw between tensioning running roller and the tensioning running roller support bar, tensioning running roller support bar is installed on the left of the wheel on the installing plate through screw; Drive between reducing motor and the axletree through band transmission synchronously; Turn to driving mechanism also to comprise steering spindle, the steering spindle bottom is equipped with wheel drive mechanism and roller, said steer axis and wheel axis perpendicular quadrature.
The invention has the advantages that:
1, climbing mechanism of the present invention adopts complex method and the full driving of three-wheel or the wheeled move mode of differential driving of absorption of contact magnet-wheel and non-contact gap absorption; Robot can move, reliably adsorb and implement the vertical position welding operation in full position, manipulating object surface independent and flexible, and overall system performance is good.
2, the present invention adopts the control mode of " macroscopical remote control, microcosmic autonomous ", but weld seam is followed the tracks of in autonomous classification, possesses the remote welding parameter and is provided with and online adjustment function; Adopt the multiple degrees of freedom The Cloud Terrace to realize the workpiece environmental monitoring, accomplish the preceding starting point macrotechnique of weldering; Adopt the molten bath monitoring sensor to realize the attitude adjustment of microcosmic plasma gun and MIG rifle, the molten bath monitoring of welding process.Possess macroscopical welding surroundings monitoring function, realized intelligent welding.
3, plasma MIG composite welding robot can adapt to all position welding seam form of large-scale steel structure; Adopt the absorption type climbing mechanism; Motion flexibly; Adopt the laser welded seam tracking transducer, possess macro environment monitoring and molten bath monitoring system, can satisfy when big slab all-position welding that swing requires, control requires and the motion requirement.
4, the method for plasma and MIG composite welding is the complex function that has two kinds of welding procedures with a kind of welding gun, can easily realize two kinds of welding manners.
5, operation of the present invention and swing mechanism are applicable to the creeping-type welding robot; Crosshead shoe by operating mechanism provides Y axle and two frees degree of Z axle, is that the welding gun of leading portion clamping provides a rotary freedom around the X axle to realize the swing function by swing mechanism.Crosshead shoe adopts the high precision ball lead screw guide rails to cooperate the stepper motor combination to form, and positioning accuracy can reach 0.02mm, follows the tracks of the craft precision requirement of weld seam to guarantee welding gun.Swing mechanism is that welding gun provides rotary freedom by worm and gear collocation stepper motor, and output torque is not less than 10Nm, and can make welding gun is that the swing welding is realized at the center with any swing angle.
But 6, the linking arm arm of operating mechanism of the present invention exhibition manual adjustments, maximum arm exhibition can reach 450mm.The clamping device clip position of weld seam tracking sensor can manual adjustments; X axle adjustable extent 120mm; Y axle maximum adjustable scope 350mm; Z axle adjustable extent 100mm, bigger adjustable space scope guarantees that weld seam tracking sensor position under the multiple welding procedure can adapt to the various attitude demands of welding gun.
7, pass through band transmission synchronously between driving reducing motor and the axletree, can obtain bigger installing space through regulating transmission centre-to-centre spacing, thus the more powerful driving reducing motor raising of installation driving moment.
8, be provided with and independently turn to the free degree and make steer axis and the wheel axis perpendicular quadrature, can realize the independent steering of wheel, improve the climbing robot kinematic dexterity.
9, be provided with passive banking degree of freedom and through inclination confinement block constrained side tilt angle positive and negative 10 the degree in, make climbing robot have curved surface adaptive capacity preferably.
10, the inclination confinement block is realized the function of constrained side degree of tilt through mechanical position limitation.
11, said steering structure and wheel rolling all are provided with independent driving mechanisms.
12, the advantage that combines with the plasma MIG welding rifle of autonomous mobile robot is that whole welding robot system can realize that plasma MIG welding connect in autonomous moving, and speed of welding is fast, is 2-3 times that traditional MIG/MAG welds; Compare with conventional MIG/MAG, fusion penetration is bigger; Lower because of the sweating heat input, the heat affected area is narrower, is difficult for causing the parts distortion; Spatter significantly reduces; Welding quality is good; Plasma power supply and traditional MIG power supply organic assembling, united and coordinating control makes plasma-MIG composite heat power supply solder technology become the upgrading of traditional MIG/MAG.
Description of drawings
Fig. 1 is a structure chart of the present invention.
Fig. 2 is robot body figure of the present invention.
Fig. 3 is a climbing mechanism structural representation of the present invention.
Fig. 4 is a climbing mechanism trailing wheel module diagram of the present invention.
Fig. 5 is an operating mechanism sketch map of the present invention.
Fig. 6 is a sequential chart of the present invention.
Fig. 7 is a permanent magnetism gap adsorbent equipment structural representation.
Fig. 8 is for driving steering integrated magnet-wheel structural representation.
Fig. 9 crosses the cutaway view of steering spindle and bevel gear shaft for front-wheel.
Figure 10 is the magnet-wheel cutaway view.
1 operating mechanism in the accompanying drawing, 2 molten bath monitoring sensors, the compound welding gun of 3 plasma MIG, 4 Laser Tracking sensors; 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, the 12MIG source of welding current; 13 protection gas, 14 plasmas welding power supply, 15 robot master control systems, 16 straighforward 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 are with synchronously, 28 decelerators, and 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
A kind of autonomous mobile robot system that is used for plasma MIG composite welding comprises robot body, control system and plasma MIG composite welding system, and robot body comprises climbing mechanism and operating mechanism: said climbing mechanism comprises that employing drives the trailing wheel module of the front-wheel module of steering integrated magnet-wheel, employing permanent magnetism gap adsorbent equipment, is connected the vehicle frame of front and back wheel and is installed in the motor drive controller on the vehicle frame; Described operating mechanism comprises crosshead shoe and swing mechanism; The compound welding gun of swing mechanism front end clamping plasma MIG; The free degree of level and vertical both direction is realized that by the crosshead shoe that two lead screw guide rails assembled units combine swing mechanism adopts stepper motor collocation worm type of reduction gearing; The control system comprises sensor-based system, robot body control cabinet and robot master control system; Plasma MIG composite welding system comprises the digitlization MIG source of welding current, plasma power supply, wire-feed motor, protection gas, the compound welding gun of plasma MIG; Robot body, control system and the plasma MIG composite welding three of system are connected through cable.
Front-wheel module and trailing wheel module are installed in the vehicle frame two ends respectively, and the place is provided with the trailing wheel chassis in the trailing wheel module, and the trailing wheel chassis is provided with permanent magnet; The front-wheel module comprises permanent magnet and wheel for driving steering integrated magnet-wheel, and the permanent magnet of front-wheel adopts along the magnetized annular permanent magnet of thickness direction; The trailing wheel module adopts permanent magnetism gap suction type; Comprise permanent magnetism gap adsorbent equipment and wheel; Permanent magnetism gap adsorbent equipment comprises around wheel and is installed in the permanent magnet on the trailing wheel chassis; Permanent magnetism gap adsorbent equipment is installed on the chassis around trailing wheel, is noncontact between said permanent magnetism gap adsorbent equipment and magnetic conduction wall, sets the air gap between permanent magnetic adhesion device and magnetic conduction wall through the distance of regulating between chassis and the magnetic conduction wall; 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 be implemented in turning to and rectilinear motion on the magnetic conduction wall.
Operating mechanism comprises crosshead shoe transverse axis, the crosshead shoe longitudinal axis, linking arm, weld seam tracking sensor connector, welding gun connector; The crosshead shoe transverse axis and the crosshead shoe longitudinal axis are to be made up of stepper motor and precision ball screw guide rail respectively; Weld seam tracking sensor is installed in the front end of weld joint tracking connector, and welding gun connector 57 is installed in the end of linking arm.
Sensor-based system comprises Laser Tracking sensor, environmental monitoring sensor and molten bath monitoring sensor; Operating mechanism and environmental monitoring sensor are installed on the climbing mechanism; Terminal Laser Tracking sensor, molten bath monitoring sensor and the compound welding gun of plasma MIG installed of operating mechanism; The robot body control cabinet is installed on the climbing mechanism; The robot body control cabinet links to each other through cable with the robot master control system, and the source of welding current, wire-feed motor, protection gas link to each other through cable with the compound welding gun of plasma MIG.
The working method of robot control system is: the operator utilizes remote control hand behaviour box control robot to move near the starting the arc position; Accomplish the adjustment of initial point position again by robot sensing's control system; Follow the tracks of weld seam by autonomous classification at last and realize the tracking of weld groove center position; Robot control system adopts PCC or other Industrial PC as master control system, groove central point deviation signal control robot body that the Laser Tracking sensor-based system is gathered and operating mechanism motion; The control of plasma MIG composite welding system comprises switching value control, technological parameter setting, plasma arc and the starting the arc of MIG arc and receives arc coordination control.
Robot control system adopts the multiple degrees of freedom The Cloud Terrace to realize the monitoring of macroscopical welding surroundings, accomplishes the preceding starting point macrotechnique of weldering; Adopt the molten bath monitoring sensor to realize the attitude adjustment of microcosmic plasma gun and MIG rifle, the molten bath monitoring of welding process, The Cloud Terrace belongs to sensor-based system.
Plasma gun and MIG rifle are arranged along the weld groove direction; Plasma gun is in the place ahead of welding traffic direction; The MIG rifle is at the plasma gun rear; The compound welding gun of plasma MIG is that plasma gun head and MIG rifle head are integrated on the welding gun, and plasma MIG composite welding robot control system utilizes X20DI9371 input module, X20DO9322 output module to be connected with plasma welding power supply, the MIG source of welding current; MIG source of welding current external interface is a relay, and after relay closes, the MIG source of welding current begins welding, and after relay broke off, the MIG source of welding current stopped welding; In the welding process, control, it is characterized in that in the starting the arc process, start plasma welding machine earlier, behind the 2S, restart the MIG source of welding current at interval, and open the robot feed motion according to set logical sequence; Receive in the arc process, plasma is welded power supply, the MIG source of welding current, robot close simultaneously.
Plasma MIG composite welding system, the robot system main control system carries out communication through the RS485 and the MIG source of welding current, accomplishes welding parameter setting and the online adjustment of welding parameter through the host computer control interface, and welding starts and stops.
As shown in Figure 1, the autonomous mobile robot system of plasma MIG composite welding is made up of robot body, control system, plasma MIG composite welding system.Robot body comprises operating mechanism and climbing mechanism; The control system comprises that (multiple degrees of freedom The Cloud Terrace, Laser Tracking sensor and molten bath monitoring sensor, robot body control cabinet and robot master control system, plasma MIG composite welding system comprises plasma power supply, the MIG source of welding current, wire-feed motor, protection gas to sensor-based system.
Robot system can be divided into walking from the space on " machine top " on the operation workpiece be installed on " the machine lower part " outside the operation workpiece.Machine top comprises robot body (operating mechanism, climbing mechanism), robot body control cabinet, sensor-based system, welding gun, and sensor-based system mainly is made up of Laser Tracking sensor, environmental monitoring sensor and molten bath monitoring sensor.Operating mechanism and environmental monitoring sensor are installed on the climbing mechanism, terminal Laser Tracking sensor, molten bath monitoring sensor and the welding gun installed of operating mechanism, and the robot body control cabinet is installed on the climbing mechanism.Robot system machine lower part comprises main control system, straighforward operation, the source of welding current, wire-feed motor, protection gas.The robot control cabinet on machine top links to each other through cable with the main control system of machine lower part, and the source of welding current, wire-feed motor, protection gas link to each other through cable with the welding gun on machine top.Cable comprises fulgurite, tracheae and holding wire.The operating mechanism end has oscillator of welding gun, compound welding gun clamping of plasma MIG and attitude-adjusting system.
Machine top: comprise robot body (operating mechanism, climbing mechanism), robot body control cabinet, sensor-based system (multiple degrees of freedom The Cloud Terrace, Laser Tracking sensor and molten bath monitoring sensor), welding gun.Operating mechanism and multiple degrees of freedom The Cloud Terrace are installed on the climbing mechanism, terminal Laser Tracking sensor, molten bath monitoring sensor, the welding gun installed of operating mechanism, and the robot body control cabinet is installed on the climbing mechanism.Wherein climbing mechanism be installed in operating mechanism on the climbing mechanism and close and be called robot body.
Machine lower part: comprise robot master control system, straighforward operation box, the MIG source of welding current, plasma welding power supply, wire-feed motor, protection gas.The robot body control cabinet on machine top links to each other through cable with the robot master control system of machine lower part, and the MIG source of welding current, plasma welding power supply, wire-feed motor, protection gas link to each other through cable with the welding gun on machine top.Cable comprises fulgurite, water pipe, tracheae and holding wire.
As shown in Figure 2, robot body comprises climbing mechanism and operating mechanism.
Like Fig. 3 and shown in Figure 4, climbing mechanism comprises the vehicle frame that adopts the front-wheel module that drives steering integrated magnet-wheel, the trailing wheel module that adopts permanent magnetism gap adsorbent equipment, connection front and back wheel and is installed in the motor drive controller on the vehicle frame.Wherein, mild steel (like Q235) manufacturing is adopted on the trailing wheel chassis, except that as the function that supports the back wheel construction, also as yoke be installed in the part that permanent magnet on the trailing wheel chassis constitutes magnetic circuit around wheel.Connect two stage reducer behind the motor and drive wheel, the first order is a planetary reducer, and the second level is the turbine and worm decelerator, and the turbine and worm decelerator is mounted on the trailing wheel chassis through screw.Magnet-wheel is made up of 1 permanent magnet and 2 yokes.Said permanent magnet adopts along the magnetized annular permanent magnet of thickness direction, and permanent magnet can adopt manufacturings such as high performance permanent magnetic materials such as NdFeB, and yoke adopts mild steel (like Q235 etc.) to make.
As shown in Figure 5, operating mechanism mainly is made up of crosshead shoe transverse axis, the crosshead shoe longitudinal axis, linking arm, weld seam tracking sensor connector, wig-wag connector.The crosshead shoe transverse axis and the crosshead shoe longitudinal axis are to be made up of stepper motor and precision ball screw guide rail respectively.Transverse axis is installed on the mobile platform through support, and the longitudinal axis is installed on the transverse axis slide block.Transverse axis provides the Y axle free degree, working range 90mm; The longitudinal axis provides the Z axle free degree, working range 75mm.Crosshead shoe single shaft positioning accuracy 0.02mm.Linking arm is installed on the longitudinal axis slide block through fixture block, the maximum arm exhibition of linking arm 450mm, and can carry out manual adjustments through regulating the fixture block clip position.The weld seam tracking sensor connector is clamped on the linking arm, and the clip position of manual adjustments connector can provide the position range of 350mm for weld seam tracking sensor.Weld seam tracking sensor is installed in the front end of connector, launches laser beam and scans weld seam to weld seam during work, instructs the action of crosshead shoe and mobile platform.The wig-wag connector is installed in the end of linking arm, and the height of connector can manual adjustments, and the adjusting range of the axial 80mm of Z is provided for swing mechanism.Swing mechanism is installed on the connector, front end clamping welding gun.
Shown in Figure 6 is the robot control system sequential chart.The 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 sensor and the motion of operating mechanism; Utilize actions such as switching value control welding starts, stops; Possessing the remote welding parameter is provided with and online adjustment function; Tool adopts the multiple degrees of freedom The Cloud Terrace to realize the monitoring of macroscopical welding surroundings, adopts the molten bath monitoring sensor to realize the monitoring of microcosmic welding pool; During operation, start plasma welding power supply earlier, behind the 2S, restart the MIG source of welding current at interval, and open the robot feed motion; Receive in the arc process, plasma is welded power supply, the MIG source of welding current, robot system close simultaneously.
Plasma gun and MIG rifle are arranged along the weld groove direction; Plasma gun is in the place ahead of welding traffic direction; The MIG rifle is at the plasma gun rear, and plasma MIG composite welding robot control system utilizes X20DI9371 input module, X20DO9322 output module to be connected with plasma welding power supply, the MIG source of welding current; MIG source of welding current external interface is a relay, and after relay closes, the MIG source of welding current begins welding, and after relay broke off, the MIG source of welding current stopped welding.In the welding process, control, it is characterized in that in the starting the arc process, start plasma welding machine earlier, behind the 2S, restart the MIG source of welding current at interval, and open the robot feed motion according to set logical sequence; Receive in the arc process, plasma is welded power supply, the MIG source of welding current, robot close simultaneously, the control sequential is as shown in Figure 5.
Permanent magnetism gap adsorbent equipment is as shown in Figure 7; Nd-Fe-B permanent magnet by 12 thickness directions magnetize is formed; Each trailing wheel is respectively arranged 6 permanent magnets, and the N utmost point and the S utmost point formation magnetic circuit that is staggered is installed on the chassis around trailing wheel; Between said permanent magnetism gap adsorbent equipment and magnetic conduction wall is noncontact, sets the air gap between said permanent magnetic adhesion device and magnetic conduction wall through the distance of regulating between chassis and the 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 the bevel gear shaft rotation through 20 tooth straight bevel gears and 40 tooth Straight Bevel Gear Drive; Bevel gear shaft drives the steering spindle rotation through 19 tooth roller gears and 60 tooth column gear transmission again, steering spindle with turn to soleplate to fix through screw attachment.Front-wheel drive motor and decelerator adopt brush direct current motor and planetary reducer, drive front-wheel through synchronous band transmission.Front-wheel is a magnet-wheel, and structure is seen Fig. 9.Magnet-wheel is made up of 1 front-wheel module permanent magnet and 2 yokes.Said permanent magnet adopts along the magnetized annular permanent magnet of thickness direction, and permanent magnet can adopt manufacturings such as high performance permanent magnetic materials such as NdFeB, and yoke adopts mild steel (like Q235 etc.) to make.
A kind of embodiment that drives steering integrated magnet-wheel does, inclination rotating shaft one end is by the sliding supported condition that is installed on the car body fixed frame, and the other end and turntable lower supporting plate are affixed through thread connection; Turntable upper backup pad, turret supports column and turntable lower supporting plate are connected through screw; The turntable cover plate is connected through screw with the turntable upper backup pad, and two taper roll bearings are installed on two gripper shoes face-to-face, and steering spindle is bearing on these two taper roll bearings; Steering spindle is connected through flat key with 60 tooth straight-tooth gears; Angular transducer power shaft and steering spindle are affixed, and the angular transducer support bar is connected through screw with the turntable upper backup pad, and angular transducer is connected through screw with the angular transducer support bar; The steer motor installing plate is connected through screw with the turntable upper backup pad; Turn to reducing motor to be connected through screw with the steer motor installing plate, 20 tooth straight bevel gears are fixed in and turn on the reducing motor output shaft, and the 40 tooth straight bevel gears that are meshed with it are installed on the bevel gear shaft through the flat key connection; Bevel gear shaft is by first deep groove ball bearing supporting that is installed in the turntable upper backup pad; The opposite side of bevel gear shaft connects through flat key with 19 tooth straight-tooth gears, the engagement of 19 tooth straight-tooth gears and 60 tooth straight-tooth gears, the lower end of steering spindle with turn to substrate to pass through screw to be connected; Wheel left side installing plate, wheel right side installing plate, drive motors installing plate and turn to substrate to pass through screw to be connected; Drive reducing motor and be connected through screw with the drive motors installing plate, the small synchronous pulley axle is affixed with the output shaft that drives reducing motor, and small synchronous pulley is installed on the small synchronous pulley axle through the flat key connection; Wheel permanent-magnet body and wheel yoke are installed on the axletree through the flat key connection; Axletree is bearing between wheel left side installing plate and the wheel right side installing plate through first deep groove ball bearing and second deep groove ball bearing, and big synchronous pulley connects the opposite side that is installed in axletree through flat key, is connected by synchronous band between big synchronous pulley and the small synchronous pulley; Be connected through screw between tensioning running roller and the tensioning running roller support bar, tensioning running roller support bar is installed on the installing plate of wheel left side through screw.Magnet-wheel comprises front-wheel module permanent magnet and wheel yoke.
Plasma MIG composite welding of the present invention system, compound welding gun is formed by the digitlization MIG source of welding current, plasma power supply, wire-feed motor, protection gas, plasma MIG.The robot system main control system carries out communication through the RS485 and the MIG source of welding current, accomplishes welding parameter setting and the online adjustment of welding parameter through the host computer control interface, and welding starts and stops.
Preparation before at first welding.The layout of checking each system be connected, particularly robot body is adsorbed on the workpiece, the car body fore-and-aft direction is parallel to weld seam and guarantees that welding gun aims at weld seam basically.Through supervisory control comuter each executing agency, sensor etc. are checked.
Secondly, carry out the manual work setting of init state.Through regulating welding gun clamping and attitude-adjusting system manual adjustment welding gun height and posture of welding torch to proper state.Utilize supervisory control comuter, the video information of environmental monitoring video camera is carried out the observation of position while welding, state, move climbing mechanism and crosshead shoe, carry out artificial centering through hand behaviour box.Then, carry out the setting of welding parameter, on supervisory control comuter or hand behaviour box, carry out the setting of weldingvoltage, welding current, wire feed rate, wig-wag wobbling action and climbing mechanism pace.
At last, start welding, carry out the monitoring in molten bath through the molten bath rig camera through hand behaviour box.In welding process, Laser Tracking sensor in real time feedback weld seam scanning information also instructs climbing mechanism fine setting direction of advance, two axial motions of guiding operation mechanism fine setting with this, with this guarantee welding gun when the welding all the time exactly along the seam track feeding.After welding is accomplished, finish welding procedure through hand behaviour box.
The magnetic conduction wall is meant the workpiece face, and workpiece is meant welding object, and on workpiece, moves simultaneously.
The described plasma MIG of the application meets that welding gun is known for those skilled in the art, as to can be used for plasma MIG composite welding system welding gun, is different from the welding gun of other types.
Claims (9)
1. an autonomous mobile robot system that is used for plasma MIG composite welding comprises robot body, control system and plasma MIG composite welding system, it is characterized in that:
Robot body comprises climbing mechanism (6) and operating mechanism (1): said climbing mechanism (6) comprises that employing drives the trailing wheel module (20) of the front-wheel module (17) of steering integrated magnet-wheel, employing permanent magnetism gap adsorbent equipment, is connected the vehicle frame (18) of front and back wheel and is installed in the motor drive controller (19) on the vehicle frame (18); Described operating mechanism (1) comprises crosshead shoe and swing mechanism (46); Swing mechanism (46) the front end clamping compound welding gun of plasma MIG (3); The free degree of level and vertical both direction is realized that by the crosshead shoe that two lead screw guide rails assembled units combine swing mechanism (46) adopts stepper motor collocation worm type of reduction gearing (28);
The control system comprises sensor-based system, robot body control cabinet (8) and robot master control system (15);
Said plasma MIG composite welding system comprises the digitlization MIG source of welding current (3), plasma power supply (12), wire-feed motor (11), protection gas (13), plasma gun and MIG welding gun (14);
Robot body, control system and the plasma MIG composite welding three of system are connected through cable (9).
2. a kind of autonomous mobile robot system that is used for plasma MIG composite welding according to claim 1; It is characterized in that: said front-wheel module (17) and trailing wheel module (20) are installed in vehicle frame (18) two ends respectively; Locate to be provided with trailing wheel chassis (22) in trailing wheel module (20), trailing wheel chassis (22) are provided with permanent magnet (21);
Front-wheel module (17) comprises permanent magnet (21) and wheel (23) for driving steering integrated magnet-wheel, and the permanent magnet of front-wheel (21) adopts along the magnetized annular permanent magnet of thickness direction (21); 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 installed in the permanent magnet (21) on the trailing wheel chassis (22); Permanent magnetism gap adsorbent equipment is installed on the chassis (22) around trailing wheel, is noncontact between said permanent magnetism gap adsorbent equipment and magnetic conduction wall, sets the air gap between permanent magnetic adhesion device and magnetic conduction wall through the distance of regulating between chassis (22) and the magnetic conduction wall;
Said 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 be implemented in turning to and rectilinear motion on the magnetic conduction wall.
3. a kind of autonomous mobile robot system that is used for plasma MIG composite welding according to claim 2; 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 (48) connector (44) and wig-wag connector (45); Crosshead shoe transverse axis (41) is to comprise stepper motor and precision ball screw guide rail respectively with the crosshead shoe longitudinal axis (42); Weld seam tracking sensor (48) is installed in the front end of connector; Wig-wag connector (45) is installed in the end of linking arm (43); Swing mechanism (46) is installed on the wig-wag connector (45), swing mechanism (46) the front end clamping compound welding gun of plasma MIG (3), compound weldering welding gun (3) clamping of plasma MIG and attitude-adjusting system.
4. a kind of autonomous mobile robot system that is used for plasma MIG composite welding according to claim 3; It is characterized in that: said sensor-based system comprises Laser Tracking sensor (4), environmental monitoring sensor and molten bath monitoring sensor (2); Operating mechanism (1) and environmental monitoring sensor are installed on the climbing mechanism (6); Terminal Laser Tracking sensor (4), molten bath monitoring sensor (2) and the compound welding gun of plasma MIG (3) installed of operating mechanism (1); Robot body control cabinet (8) is installed on the climbing mechanism (6); The robot body control cabinet links to each other through cable with the robot master control system, and the source of welding current (12), wire-feed motor (11), protection gas (13) link to each other through cable (9) with the compound welding gun of plasma MIG (3).
5. a kind of autonomous mobile robot system that is used for plasma MIG composite welding according to claim 4; It is characterized in that: the working method of described robot control system is: the operator utilizes remote control hand behaviour box control robot to move near the starting the arc position; Accomplish the adjustment of initial point position again by robot sensing's control system; Follow the tracks of weld seam by autonomous classification at last and realize the tracking of weld groove center position; Robot control system adopts PCC or other Industrial PC as master control system, groove central point deviation signal control robot body that the Laser Tracking sensor-based system is gathered and operating mechanism motion; The control of plasma MIG composite welding system comprises switching value control, technological parameter setting, plasma arc and the starting the arc of MIG arc and receives arc coordination control.
6. a kind of autonomous mobile robot system that is used for plasma MIG composite welding according to claim 4; 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, accomplishes the preceding starting point macrotechnique of weldering; Adopt molten bath monitoring sensor (2) to realize the attitude adjustment of microcosmic plasma gun and MIG rifle, the molten bath monitoring of welding process, The Cloud Terrace belongs to sensor-based system.
7. a kind of autonomous mobile robot system that is used for plasma MIG composite welding according to claim 5; It is characterized in that: plasma gun and MIG rifle are arranged along the weld groove direction; Plasma gun is in the place ahead of welding traffic direction; The MIG rifle is at the plasma gun rear; The compound welding gun of plasma MIG is that plasma gun head and MIG rifle head are integrated on the welding gun, and plasma MIG composite welding robot control system utilizes X20DI9371 input module, X20DO9322 output module to be connected with plasma welding power supply, the MIG source of welding current; MIG source of welding current external interface is a relay, and after relay closes, the MIG source of welding current begins welding, and after relay broke off, the MIG source of welding current stopped welding; In the welding process, control, it is characterized in that in the starting the arc process, start plasma welding machine earlier, behind the 2S, restart the MIG source of welding current at interval, and open the robot feed motion according to set logical sequence; Receive in the arc process, plasma is welded power supply, the MIG source of welding current, robot close simultaneously.
8. a kind of autonomous mobile robot system that is used for plasma MIG composite welding according to claim 6; It is characterized in that: described plasma MIG composite welding system; The robot system main control system carries out communication through the RS485 and the MIG source of welding current; Accomplish welding parameter setting and the online adjustment of welding parameter through the host computer control interface, welding starts and stops.
9. a kind of autonomous mobile robot system that is used for plasma MIG composite welding according to claim 2 is characterized in that: the steering integrated magnet-wheel concrete structure of said driving is: inclination rotating shaft one end is installed on the car body fixed frame, and other end turntable lower supporting plate connects; Turntable upper backup pad, turret supports column and turntable lower supporting plate are connected; The turntable cover plate is connected with the turntable upper backup pad, and taper roll bearing is installed on two gripper shoes, and steering spindle (31) is bearing on the taper roll bearing; Steering spindle (31) is connected with 60 tooth straight-tooth gears; Angular transducer power shaft and steering spindle (31) are affixed, and the angular transducer support bar is connected with the turntable upper backup pad, and angular transducer is connected with the angular transducer support bar; The steer motor installing plate is connected with the turntable upper backup pad; Turn to reducing motor (26) to be connected with the steer motor installing plate, 20 tooth straight bevel gears (30) are fixed in and turn on reducing motor (26) output shaft, and the 40 tooth straight bevel gears (35) that are meshed with it are mounted on the bevel gear shaft (34); Bevel gear shaft (34) is by first deep groove ball bearing supporting that is installed in the turntable upper backup pad; The opposite side of bevel gear shaft (34) connects through flat key with 19 tooth straight-tooth gears, 19 tooth straight-tooth gears and the engagement of 60 tooth straight-tooth gears, and 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 are connected with turning to substrate; Drive reducing motor (26) and be connected with the drive motors installing plate, little synchronous band (27) wheel shaft is affixed with the output shaft that drives reducing motor (26), and little synchronous band (27) wheel is installed on little synchronous band (27) wheel shaft through the flat key connection; Front-wheel module permanent magnet (21) and wheel yoke (37) are installed on the axletree through the flat key connection; Axletree is bearing between wheel left side installing plate and the wheel right side installing plate through first deep groove ball bearing and second deep groove ball bearing, and the big wheel of band (27) synchronously connects the opposite side that is installed in axletree through flat key, is connected by synchronous band (27) between big wheel of band (27) synchronously and little synchronous band (27) wheel; Be connected through screw between tensioning running roller and the tensioning running roller support bar; Tensioning running roller support bar is installed on the installing plate of wheel left side through screw, drives and passes through band (27) transmission synchronously between reducing motor (26) and the axletree, turns to driving mechanism also to comprise steering spindle (31); Steering spindle (31) bottom is equipped with wheel drive mechanism and roller, said steering spindle (31) line and wheel axis perpendicular quadrature.
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