CN105057964A - Control system and control method for welding non-perfect-circle tank body - Google Patents
Control system and control method for welding non-perfect-circle tank body Download PDFInfo
- Publication number
- CN105057964A CN105057964A CN201510546903.4A CN201510546903A CN105057964A CN 105057964 A CN105057964 A CN 105057964A CN 201510546903 A CN201510546903 A CN 201510546903A CN 105057964 A CN105057964 A CN 105057964A
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- China
- Prior art keywords
- tank body
- welding
- control system
- tank
- bonding wire
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Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K37/00—Auxiliary devices or processes, not specially adapted to a procedure covered by only one of the preceding main groups
- B23K37/04—Auxiliary devices or processes, not specially adapted to a procedure covered by only one of the preceding main groups for holding or positioning work
- B23K37/047—Auxiliary devices or processes, not specially adapted to a procedure covered by only one of the preceding main groups for holding or positioning work moving work to adjust its position between soldering, welding or cutting steps
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K37/00—Auxiliary devices or processes, not specially adapted to a procedure covered by only one of the preceding main groups
-
- G—PHYSICS
- G05—CONTROLLING; REGULATING
- G05D—SYSTEMS FOR CONTROLLING OR REGULATING NON-ELECTRIC VARIABLES
- G05D13/00—Control of linear speed; Control of angular speed; Control of acceleration or deceleration, e.g. of a prime mover
- G05D13/62—Control of linear speed; Control of angular speed; Control of acceleration or deceleration, e.g. of a prime mover characterised by the use of electric means, e.g. use of a tachometric dynamo, use of a transducer converting an electric value into a displacement
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- Physics & Mathematics (AREA)
- Engineering & Computer Science (AREA)
- Optics & Photonics (AREA)
- Mechanical Engineering (AREA)
- General Physics & Mathematics (AREA)
- Automation & Control Theory (AREA)
- Butt Welding And Welding Of Specific Article (AREA)
Abstract
The invention provides a control system and control method for welding a non-perfect-circle tank body. According to the control system and method, the investment cost is low, and welding efficiency and welding quality are high. The control system comprises a main controller, a welding platform and a welding gun component, and further comprises a tank body rotating supporting assembly which is used for carrying the tank body to rotate around the axis of the tank body when the welding gun component is used for welding the surface of the tank body. The tank body rotating supporting assembly is composed of a tank body support and a servo motor. The main controller sends out a frequency signal for adjusting the angular speed of the servo motor to a frequency converter according to a corresponding angular speed function of a tank body bonding wire graph curve under the condition of a preset linear speed. According to the control system and control method, the tank body graph curve is directly subjected to angle differential processing, and the corresponding tank body rotating angular speed when the linear speed of tank body surface welding spots is constant is calculated; the main controller is used for controlling the rotating angular speed of the tank body, the moving speed of the tank body surface welding spots relative to a welding gun is made constant, and automatic welding of the non-perfect-circle tank body is achieved. The control system is stable in operation, good in welding effect and high in work efficiency.
Description
Technical field
The present invention relates to a kind of automatic welding system and welding method, particularly a kind ofly carry out the automatic welding control system of welding and control method for non-regular round tank.
Background technology
Non-regular round tank, as oil truck, bulk cement carrier and chemicals storage tank car etc., its tank body cross sectional shape is anon-normal toroidal, when adopting automatic welding to it, welding gun will affect the height of welding quality to whether the speed of welding of tank surface is even, thus also will affect this tank body result of use in use, life-span and security reliability.
As shown in Figure 1, 2, usually, welding curve in non-regular round tank cross section is made up of numerous straight-line segment and radius circular arc not etc., and its track is irregular to follow.
In prior art, have several as follows to the welding method of such non-regular round tank:
1, human weld is adopted
When adopting human weld, welder will adjust at any time to welding position, height and angle, and its solder technology to welder requires higher.Usually, the method working strength is large, welding efficiency is low and welding quality is unstable.
2, surface scan welding
As shown in Figure 3, during welding, welding gun is mobile welding above actionless tank body.It adopts ceramic pressure sensor to be close to tank surface and rolls with constant linear velocity and move, in rolling process, according to the irregular change of motion track, horizontal pressure force and the pressure at right angle of ceramic pressure sensor induction will change, and the high-low signal of collection is passed to master controller by it.This signal of master controller process, in order to Synchronization Control welding gun height and translational speed, thus realizes automatic welding.
But the method has the following disadvantages:
1) this kind of ceramic sensor element needs to bear larger pressure and vibrations, and sensitivity requirement is higher.Domestic at present only have few producer can provide this ceramic sensor element, and major part can only rely on external import, and price costly, and needs periodic replacement.Whole cost is higher.
2), during welding, ceramic sensor element only rolls at the upper surface of tank body, so welding gun can only weld a part for tank body bonding wire each welding interval.When needing welding remainder (when the side of namely not welding and bottom surface), then needing to stop welding, waiting and the tank body side of not welding or bottom surface rotated upward and after remaining static, could continue to weld.Therefore, welding efficiency is under some influence, and easily forms the bad welding qualities such as solder skip in the first coupling part of the tail in two adjacent solder cycles.
3, PLC frequency conversion drive welding
This welding method is comparatively advanced in current welding method.
As shown in Figure 4, during welding, tank body rotates, and welding gun moves up and down its welding above tank surface.It adopts the pad on range sensor acquisition tank body welding curve to the range information of tank body pivot and this information is passed to PLC.This programmable controller is according to the output frequency of the change adjustment frequency converter of this range information, thus rotary speed when controlling tank body welding, with this, ensure the linear velocity constant of solder side.
But the method exists following not enough:
1) weld the same with surface scan, range sensor needs to bear larger pressure and vibrations, and sensitivity requirement is higher.Main dependence on import at present, price costly, and needs periodic replacement, and whole cost is higher.
2) stability is not high.When tank surface has projection or pit, its range information obtained will produce deviation, and cause PLC output frequency error rate high, when making welding, welding gun is non-constant relative to the linear velocity of tank body bonding wire, finally causes welding quality to decline.
Summary of the invention
The technical problem to be solved in the present invention is to provide control system and the control method for welding non-regular round tank that a kind of cost of investment is low, welding efficiency is high with welding quality.
In order to solve the problems of the technologies described above, the technical solution used in the present invention is:
Control system for welding non-regular round tank of the present invention, comprise master controller, vertical lift jig and the welding gun assembly be arranged on this lifting welding platform, also be included in described welding gun assembly when described tank surface is welded, take the tank body rotary support assembly that described tank body rotates around its axis, this tank body rotary support assembly is made up of tank body bearing and servomotor, described master controller sends according to the angular speed function corresponding to default linear velocity by tank body bonding wire graph curve the frequency signal adjusting described servomotor angular speed to frequency converter.
It also comprises personal control.
Described master controller comprises industrial control host and each one of touch-screen display, single axial movement control card one, input/output control signal adapter assembly and the non-regular round tank be arranged in industrial control host weld control program.
The method of welding non-regular round tank of the present invention, utilize CAD PaintShop, carry out the process of angle differential to non-regular round tank bonding wire graph curve to be welded and weld controlling welding gun assembly in the master controller of process data input welding control system this tank body be rotating, concrete treatment step is as follows:
1) first by the computer of the DXF format file of the CAD of non-regular round tank bonding wire figure to be welded input master controller;
2) by the lopcus function P=[xi, yi] of this tank body bonding wire graph curve, be converted into and specify axle center coordinate and specify segmentation angle determined analog track function Q=f (r
i, θ
i), wherein, r
ifor the distance between simulating solder joint on described curve to described rotation, θ
ifor the central angle that unit arc length on bonding wire track is corresponding;
3) according to linear velocity and angular speed conversion formula ω
i× r
i=V, obtains the instantaneous angular velocity ω that tank body rotates
i=V/r
i; Then release tank body angular velocity of rotation function W (ω, v, θ, t), wherein V is the constant speed of predetermined tank body bonding wire phase Butt welding gun movement;
4) program origin is determined, master controller is according to described angular speed function W (ω, v, θ, t) by sending the frequency signal f β of the angular velocity omega i of the servomotor that adjustment drives tank body to rotate in real time to frequency converter, meanwhile, the distance in welding gun assembly between welding gun and tank body bonding wire surface is adjusted in real time.
Described lopcus function P=[xi, yi] being converted in the inventive method is specified axle center coordinate and is specified segmentation angle determined analog track function Q=f (r
i, θ
i) method as follows:
Instantaneous gyration ω i obtains as follows:
ωi＝WLSP×MPPD×GEAR/PSCALE/(2.0×PI×R0)
Wherein, WLSP specifies linear velocity for user, and MPPD is motor resolution ratio, and GEAR is the speed reducing ratio of reduction box, and PSCALE is servo-driver amplification ratio, and PI is pi, and R0 is the distance that current solder joint is arrived in axle center.
Compared with prior art, the present invention is directly by carrying out the process of angle differential to tank body graph curve, when calculating tank surface pad linear velocity constant, corresponding tank body angular velocity of rotation, master controller is again according to this angular velocity data, control the angle rotating speed that tank body rotates, make the rate travel of tank surface phase of solder joint Butt welding gun constant, thus realize the automatic welding of non-regular round tank.Welding control system of the present invention is stable, welding effect good, operating efficiency is high.
Accompanying drawing explanation
Fig. 1 is the lateral plan of non-regular round tank car.
Fig. 2 is the rear view of non-regular round tank car.
Fig. 3 is surface scan of the prior art welding schematic diagram.
Fig. 4 is PLC frequency conversion drive of the prior art welding schematic diagram.
Fig. 5 is welding control system block diagram of the present invention.
Fig. 6 is tank body bonding wire lopcus function P=[xi, yi], is converted into analog track function Q=[r
i, θ
i] corresponding schematic diagram.
Fig. 7 is the refinement schematic diagram of Fig. 6.
Fig. 8 is welding system of the present invention schematic diagram dorsad.
Fig. 9 is welding system side schematic view of the present invention.
Detailed description of the invention
As shown in Figure 1, 2, non-regular round tank (oil truck, bulk cement carrier, chemicals tank car etc.) cross section welding curve is by numerous straight line, and the circular arc that radius does not wait forms.When welding, welding gun cannot move with fixing speed, realizes the difficult problem that automatic welding is industry always.
For solving non-regular round tank face of weld linear velocity evenly (i.e. face of weld linear velocity constant) difficult problem, realize stepless adjustable, various trial and experiment were done by a lot of producer both domestic and external and mechanism.
From the welding of initial surface scan, to manual frequency conversion and the welding of PLC frequency conversion drive, all and thoroughly do not solve an above-mentioned difficult problem.To this applicant through making great efforts for many years, the technology control system of the complexity of abandoning over, digital control system is adopted to add independently developed process software, directly computing is carried out to CAD map file, transform and generate control routine, automatically complete the overall process of non-regular round tank welding, thus, thoroughly solve this puzzlement industry technical barrier for many years.
As shown in Fig. 5,6,7,8,9, the control system for non-regular round tank welding of the present invention by the master controller containing computer, CAD PaintShop, personal control, move horizontally support frame, vertical lift jig, welding gun assembly and tank body rotary support and form.
Described master controller comprise industrial control host (namely mainboard, plate carries CPU double-core 1.8GHz, plate carries 2G internal memory, high speed solid hard disk 32G and keyboard, mouse etc.) and each one of touch-screen display, single axial movement control card one, input/output control signal adapter assembly and the non-regular round tank welding control program that is arranged in industrial control host.
Industrial control host: adopt the low-power consumption industrial control mainboard that the full plate of CPU internal memory carries, then arrange in pairs or groups with high speed solid hard disk, greatly improve the high speed of digital control system, durable and stability.
Touch-screen display: user-friendly, improves experience value.
Single axial movement control card and input/output control signal switching circuit board: the stable effectively work guaranteeing running accuracy and online speed changing function.
Non-regular round tank welding control software design: the DXF format file directly reading in CAD, full-automatic conversion and machining control.
Adopt aforesaid way, when after the bonding wire figure painting non-regular round tank to be welded, namely complete program, greatly accelerate operating process, meanwhile, also ensure that the accuracy of processing.
The method of welding non-regular round tank of the present invention is:
Utilize CAD PaintShop, carry out the process of angle differential to non-regular round tank bonding wire graph curve to be welded and weld controlling welding gun assembly in the master controller of process data input welding control system this tank body be rotating, concrete treatment step is as follows:
1) first by the computer of the DXF format file of the CAD of non-regular round tank bonding wire figure to be welded input master controller;
2) by PaintShop, analyzing and processing is carried out to this tank body graph curve, by the lopcus function P=[xi, yi] of this tank body bonding wire graph curve, be converted into and specify axle center coordinate and specify segmentation angle determined analog track function Q=f (r
i, θ
i), wherein, r
ifor the distance between simulating solder joint on described curve (the A point in Fig. 9) to described rotation, θ
ifor the central angle that unit arc length on bonding wire track is corresponding;
3) according to linear velocity and angular speed conversion formula ω
i× r
i=V, obtains the instantaneous angular velocity ω that tank body rotates
i=V/r
i; Then release tank body angular velocity of rotation function W (ω, v, θ, t), wherein V is the constant speed of predetermined tank body bonding wire phase Butt welding gun movement;
4) determine program origin, the real-time angular velocity data W (v, ω, θ, t) of tank body that master controller is produced by analysis software, change the output frequency f β of frequency converter, in real time the rotational speed omega i of adjustment tank body rotating servo motor.Thus make tank body welding surface phase Butt welding gun linear velocity remain on V.
Described lopcus function P=[xi, yi] is converted into and specifies axle center coordinate and specify segmentation angle determined analog track function Q=f (r
i, θ
i) method as follows:
Instantaneous gyration ω i obtains as follows:
ωi＝WLSP×MPPD×GEAR/PSCALE/(2.0×PI×R0)
Wherein, WLSP specifies linear velocity for user, and MPPD is motor resolution ratio (a circle pulse subdivision number), and GEAR is the speed reducing ratio of reduction box, and PSCALE is servo-driver amplification ratio, and PI is pi, and R0 is the distance that current solder joint is arrived in axle center.
During automatic welding equipment weld metal, welding gun needs at the uniform velocity to move (relative face of weld), could realize stable, qualified welding.
The present invention compares with existing similar technique has following outstanding advantages and good effect:
1. directly adopt software control tank body rotating speed, avoid sensor and directly contact with tank body, improve the stability of system.
2. welding effect is good compared with other homogeneous system, and fraction defective reduces by 20 ~ 30%.
3. directly adopt software control tank body rotating speed, avoid the loss of sensor, reduce equipment operating cost.
Claims (5)
1. one kind for welding the control system of non-regular round tank, comprise master controller, vertical lift jig and the welding gun assembly be arranged on this lifting welding platform, it is characterized in that: be also included in described welding gun assembly when described tank surface is welded, take the tank body rotary support assembly that described tank body rotates around its axis, this tank body rotary support assembly is made up of tank body bearing and servomotor, described master controller sends according to the angular speed function corresponding to default linear velocity by tank body bonding wire graph curve the frequency signal adjusting described servomotor angular speed to frequency converter.
2. the control system for welding non-regular round tank according to claim 1, is characterized in that: it also comprises personal control.
3. the control system for welding non-regular round tank according to claim 1, is characterized in that: described master controller comprises industrial control host and each one of touch-screen display, single axial movement control card one, input/output control signal adapter assembly and the non-regular round tank be arranged in industrial control host weld control program.
4. one kind is welded the method for non-regular round tank, it is characterized in that: utilize CAD PaintShop, carry out the process of angle differential to non-regular round tank bonding wire graph curve to be welded and weld controlling welding gun assembly in the master controller of process data input welding control system this tank body be rotating, concrete treatment step is as follows:
1) first by the computer of the DXF format file of the CAD of non-regular round tank bonding wire figure to be welded input master controller;
2) by the lopcus function P=[xi, yi] of this tank body bonding wire graph curve, be converted into and specify axle center coordinate and specify segmentation angle determined analog track function Q=f (r
i, θ
i), wherein, r
ifor the distance between simulating solder joint on described curve to described rotation, θ
ifor the central angle that unit arc length on bonding wire track is corresponding;
3) according to linear velocity and angular speed conversion formula ω
i× r
i=V, obtains the instantaneous angular velocity ω that tank body rotates
i=V/r
i; Then release tank body angular velocity of rotation function W (ω, v, θ, t), wherein V is the constant speed of predetermined tank body bonding wire phase Butt welding gun movement;
4) program origin is determined, master controller is according to described angular speed function W (ω, v, θ, t) by sending the frequency signal f β of the angular velocity omega i of the servomotor that adjustment drives tank body to rotate in real time to frequency converter, meanwhile, the distance in welding gun assembly between welding gun and tank body bonding wire surface is adjusted in real time.
5. method according to claim 4, is characterized in that: described lopcus function P=[xi, yi] be converted into and specify axle center coordinate and specify segmentation angle determined analog track function Q=f (r
i, θ
i) method as follows:
Instantaneous gyration ω i obtains as follows:
ωi＝WLSP×MPPD×GEAR/PSCALE/(2.0×PI×R0)
Wherein, WLSP specifies linear velocity for user, and MPPD is motor resolution ratio, and GEAR is the speed reducing ratio of reduction box, and PSCALE is servo-driver amplification ratio, and PI is pi, and R0 is the distance that current solder joint is arrived in axle center.
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| CN201510546903.4A CN105057964B (en) | 2015-08-28 | 2015-08-28 | Control system and control method for welding non-perfect-circle tank body |
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| CN105057964B CN105057964B (en) | 2017-04-12 |
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Cited By (4)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN109434335A (en) * | 2018-12-18 | 2019-03-08 | 冯军 | A kind of lap welding method and device |
| CN112453743A (en) * | 2020-11-27 | 2021-03-09 | 淄博永正化工设备有限公司 | Method for welding tank opening in oval manner |
| CN112453721A (en) * | 2020-11-09 | 2021-03-09 | 上海柏楚电子科技股份有限公司 | Control method, system, device, equipment and medium for pipe support |
| CN113942017A (en) * | 2021-11-29 | 2022-01-18 | 武汉理工大学 | Tank welding point pose planning method, welding workstation, equipment and medium |
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| CN112453743A (en) * | 2020-11-27 | 2021-03-09 | 淄博永正化工设备有限公司 | Method for welding tank opening in oval manner |
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| CN113942017B (en) * | 2021-11-29 | 2023-08-08 | 武汉理工大学 | Tank welding point position planning method, welding workstation, equipment and medium |
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