CN105728904A - System and method for tracking weaving arc space weld based on MEMS (micro-electromechanical systems) sensor - Google Patents
System and method for tracking weaving arc space weld based on MEMS (micro-electromechanical systems) sensor Download PDFInfo
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- CN105728904A CN105728904A CN201610312379.9A CN201610312379A CN105728904A CN 105728904 A CN105728904 A CN 105728904A CN 201610312379 A CN201610312379 A CN 201610312379A CN 105728904 A CN105728904 A CN 105728904A
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- 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
- B23K9/00—Arc welding or cutting
- B23K9/12—Automatic feeding or moving of electrodes or work for spot or seam welding or cutting
- B23K9/127—Means for tracking lines during arc welding or cutting
- B23K9/1272—Geometry oriented, e.g. beam optical trading
- B23K9/1276—Using non-contact, electric or magnetic means, e.g. inductive means
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Abstract
The invention discloses a system and a method for tracking a weaving arc space weld based on an MEMS (micro-electromechanical systems) sensor. The system comprises a manipulator, a welding power source, a wire delivery machine, an electric arc sensor, a built-in type MEMS sensor welding gun, a weaving arc space weld tracking signal processor, a welding gun tilting angle operator, a swinging direction operator, a welding gun attitude real-time adjuster, and a welding expert system. The system adopts a core principle that the space weld can be tracked by the weaving arc space weld tracking method based on the MEMS sensor, and has the advantage that the space attitude of the welding gun is collected by an arc sensor, a gyroscope and an accelerometer, and the tilting angle and swinging direction of the welding gun are automatically adjusted by weld angle differential identification, vertical displacement orientation and other methods, so that the real-time tracking of the space complicated weld is realized.
Description
Technical field
The present invention relates to welding automatization technology field, be specifically related to a kind of based on MEMS sensor space weld tracking System and method for.
Background technology
Although THE WELD SEAM TRACKING TECHNOLOGY has tended to ripe at present, but the research of complicated space weld is also not as many, application effect is also not as.Owing to large-scale important component gets more and more, be not limited only to side seam from motion tracking, so the discussion that space weld is followed the tracks of system becomes the key of Automation of Welding.Therefore, only taken into full account the complexity of welding surroundings, the multiformity of weldment position, the quality of welding can have been ensured, establish solid foundation for realizing automatic welding.Produce the development trend of especially industry 4.0 for adapting to modern industry, commercial production increasingly produces to small batch, or even single-piece production development.This just proposes high requirement for production line flexibility.For reducing production cost, Automation of Welding equipment must adapt to the welding of space weld so that expanding the welding scope of Automation of Welding equipment.
Space weld further relates to the self-regulation at welding gun inclination angle and swaying direction compared to common downhand weld.The difficult point that space weld is followed the tracks of is in that the extraction of signal and the identification of deviation.Such as disclosed invention patent: what adopt in a kind of complicated angle welding method for detecting position based on Binocular stereo vision with laser (application number is 2014100428828) is binocular CCD imaging identification technology.CCD is subject to the interference of arc light, and general volume is not easily installed relatively greatly, limits the accessibility of welding gun.In contrast, arc sensor just has the advantage being difficult to substitute.Arc sensing technology directly obtains weld information from arc signal, has natural anti-interference and real-time characteristic." rotating arc sensor gun welder space gesture identification " literary grace least square method construction feature plane, detects left-right deviation and the inclination angle of welding gun according to the slope of characteristic plane Yu coordinate plane intersection.It extracts the method for weld slope signal and has similarity herein but have essential distinction.It is the space weld recognition methods proposed on the basis of swing arc herein.MEMS gyroscope and developing rapidly of mems accelerometer sensor efficiently solve the problem such as Aero-Space, accurate navigation, space orientation, displacement monitoring in recent years, but remain without so far and see the document and report being applied to weld joint tracking field.Existing welding robot generally possesses anti-collision, but welding gun does not have exclusive anti-collision as the additional position of robot body.Welding surroundings is relatively more severe, and welding gun is encountered component at the volley and caused that welding gun deviation normal operation position or robot produce excessive shake because of program error generation misoperation, and these all have a strong impact on welding quality.MEMS gyroscope, accelerometer and welding gun are organically blended by the present invention, extend the application of micro mechanical sensor, have filled up micro mechanical sensor and have achieved space weld real-time tracking and this blank of welding gun anti-collision.
Summary of the invention
The invention aims to solve space and weld the problem being difficult to automatization, it is provided that a kind of swing arc space weld based on MEMS sensor follows the tracks of System and method for.With reference to accompanying drawing 1, this system includes mechanical hand, the source of welding current, wire-feed motor, arc sensor, built-in MEMS sensor welding gun, swing arc space weld follow the tracks of signal processor, welding gun inclination angle arithmetical unit, swaying direction arithmetical unit, the real-time adjustor of posture of welding torch, welding expert system.Built-in MEMS sensor welding gun is the welding gun exclusively for native system design, it is integrated with MEMS sensor 4 (gyroscope, accelerometer) as shown in Figure 2 in this welding gun and collision recognition circuit 5,4,5 is all that individual packages is with in the module of function of shielding.The function of collision recognition circuit 5 is that the exception identified in welding job is collided and controls periods of robot operation stop.In its principle such as accompanying drawing 2 shown in " collision recognition ".Occur the sudden change more than M or sudden change of acceleration more than N when monitoring gyroscope inclination angle, just judge that welding gun there occurs collision and sends halt instruction.It is design on the basis of the seam tracking system of technology today maturation that swing arc space weld follows the tracks of signal processor.This processor, except having welding line tracking function, goes back two functions of self-regulation of integrated welding gun inclination angle, swaying direction.Welding gun inclination angle arithmetical unit is the angle that the weld bead height information utilizing arc sensor to collect calculates weld seam by weld seam angle differential method of identification, and this angle is sent to welding expert system can obtain meeting the welding gun inclination angle of technological requirement.Swaying direction utilizes the displacement of accelerometer measures and the vertical relation of swaying direction and weld seam to calculate and obtain correct swaying direction arithmetical unit.Posture of welding torch adjustor in the present invention be equally integrate weld joint tracking pose adjustment, welding gun obliquity and attitude adjusts, torch swinging pose adjustment three zones, and be coupled relation between three zones is not independent of one another.
Based on the swing arc space weld tracking of MEMS sensor, its workflow is such.With reference to accompanying drawing 3, arc sensor gathers weld seam deviation signal and sends into weld joint tracking signal processor, obtains weld seam left-right deviation value A and the high difference B in front and back after being computed.Control A, B realize welding gun centering and keep certain height with weld seam.B value is sent to welding gun inclination angle internalarithmetic simultaneously and goes out to meet the leg C of welding process requirement, realizes the tracking of leg in conjunction with the angle of gyroscope feedback.At the same time, the displacement of the accelerometer record welding gun within welding gun, welding gun displacement signal is sent to swaying direction internalarithmetic and goes out suitable swaying direction D.Last A, B, C, D send into the real-time adjustor of gun welder space gesture, control mechanical hand and perform tracking action.
The weld seam angle differential method of identification that in the present invention, welding gun inclination angle is used arithmetical unit is utilize differential thought and the slope of curve calculated.With reference to accompanying drawing 4, a Welded Joint Curve is placed in y-t coordinate system.Welding gun, when position a, can obtain the welding gun vertical dimension y to weld seam by the analysis of weld seam signal0, in like manner during note position b, distance is y1.If setting the time respectively t of a, b0、t1, can obtain according to slope formula:
Then, weld slope θ=arctank.Weld slope is sent into welding expert system and just obtains meeting the welding gun inclination angle of technological requirement, this angle and gyroscope measurement to angle contrast, if there being deviation deviation-rectifying system to rectify a deviation.The amplification that above explanation is really once calculating position is explained, next the differential thought of application in weld seam angle differential method of identification is described.In real work, the height change of interval and welding gun is very little.In theory can infinitely small but due to conditions such as sensor accuracy and computer speed, according to welding quality require selection meet permissible accuracy.
The computational methods of swaying direction arithmetical unit are that method is pointed in vertical displacement, and its essence is the relation utilizing swaying direction vertical with weld seam maintenance.Its operation principle is to detect the displacement of welding gun according to accelerometer and Dip countion in conjunction with gyroscope obtains swaying direction.Method is pointed to as accompanying drawing 5 describes vertical displacement intuitively.Curved welding seam is regarded as the broken line being made up of a plurality of broken line.Welding gun moves to B (X along funiclar curve by initial point A under the guiding of weld joint tracking1、Y1) point, accelerometer records its displacement in X, Y both direction in the process.According to slope formulaThe AB line segment that is easy to get is q with X-axis angle1.Now system operations goes out the swaying direction of welding gun, and welding gun carries out the adjustment of a swaying direction.Welding gun continues to move to C (X along funiclar curve under the guiding of weld joint tracking2、Y2) point.Also according to slope formulaObtain BC line segment and be q with X-axis angle2.For reducing operand, adopt q herein2-q1(angle step) obtains the angle that swaying direction needs to adjust.
The present invention effectively solves the weld joint tracking problem of space weld, has expanded the welding scope of mechanical hand.
Accompanying drawing explanation
Fig. 1 is that system hardware is always schemed
Fig. 2 is built-in MEMS sensor welding gun structure and collision recognition workflow diagram
Fig. 3 is systematic schematic diagram
Fig. 4 is weld seam angle differential method of identification explanation
Method explanation is pointed in Fig. 5 vertical displacement
Detailed description of the invention
Below in conjunction with Figure of description and two embodiments, the present invention is described further.
Embodiment one:
Shown in accompanying drawing 1 is the system hardware linked, diagram of the embodiment of the present invention, possesses mechanical hand 1, wire-feed motor 2, swing operational device 3, welding gun inclination angle arithmetical unit 4, swing arc space weld follow the tracks of signal processor 5, welding expert system 6, the real-time adjustor of posture of welding torch 7, built-in MEMS sensor welding gun 8, arc sensor 9, the source of welding current 10.
Built-in MEMS sensor welding gun 8 is the welding gun exclusively for native system design, referring in this welding gun of accompanying drawing 2 except rifle head 2 and cover plate 6, also it is integrated with MEMS sensor 4 (gyroscope, accelerometer), collision recognition circuit 5 and the vibration damper pad 3 of necessity.There is its body for welding robot and possess anticollision but the defect that do not possess of welding gun.The function of collision recognition circuit 5 is that the exception identified in welding job is collided and controls periods of robot operation stop.In its principle such as accompanying drawing 2 shown in " collision recognition ".Occur the sudden change more than M or sudden change of acceleration more than N when monitoring gyroscope inclination angle, just judge that welding gun there occurs collision and sends halt instruction.
In accompanying drawing 1, it is that design improvement forms on the basis of the seam tracking system of technology today maturation that swing arc space weld follows the tracks of signal processor 5.This processor, except having welding line tracking function, goes back two functions of self-regulation of integrated welding gun inclination angle, swaying direction.Welding gun inclination angle arithmetical unit 4 is the angle that the weld bead height information utilizing arc sensor 9 to collect calculates weld seam by weld seam angle differential method of identification, and this angle is sent to welding expert system 6 can obtain meeting the welding gun inclination angle C of technological requirement.The displacement of accelerometer measures and the swaying direction relation vertical with weld seam is utilized swaying direction arithmetical unit 3 to calculate and obtain correct swaying direction.Posture of welding torch adjustor 7 in the present invention be equally integrate weld joint tracking pose adjustment, welding gun obliquity and attitude adjusts, torch swinging pose adjustment three zones, and be coupled relation between three zones is not independent of one another.
Based on the swing arc space weld tracking of MEMS sensor, its workflow is such.With reference to accompanying drawing 3, arc sensor 9 gathers weld seam deviation signal and sends into swing arc space weld tracking signal processor 5, obtains weld seam left-right deviation value A and the high difference B in front and back after being computed.Control A, B realize welding gun centering and keep certain height with weld seam.B value is sent to the tracking calculating the leg C meeting welding process requirement welding gun inclination angle arithmetical unit 4, realizing leg in conjunction with the angle of gyroscope feedback simultaneously.At the same time, the displacement of the accelerometer record welding gun within welding gun, welding gun displacement signal is sent to and calculates suitable swaying direction D swaying direction arithmetical unit 3.Last A, B, C, D send into the real-time adjustor of gun welder space gesture, control mechanical hand and perform tracking action.
The weld seam angle differential method of identification that the present embodiment welding gun inclination angle is used arithmetical unit is utilize differential thought and the slope of curve calculated.With reference to accompanying drawing 4, a Welded Joint Curve is placed in y-t coordinate system.Welding gun, when position a, can obtain the welding gun vertical dimension y to weld seam by the analysis of weld seam signal0, in like manner during note position b, distance is y1.If setting the time respectively t of a, b0、t1, can obtain according to slope formula:
Then, weld slope θ=arctank.Weld slope is sent into welding expert system 6 and just obtains meeting the welding gun inclination angle of technological requirement, this angle and gyroscope measurement to angle contrast, if there being deviation deviation-rectifying system to rectify a deviation.The amplification that above explanation is really once calculating position is explained, next the differential thought of application in weld seam angle differential method of identification is described.In real work, the height y change of interval t and welding gun is very little.In theory can infinitely small but due to conditions such as sensor accuracy and computer speed, according to welding quality require selection meet permissible accuracy.
The computational methods of swaying direction arithmetical unit are that method is pointed in vertical displacement, and its essence is the relation utilizing swaying direction vertical with weld seam maintenance.Its operation principle is the direction of displacement of accelerometer detection welding gun, and this direction is sent into welding expert system 4.Welding expert system obtains swaying direction in conjunction with the Dip countion of gyroscope, and then control mechanical hand 1 realizes the self-regulation of swaying direction.Such as accompanying drawing 5, describe vertical displacement intuitively and point to method.Curved welding seam is regarded as the broken line being made up of a plurality of broken line.Welding gun moves to B (X along funiclar curve by initial point A under the guiding of weld joint tracking1、Y1) point, accelerometer records its displacement in X, Y both direction in the process.According to slope formulaThe AB line segment that is easy to get is q with X-axis angle1.Now system operations goes out the swaying direction of welding gun, and welding gun carries out the adjustment of a swaying direction.Welding gun continues to move to C (X along funiclar curve under the guiding of weld joint tracking2、Y2) point.Also according to slope formulaObtain BC line segment and be q with X-axis angle2.For reducing operand, adopt q herein2-q1(angle step) obtains the angle that swaying direction needs to adjust.
Welding line tracking function remains that welding gun swings (two swinging in the middle of imaginary curve) at Weld pipe mill.Straight dashed line is perpendicular to the torch swinging direction of welding gun displacement.In actual welding works, the amplitude of accommodation of swaying direction is typically small, therefore the present embodiment uses the swaying direction that the welding gun direction of displacement in a period of time T is determined, under the premise meeting instructions for use, thus reduce the requirement to accelerometer precision and data processing speed, reduce system cost simultaneously and increase economic efficiency.Same utilization differential thought is it can be seen that the method can reach real-time adjustment in theory.The present embodiment effectively solves the weld joint tracking problem of space weld, has expanded the welding scope of mechanical hand and has achieved the anti-collision of welding gun, has important engineer applied and is worth.
Claims (5)
1. follow the tracks of System and method for based on the swing arc space weld of MEMS sensor, it is characterised in that this system includes mechanical hand, the source of welding current, wire-feed motor, arc sensor, built-in MEMS sensor welding gun, swing arc space weld follow the tracks of signal processor, welding gun inclination angle arithmetical unit, swaying direction arithmetical unit, the real-time adjustor of posture of welding torch, welding expert system；Its core is to utilize the swing arc space weld tracking based on MEMS sensor to realize space weld to follow the tracks of.
2. built-in MEMS sensor welding gun as claimed in claim 1, it is characterised in that MEMS sensor is arranged on inside welding gun, comprises three-axis gyroscope sensor, 3-axis acceleration sensor and collision recognition circuit.
3. the swing arc space weld tracking based on MEMS sensor as claimed in claim 1, it is characterized in that comprising the steps: during system work, arc sensor gathers weld seam deviation signal and sends into weld joint tracking signal processor, obtains weld seam left-right deviation value A and the high difference B in front and back after being computed；Control A, B realize welding gun centering and keep certain height with weld seam；B value is sent to welding gun inclination angle internalarithmetic simultaneously and goes out to meet the leg C of welding process requirement, realizes the tracking of leg in conjunction with the angle of gyroscope feedback；At the same time, the displacement of the accelerometer record welding gun within welding gun, welding gun displacement signal is sent to swaying direction internalarithmetic and goes out suitable swaying direction D；Last A, B, C, D send into the real-time adjustor of gun welder space gesture, control mechanical hand and perform tracking action.
4. welding gun inclination angle as claimed in claim 3 arithmetical unit, it is characterized in that it passes through the high difference B calculating twice collection in the front and back differential to period of time T, then through the angle being converted to weld seam, this angle is sent into welding expert system and is provided parameters such as meeting the leg of technological requirement, the source of welding current, welding current by specialist system.
5. as claimed in claim 3 swaying direction arithmetical unit, it is characterised in that it, by recording the direction of displacement of welding gun in period of time T, obtains correct swaying direction further according to the relation that swaying direction is vertical with bead direction.
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| CN108015395A (en) * | 2016-11-04 | 2018-05-11 | 林肯环球股份有限公司 | Magnet rate selection for electromagnetic position tracking |
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| CN114393286A (en) * | 2022-01-19 | 2022-04-26 | 湘潭大学 | Welding line deviation extraction method for torsional swing arc of manipulator |
| CN114393279A (en) * | 2022-01-19 | 2022-04-26 | 湘潭大学 | Magnetic control arc welding seam tracking sensing device adopting double MEMS magnetic field intensity sensors |
| CN114393279B (en) * | 2022-01-19 | 2023-11-14 | 湘潭大学 | Weld joint tracking and sensing system based on double MEMS magnetic field intensity sensors |
| CN115055788A (en) * | 2022-07-11 | 2022-09-16 | 湘潭大学 | Arc oscillation amplitude control method based on magnetic control GTAW arc sensing |
| CN115055788B (en) * | 2022-07-11 | 2023-08-25 | 湘潭大学 | Arc swing amplitude control method based on magnetic control GTAW arc sensing |
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