CN107052508B - Intelligent welding system for ship plate frame structure robot and welding process thereof - Google Patents
Intelligent welding system for ship plate frame structure robot and welding process thereof Download PDFInfo
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- CN107052508B CN107052508B CN201611263692.4A CN201611263692A CN107052508B CN 107052508 B CN107052508 B CN 107052508B CN 201611263692 A CN201611263692 A CN 201611263692A CN 107052508 B CN107052508 B CN 107052508B
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- 238000003466 welding Methods 0.000 title claims abstract description 275
- 238000000034 method Methods 0.000 title claims abstract description 33
- 230000008569 process Effects 0.000 title claims abstract description 17
- 230000003993 interaction Effects 0.000 claims abstract description 11
- 238000004140 cleaning Methods 0.000 claims description 12
- 238000005520 cutting process Methods 0.000 claims description 12
- 230000007704 transition Effects 0.000 claims description 8
- 229910000831 Steel Inorganic materials 0.000 claims description 5
- 239000010959 steel Substances 0.000 claims description 5
- 238000010791 quenching Methods 0.000 claims description 3
- 230000000171 quenching effect Effects 0.000 claims description 3
- 238000005498 polishing Methods 0.000 claims description 2
- 238000010586 diagram Methods 0.000 description 5
- 230000007547 defect Effects 0.000 description 3
- 230000008859 change Effects 0.000 description 2
- 230000008033 biological extinction Effects 0.000 description 1
- 210000000988 bone and bone Anatomy 0.000 description 1
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- 238000004519 manufacturing process Methods 0.000 description 1
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Classifications
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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
- B23K9/0026—Arc welding or cutting specially adapted for particular articles or work
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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
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Abstract
The invention relates to an intelligent welding system for a robot with a ship plate frame structure, which is characterized in that: the intelligent welding system comprises a welding device, a digital welding power supply and a control system, wherein the digital welding power supply and the control system are connected with the welding device; the welding device comprises a guide rail and a welding robot system arranged on the guide rail, wherein the control system is connected with a man-machine interaction system, and the man-machine interaction system controls the welding robot system; the welding robot system comprises a mechanical arm, and the mechanical arm is connected with a laser scanning piece and a welding gun device. The welding robot system provided by the invention is free from manual intervention in the whole process after being started, has lower requirements on the assembly precision and the placement position of the structure, is convenient to assemble, disassemble and hoist, and can solve the current situations that the work piece of a shipyard is large and is not easy to move.
Description
Technical Field
The invention relates to the technical field of ship equipment, in particular to an intelligent welding system for a robot with a ship plate frame structure, and especially relates to an intelligent welding system for a welding robot among grids with an assembled plate frame structure in a ship.
Background
In shipbuilding, welding occupies an important position, and the workload and cost account for 30% -40% of the ship body construction. Aiming at long and straight welding seams, for example, in the procedures of splicing plates, small assembly and the like, a large number of shipyards already adopt automatic equipment such as special welding machines, but for the assembly structures such as segmented cabins and the like, the welding seams are short, the structural forms are various and the like, and the welding machines are not suitable for adopting the automatic equipment such as special welding machines, and the manual welding mode is adopted at present.
Robots have been widely used in the manufacturing industry due to their cost saving, efficiency improvement, quality assurance, high repeatability, etc. The traditional robot adopts modes of teaching, off-line programming and the like to determine a welding path, is suitable for industries such as small products, large batches, accurate assembly and the like, such as automobiles, parts and the like, but has the characteristics of the ship industry. Taking the invention as an example, the ship plate frame structure is a typical structure of a ship cabin, wherein the welding seam structure is various in form, small in quantity and product, short in welding seam, and low in assembly precision of a shipyard, and even the same structure has deviation, so that the teaching mode of the traditional robot is huge in operation workload, low in efficiency and obviously unsuitable for the ship industry.
Disclosure of Invention
The invention aims to provide an improved intelligent welding system for a ship plate frame structure robot, which can overcome the defects of poor precision and low efficiency in the prior art.
In order to achieve the above object, the technical scheme of the present invention is as follows: a intelligent welding system for boats and ships grillage structure robot, its characterized in that: the intelligent welding system comprises a welding device, a digital welding power supply and a control system, wherein the digital welding power supply and the control system are connected with the welding device; the welding device comprises a guide rail and a welding robot system arranged on the guide rail, wherein the control system is connected with a man-machine interaction system, and the man-machine interaction system is used for controlling the welding robot system; the welding robot system comprises a mechanical arm, and the mechanical arm is connected with a laser scanning piece and a welding gun device.
Further, the guide rail is arranged on the guide rail frame, a welding device base is arranged on the guide rail frame, a guide wheel is arranged on the welding device base, and the welding device can slide on the guide rail frame through the guide wheel; the welding device base is provided with a welding wire feeder and a gun cleaning and wire cutting device.
The welding method comprises the following steps: a. the intelligent welding system is adopted for welding, firstly, a control system plans a welding line information acquisition position according to a welding structure form, and a corresponding movement track of a mechanical arm is compiled according to a scanning range of a laser scanner;
b. the mechanical arm performs a first pre-welding motion, the mechanical arm drives the laser scanner to scan the welding line information acquisition position, after the scanning is completed, the actual position information of the welding line is transmitted to the control system, and the control system compares the actual position information with preset data and then re-compiles the welding track of the corresponding mechanical arm;
c. The welding gun device performs welding work, and when the mechanical arm reaches a welding seam starting and stopping position, the control system controls the mechanical arm to execute a starting and arc-receiving program;
d. When the work of one welding unit is finished, the mechanical arm drives the gun cleaning and wire cutting equipment to finish gun cleaning and wire cutting, and the welding robot system automatically moves to the next welding unit through the guide rail to continue to work.
In the step b, the laser scanning piece transmits the collected weld position characteristic point data to the control system, the control system compares the obtained data with preset data, deviation is obtained, welding track planning is carried out again, the welding track planning is converted into movement data of the mechanical arm, the data are fed back to the mechanical arm, and the mechanical arm moves according to the finally obtained data.
When the welding robot system is used, the welding robot system is specially used for assembling a plate frame structure in a ship, manual intervention is not needed in the whole course after the welding robot system is started, and after the robot finishes the work of one unit, the welding robot system can automatically move to the next unit to work through the guide rail. The assembly precision and the placing position of the structure are required to be low, the whole system is convenient to assemble, disassemble and hoist, and the current situations that the work piece of a shipyard is large and difficult to move can be solved.
Drawings
Fig. 1 is a schematic structural diagram of an embodiment of the present invention.
Fig. 2 is a schematic view of a guide rail structure according to the present invention.
FIG. 3 is a schematic diagram of the structure of a welded blank required for the intelligent welding system of the present invention.
Fig. 4 is a schematic diagram of a welding and plate-supplementing fillet transition of the robot with the ship plate frame structure.
Fig. 5 is a schematic diagram of a welding patch lap transition of a robot with a marine plate frame structure.
Fig. 6 is a schematic view of a welding wrap angle of the robot with a ship plate frame structure.
Fig. 7 is a partially enlarged schematic view of the structure of fig. 6.
Fig. 8 is an electrical diagram of a control system of the present invention.
Detailed Description
The invention is further described below with reference to the drawings and examples.
The designations in the various drawings indicate: 1 welding gun device, 2 laser scanning piece, 3 robotic arm, 4 clear rifle wire cutting equipment, 5 guide rail, 6 welding wire feeder, 7 digital welding power supply, 8 control system, 9 human-computer interaction system, 10 bottom plate, 11 floor, 12 patch, 13 through welding hole, 14 longitudinal bone.
The intelligent welding system for the robot with the ship plate frame structure disclosed by the invention is different from the prior art in that: the intelligent welding system comprises a welding device, a digital welding power supply and a control system, wherein the digital welding power supply and the control system are connected with the welding device; the welding device comprises a guide rail and a welding robot system arranged on the guide rail, wherein the control system is connected with a man-machine interaction system, and the man-machine interaction system is used for controlling the welding robot system;
the welding robot system comprises a mechanical arm, and the mechanical arm is connected with a laser scanning piece and a welding gun device.
Optionally, the guide rail is arranged on a guide rail frame, a welding device base is arranged on the guide rail frame, a guide wheel is arranged on the welding device base, and the welding device can slide on the guide rail frame through the guide wheel; the welding device base is provided with a welding wire feeder and a gun cleaning and wire cutting device.
Further, the guide rail be connected by vertical guide rail strip and horizontal guide rail strip and form, the junction of vertical guide rail strip and horizontal guide rail strip is equipped with protruding contact strip, protruding contact strip be guide rail stop device, whole track is rectangle, be equipped with boundary screens piece at orbital both ends and middle part, boundary screens piece totally six, two liang be a set of, set up respectively in orbital both ends and middle part, boundary screens piece sets up in orbital below, every boundary screens piece comprises a bottom plate and the bellied card strip of establishing on the bottom plate, the distance between card strip and the guide rail is 10-35mm, the card strip is the electro-magnet, the walking of welding robot on the guide rail of above-mentioned structure can accurate control, stop and turn to the motion.
In one embodiment, a support arm is arranged on a base of the welding device, the mechanical arm is rotatably connected with the support arm, a shaft flange is arranged on the mechanical arm, the welding gun device and the laser scanning piece are arranged on the shaft flange, and the laser scanning piece is arranged below the welding gun device.
Further, a welding wire feeder is arranged on the supporting arm, the welding gun device is rotatably connected with the mechanical arm, and a welding gun is arranged on the welding gun device.
In one method embodiment, the welding method comprises the steps of: a. the intelligent welding system is adopted for welding, firstly, a control system plans a welding line information acquisition position according to a welding structure form, and a corresponding movement track of a mechanical arm is compiled according to a scanning range of a laser scanner; b. the mechanical arm performs a first pre-welding motion, the mechanical arm drives the laser scanner to scan the welding line information acquisition position, after the scanning is completed, the actual position information of the welding line is transmitted to the control system, and the control system compares the actual position information with preset data and then re-compiles the welding track of the corresponding mechanical arm; c. the welding gun device performs welding work, and when the mechanical arm reaches a welding seam starting and stopping position, the control system controls the mechanical arm to execute a starting and arc-receiving program; d. when the work of one welding unit is finished, the mechanical arm drives the gun cleaning and wire cutting equipment to finish gun cleaning and wire cutting, and the welding robot system automatically moves to the next welding unit through the guide rail to continue to work.
In the step b, the laser scanning piece transmits the collected weld position characteristic point data to the control system, the control system compares the obtained data with preset data, deviation is obtained, welding track planning is carried out again, the welding track planning is converted into movement data of the mechanical arm, the data are fed back to the mechanical arm, and the mechanical arm moves according to the finally obtained data. The number of welding lines depends on the number of patch boards and the number of welding holes, the patch boards can be arranged on the left side, the right side, the two sides and the nothing of the plate frame structure, and the welding holes can be arranged on the left side, the right side and the upper part of the patch boards and the nothing of the welding holes.
Compared with the prior art, the invention has obvious advantages. The welding robot system provided by the invention is free from manual intervention in the whole process after being started, has lower requirements on the assembly precision and the placement position of the structure, is convenient to assemble, disassemble and hoist, and can solve the current situations that the work piece of a shipyard is large and is not easy to move.
In another method embodiment, when the welding gun device is used for welding the ship plate frame structure, the welding gun device comprises vertical fillet welding, flat fillet welding, round fillet welding and fillet welding, the welding seam gap is 0-5mm, the surface of the steel plate is pretreated with primer, and polishing is not needed near the welding seam; in the welding process, CO2 gas shielded welding, flux-cored wire, flat fillet welding and vertical fillet welding are adopted, an angle of 40 degrees is formed between the welding gun device and the steel plate, the welding gun device swings in a V shape, and the welding gun device stays for 0.5-1.5 seconds according to a welding seam gap when swinging to two side ends.
For example, when welding, there is a fillet transition during the transition of the weld patch from vertical fillet welding to flat fillet welding; at this time, the angle of the welding gun is changed greatly, and the robot needs to adjust the angle greatly in a short time, and in the process, the position A to the position B are shown in fig. 4. Because of the mechanical principle of the robot, the welding quality is difficult to ensure, and corresponding process test verification is needed. Vertical fillet welds and flat fillet welds at the complementary plates are welded separately, and arc extinction occurs at the fillet transition. Specifically, the vertical angle welding is performed from bottom to top, arc is extinguished at the arc position, the horizontal angle welding is performed from left to right, arc is extinguished at the arc position, two welding seams are overlapped at the arc extinguishing position, and the quenching points of the two welding seams respectively pass through each other by 3-5mm.
In one method embodiment, lap-joint transition welding is required, and a false welding problem is easy to occur at the lap-joint welding position due to too large and too fast angle change of a welding gun at the flat fillet welding position of the joint of the patch and the rib plate. From position a to position B to position C as in fig. 5. The invention adopts the method that the arc is slightly stopped when the vertical fillet weld starts, the angle between the welding gun and the bottom plate is smaller than 30 degrees for about 1-2 seconds, and the full welding seam can be ensured when the welding is performed at the position B of the flat fillet weld.
In one method embodiment, the fillet weld is performed using an intelligent welding system, where the fillet is a common defect location in the welding operation of the shipyard. When the robot is used for welding, defects can be generated due to the problem of angle change of a welding gun, and quality problems can be caused due to process reasons. From position a to position B, from position C to position D, and from position E to position F, as in fig. 6. The method solves the problem that corresponding process tests are needed to be carried out, and the process parameters and the welding paths are also needed to be adjusted. The invention adopts two welding modes at the same position to realize the fillet welding, namely, the welding is carried out from the position A (C, E) to the position B (D, F) and then from the position B (D, F) to the position A (C, E), and the middle part is not remained.
In a specific embodiment, vertical fillet welding and horizontal fillet welding of the ship plate frame structure are carried out, CO 2 gas shield welding is adopted aiming at common ship grade-A steel with the thickness of 12mm, the height of a welding leg is about 7mm, and specific technological parameters of robot welding are determined as shown in tables 1 and 2.
TABLE 1 Flat fillet welding process parameters
Table 2 vertical fillet welding process parameters
Specifically, the whole intelligent welding system is positioned to a position to be welded, and the operation is started in a one-key starting mode through a man-machine interaction system. The mechanical arm drives a laser scanning system arranged at the front part of the mechanical arm to move along a specific track and collect receipts, the laser scanning system transmits collected data (characteristic points of the weld joint positions) to a control system, the control system compares the obtained data with preset data to obtain a difference value (deviation amount), welding track planning is carried out again, the welding track planning is converted into moving data of the mechanical arm, the moving data are fed back to the mechanical arm, and the mechanical arm moves according to the finally obtained data. The welding system and the mechanical arm work cooperatively, and when the mechanical arm respectively reaches the starting and stopping positions of the welding seam, the welding system automatically executes the starting and stopping arc procedure. When the work of one welding unit is finished, the mechanical arm automatically executes the gun cleaning and wire cutting program to finish gun cleaning and wire cutting, and the mechanical arm automatically moves to the next welding unit through the guide rail to continue to work.
The welding system, the laser scanning system and the mechanical arm system are uniformly and coordinately controlled by the control cabinet and are communicated with each other by a DeviceNet protocol.
Firstly, according to a welding structure form, a welding line information acquisition position is planned, and according to the scanning range of a laser scanner, a corresponding mechanical arm movement track is compiled, so that the mechanical arm movement track drives the laser scanner to scan the welding line information acquisition position, and meanwhile, according to the same welding structure form, a corresponding mechanical arm welding track is compiled. And secondly, the laser scanner is fixed on the mechanical arm shaft flange, forms a fixed space geometrical relationship with a welding gun which is also fixed on the mechanical arm shaft flange, and establishes a relationship model in a control system. In the working process, after the laser scanner finishes scanning, the actual position information of the welding seam is transmitted to the control system, and according to the spatial position relation model of the laser scanner and the welding gun, the system automatically adjusts the actual welding position deviation amount of the mechanical arm and starts welding according to the well-compiled welding track of the mechanical arm.
Therefore, the invention has the following advantages:
by adopting the welding robot system, the laser scanning system can collect welding seam information through automatic scanning and transmit the welding seam information to the control system, and the control system calculates the collected information and transmits the information to the robot arm so that the welding robot arm can weld according to the actual welding seam track, and manual intervention is not needed in the whole process.
By adopting the welding robot system, the robot can be controlled through the man-machine interaction system, including starting, controlling, parameter adjusting and real-time monitoring.
By adopting the welding robot system, the gun cleaning and wire cutting equipment can automatically or manually clean the gun and cut wires according to actual conditions.
By adopting the welding robot system, after the robot finishes the work of one unit, the robot can automatically move to the next unit to work through the guide rail.
By adopting the welding robot system, workpieces are placed without fixing, the robot system is not required to be positioned in a specific precision, and the requirement on workpiece assembly precision is not high.
Compared with the prior art, the invention has obvious advantages. The welding robot system provided by the invention is free from manual intervention in the whole process after being started, has lower requirements on the assembly precision and the placement position of the structure, is convenient to assemble, disassemble and hoist, and can solve the current situations that the work piece of a shipyard is large and is not easy to move.
The foregoing is a further detailed description of the invention in connection with the preferred embodiments, and it is not intended that the invention be limited to the specific embodiments described above. It will be apparent to those skilled in the art that several simple deductions or substitutions may be made without departing from the spirit of the invention, and these should be considered to be within the scope of the invention.
Claims (4)
1. A welding method of an intelligent welding system for a ship plate frame structure robot is characterized in that: the intelligent welding system adopted by the welding method comprises a welding device, a digital welding power supply and a control system, wherein the digital welding power supply and the control system are connected with the welding device;
the welding device comprises a guide rail and a welding robot system arranged on the guide rail, wherein the control system is connected with a man-machine interaction system, and the man-machine interaction system is used for controlling the welding robot system;
the welding robot system comprises a mechanical arm, wherein the mechanical arm is connected with a laser scanning piece and a welding gun device;
the welding method comprises the following steps: a. the intelligent welding system is adopted for welding, firstly, a control system plans a welding line information acquisition position according to a welding structure form, and a corresponding movement track of a mechanical arm is compiled according to a scanning range of a laser scanner;
b. the mechanical arm performs a first pre-welding motion, the mechanical arm drives the laser scanner to scan the welding line information acquisition position, after the scanning is completed, the actual position information of the welding line is transmitted to the control system, and the control system compares the actual position information with preset data and then re-compiles the welding track of the corresponding mechanical arm;
c. the welding gun device performs welding work, and when the mechanical arm reaches a welding seam starting and stopping position, the control system controls the mechanical arm to execute a starting and arc-receiving program;
d. When the work of one welding unit is finished, the mechanical arm drives the gun cleaning and wire cutting equipment to finish gun cleaning and wire cutting, and the welding robot system automatically moves to the next welding unit through the guide rail to continue to work;
c, when the welding gun device is used for welding the ship plate frame structure, the welding gun device comprises vertical fillet welding, flat fillet welding, round fillet welding and fillet welding, the welding seam gap is 0-5mm, the surface of the steel plate is pretreated with primer, and polishing is not needed near the welding seam;
the welding process adopts CO2 gas shielded welding, flux-cored wires, flat fillet welding and vertical fillet welding, an angle of 40-45 degrees is formed between a welding gun device and a steel plate, the welding gun device swings in a V shape, and the welding gun device stays for 0.5-1.5 seconds according to a welding seam gap when swinging to two side ends;
in the step c, when welding, a fillet is in transition in the process of changing the welding patch from vertical fillet welding to flat fillet welding; the vertical angle welding is carried out from bottom to top, arc is extinguished at the arc position, the flat angle welding is carried out from left to right, arc is extinguished at the arc position, two welding seams are overlapped at the arc extinguishing position, and the quenching points of the two welding seams respectively pass through 3-5mm of each other;
Vertical fillet welding and flat fillet welding at the patch are separately welded, and quenching points are overlapped at the fillet transition; the arc is slightly stopped when the vertical angle welding starts, the time is 1-2 seconds, and the angle between the welding gun and the bottom plate is smaller than 30 degrees.
2. The welding method of the intelligent welding system for the ship plate frame structural robot according to claim 1, wherein: the guide rail is arranged on the guide rail frame, a welding device base is arranged on the guide rail frame, a guide wheel is arranged on the welding device base, and the welding device can slide on the guide rail frame through the guide wheel;
The welding device base is provided with a welding wire feeder and a gun cleaning and wire cutting device.
3. The welding method of the intelligent welding system for the ship plate frame structural robot according to claim 1, wherein: the welding device comprises a welding device base, a mechanical arm and a supporting arm are arranged on the welding device base, the mechanical arm is rotatably connected with the supporting arm, a shaft flange is arranged on the mechanical arm, a welding gun device and a laser scanning piece are arranged on the shaft flange, and the laser scanning piece is arranged below the welding gun device.
4. The welding method of the intelligent welding system for the ship plate frame structural robot according to claim 1, wherein: and b, transmitting the collected weld position characteristic point data to a control system by the laser scanning piece, comparing the obtained data with preset data by the control system to obtain deviation, then re-planning a welding track, converting the welding track into movement data of the mechanical arm, feeding the data back to the mechanical arm, and moving the mechanical arm according to the finally obtained data.
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| CN201611263692.4A CN107052508B (en) | 2016-12-30 | 2016-12-30 | Intelligent welding system for ship plate frame structure robot and welding process thereof |
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| CN201611263692.4A CN107052508B (en) | 2016-12-30 | 2016-12-30 | Intelligent welding system for ship plate frame structure robot and welding process thereof |
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