CN108161198B - Robot resistance spot welding process parameter testing and control method - Google Patents
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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
- B23K11/00—Resistance welding; Severing by resistance heating
- B23K11/10—Spot welding; Stitch welding
- B23K11/11—Spot welding
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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
- B23K11/00—Resistance welding; Severing by resistance heating
- B23K11/24—Electric supply or control circuits therefor
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- B23K11/255—Monitoring devices using digital means the measured parameter being a force
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- 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
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Abstract
The invention relates to the field of mechanical welding equipment, in particular to a robot resistance spot welding process parameter testing and controlling method, which comprises S1 and measurement position transfer verification; s2, carrying out null point welding; s3, carrying out actual measurement; s4, carrying out parameter linearization on the programmed position output parameter of S2 and the actual position output parameter of S3; and S5, verifying the set values of the process parameters. The invention has the beneficial effects that: the technical scheme comprises the steps of comparing and verifying the parameters of the empty spot and the actual spot welding, and ensuring the consistency of parameter output under two conditions; the fixed support of the welding test instrument is designed and manufactured, so that the manual participation is reduced, and the operation safety performance is improved; the fixed bracket of the welding test piece is designed and manufactured, and the history that the welding test piece cannot be verified is ended; the definition of the number of the machine ginseng is added, so that the automatic separation of the welding current and the welding pressure test is realized; the robot program is designed and written, the flexibility of operation is guaranteed, and personnel participation is reduced.
Description
Technical Field
The invention relates to the field of mechanical welding equipment, in particular to a robot resistance spot welding process parameter testing and controlling method.
Background
The welding parameters mainly defined and controlled by the electrode holder controller mainly comprise welding current, welding time and welding pressure, and the welding time and the welding pressure are not controlled in a closed loop mode, so that the difference between a set value and an output value is large; the welding current is closed-loop control, and the actual output value is different from the measured value of the robot and is also influenced by a measuring element, so that the consistency of the set value, the measured value of the robot and the actual output value cannot be ensured.
At present, two methods for testing the spot welding parameters of the robot in a domestic and foreign measuring mode are available: firstly, as shown in an abstract attached drawing, a robot is manually operated by a robot operator, a process parameter engineer measures parameters at an actual welding position, simultaneously searches parameter values and process setting range values corresponding to a calling parameter number of the robot, manually closes welding current during welding current testing, and then measures at a robot spot welding position, and the operation method has the advantages that the parameter measurement can be accurately and effectively realized, and the defects of extremely low working efficiency, excessive operators, poor safety performance and the like are overcome; the second method is to read parameter values directly through a robot welding controller, and has the advantages that the parameters can be rapidly measured, and the method has the disadvantages that only welding current has closed-loop feedback, so that only current value has certain reference, but actual output value is not known, so that reference meaning is not great.
FIG. 1 is a block diagram of a current robotic resistance welding process.
Disclosure of Invention
In order to solve the problems, the invention provides a robot resistance spot welding process parameter testing and controlling method,
s1, measurement position transfer verification: setting a testing station, performing corresponding displacement adjustment on the welding position of the welding robot, and performing welding setting on the welding robot;
s2, performing null point welding, respectively measuring a current parameter and a pressure parameter during welding, and recording the current parameter and the pressure parameter as a programmed position output parameter of the welding robot;
s3, carrying out actual measurement, respectively measuring a current parameter and a pressure parameter during welding by using a precisely calibrated current tester and a precisely calibrated pressure tester, and recording the current parameter and the pressure parameter as actual position output parameters of the welding robot;
s4, carrying out parameter linearization on the programmed position output parameter of S2 and the actual position output parameter of S3; calibrating the output slope of the current transformer and the proportional valve of the welding robot by taking the actual position output parameter of S3 as a standard, and ensuring that the actual position output parameter of the welding robot is consistent with the welding current measured by the robot through closed-loop feedback of the current transformer and the welding pressure output by the proportional valve;
and S5, verifying the process parameter set value, completing the verification of the process parameter of the welding test piece through the welding test piece testing assembly, and guiding the process setting according to the experimental data.
Preferably, the welding setting in S1 includes setting of welding parameters and programming of welding track.
Preferably, S4 further includes calibrating the welding current, and the specific method includes:
the method comprises the following steps that the current of a welding robot is measured, namely the current value measured by a current transformer, specifically the secondary side alternating current of a transformer, the measured current value is the measured value of the secondary side of the transformer, and the method is more accurate if the direct current of the secondary side is directly measured;
adding a current tester at the lower electrode, directly measuring at the holding rod of the upper electrode and the lower electrode, calculating the absolute value of the measured value of the current tester and the measured value of the secondary side of the transformer, defining the robot output when the absolute value exceeds the error, and outputting a definition signal to prompt an operator to calibrate the current;
if the measured value of the current tester is IA-b and IA + a, the measured current value of the secondary side of the transformer satisfies (IA-b)/k = IB1≤IB≤IB2If not, linearization is needed, namely the k value needs to be corrected;
wherein a and b are upper and lower deviation values of the process requirement; k is the slope of the linearization;
through the linearization of the current transformer, the effect of correcting the k value is achieved.
Preferably, when the welding gun is a pneumatic welding gun, the welding pressure calibration method comprises the following steps:
f = P.S, wherein F is spot welding pressure, S is the sectional area of the execution cylinder, P is the air pressure value of the output side of the proportional valve, and the curve measurement of the set value of the proportional valve adopts a window comparison mode P _1 < P _ 2; p _1 and P _2 are respectively the lower limit upper limit pressure values of the air inlet source meeting the process output requirements;
calculating to obtain the required proportional valve output side air pressure values Pmin and Pmax and the theoretical feasible region of the change range of the proportional valve output side air pressure value P under two limit pressures according to the welding pressure upper deviation + b and lower deviation-a of the maximum value Fm and the minimum value Fn of the pressure required by the process and a formula F = P.S;
all pressure output within the process error range can be ensured only if Pmin is more than P _1 and more than or equal to 0 and Pmax is less than P _ 2;
according to the formula F = P.S = P.2 pi R, F welding clamp output pressure, P proportional valve output pressure control, S main cylinder cross-sectional area and R main cylinder radius;
preferably, when the welding gun is a servo welding gun, the welding pressure calibration method comprises the following steps:
F=T/L=9549×P/N•L=9549x1.732U•I•cosɕ/N•L；
T＜T_limit；
wherein F is output pressure of the welding tongs, T is output torque of the motor, L is torque acting force arm, P is motor power, N is motor rotating speed, U is motor voltage, I is motor current, and cos ɕ is power factor;
the torque acting arm L, the motor power P, the motor rotating speed N, the motor voltage U, the motor current I and the power factor cos ɕ are all constants;
the method comprises the steps of obtaining an actually output torque curve through actual measurement of output welding pressure, adjusting output torque T of a motor through calibration of the slope of the torque curve, and further calibrating the welding pressure.
Preferably, the step of S5 is:
1) defining test parameters through a welding tongs controller, realizing the setting of any welding parameters through a computer, realizing welding through the given parameters by means of increased robot programming, and carrying out a test piece spot welding test;
2) the test piece can be verified through a tension test and a tearing test of the test piece, and through statistical analysis of a large amount of data, if the current process parameter set value is not the optimal set value, the welding process parameters can be further optimized according to the statistical result of experimental data and the welding appearance quality;
the consistency verification of the measurement of the actual position, the output value, the measurement of the programmed position, the output value, the actual measurement value of the welding process parameter and the set value of the welding process parameter is realized, and the actual output value is directly obtained by reading the self-measurement and output value of the actual position of the robot in the welding controller.
The embodiment of the invention has the beneficial effects that: the technical scheme comprises the steps of comparing and verifying the parameters of the empty spot and the actual spot welding, and ensuring the consistency of parameter output under two conditions; the fixed support of the welding test instrument is designed and manufactured, so that the manual participation is reduced, and the operation safety performance is improved; the fixed bracket of the welding test piece is designed and manufactured, and the history that the welding test piece cannot be verified is ended; the definition of the number of the machine ginseng is added, so that the automatic separation of the welding current and the welding pressure test is realized; the robot program is designed and compiled, so that the flexibility of operation is ensured, and the participation of personnel is reduced; the consistency output of the parameters is realized through actual measurement, and the accuracy of the parameter action is ensured.
Drawings
Fig. 1 is a block diagram of a prior art robot spot welding system according to the background of the present invention.
Fig. 2 is a block diagram of a robot spot welding system according to an embodiment of the present invention.
Fig. 3 is a schematic block diagram of an embodiment of the present invention.
FIG. 4 is a graph of DC measurements according to an embodiment of the present invention.
FIG. 5 is a pressure calibration schematic of an embodiment of the present invention.
Fig. 6 is a graph of pressure control for a pneumatic welding gun holder according to an embodiment of the present invention.
FIG. 7 is a graph of servo torch holder pressure control in accordance with an embodiment of the present invention.
Detailed Description
Example 1
Referring to fig. 2 and 3, the invention provides a robot resistance spot welding process parameter testing and controlling method, which comprises the following steps:
step one, measuring position transfer verification, namely measuring welding current and welding pressure at an actual welding position, which is very tedious, transferring the welding position to a position convenient for operation through robot programming, and realizing welding track programming;
the measurement of the welding current should be measured at the actual spot welding position of the workpiece, which for robotic welding cannot be moved to a position where the welding tongs are deemed convenient to operate without programming.
Step two, verifying that the position transfer does not change parameter output, measuring through a null point (no welding part) and actual spot welding, ensuring that the welding current does not change, and closing the current;
welding pressure and welding current can not be measured simultaneously, and when the welding pressure is tested, if the welding current output of the robot is not closed, the damage of a test pressure gauge can be caused.
The welding pressure and the welding position are not greatly changed in the test, so that the consistency of self-measurement and output of an actual position and self-measurement and output of a programmed position is realized; theoretically, the output of the welding pressure is independent of the welding position; in fact, a large number of data acquisition experiments prove that the welding pressure parameter output at the workpiece spot welding position and the actual measuring position programmed by the user is within the measuring error range of the pressure gauge.
And thirdly, measuring the actual output value of the welding process parameter by using the accurately calibrated current tester and the accurately calibrated pressure tester, calibrating the output slope of the current transformer and the proportional valve of the robot by taking the actual output value as a standard, and ensuring that the actual output value of the welding process parameter measured by using the accurately calibrated current tester and the accurately calibrated pressure tester is consistent with the welding current measured by the robot through closed loop feedback of the current transformer and the welding pressure output by the proportional valve.
The specific calibration process comprises the following steps:
the welding current calibration is referenced to the following algorithm:
the method comprises the following steps that the current of a welding robot is measured, namely the current value measured by a current transformer, specifically the secondary side alternating current of a transformer, the measured current value is the measured value of the secondary side of the transformer, and the method is more accurate if the direct current of the secondary side is directly measured;
adding a current tester at the lower electrode, directly measuring at the holding rod of the upper electrode and the lower electrode, calculating the absolute value of the measured value of the current tester and the measured value of the secondary side of the transformer, defining the robot output when the absolute value exceeds the error, and outputting a definition signal to prompt an operator to calibrate the current;
referring to FIG. 4 and FIG. 5, if the measured value of the current tester is IA-b ≦ IA + a, the measured current value of the secondary side of the transformer is (IA-b)/k = IB1≤IB≤IB2And if the value is not equal to or less than the value of k, the measurement consistency requirement is met, otherwise linearization is needed, namely the value of k needs to be corrected.
Where k is the slope of the linearization
The pressure calibration refers to the following algorithm:
pressure calibration principle:
f = P.S (where F is the spot welding pressure, S is the cross-sectional area of the actuating cylinder, and P is the proportional valve output side air pressure value), the theoretical curve is referenced to Line2 in fig. 6 below;
proportional valve setpoint profile measurements are respectively compared with window comparison P _1 < P _2 of FIG. 4.
Calculating two limit pressure requirements Pmin and Pmax according to the maximum pressure Fm, the minimum welding pressure upper deviation + B and the minimum welding pressure lower deviation-a of the process requirement and a theoretical curve Line2, and referring to FIG. 6 for a theoretical feasible region (a closed region consisting of A-B-C-D-E-F-A);
with the combination of the set values in FIG. 5, all pressure outputs within the process error range can be ensured only if Pmin is more than P _1 and more than or equal to 0 and Pmax is less than P _ 2;
parameter linearization calibration is needed when a theoretical curve caused by mechanical reasons on site changes from Line2 to Line1 and Line4, and proportional valve setting does not need to be considered; when the theoretical curve changes from Line2 to Line3 and Line5, whether the setting of the proportional valve can meet the output requirement needs to be considered when the parameter linearization calibration is performed, and feasible domain calculation is performed according to fig. 6.
Electrode holder pressure control (pneumatic welding gun): f = P.S = p.2 π R;
(F, controlling output pressure of a welding clamp, controlling output pressure of a P proportional valve, controlling cross section area of an S main cylinder, and controlling radius of an R main cylinder);
electrode holder pressure control (servo torch): f = T/L =9549 xp/N.L =9549 × 1.732u.i.cos ɕ/N.L
T＜T_limit
(F, output pressure of a welding clamp, output torque of a T motor, L torque acting force arm, P is motor power, N motor rotating speed, U motor voltage, I motor current and cos ɕ power factor).
Step four, verifying the set value of the process parameter, completing the verification of the process parameter of the welding test piece through the welding test piece testing component, guiding the process setting according to the experimental data,
1) test parameters can be defined in a welding tongs controller, any welding parameter is given through a PC, welding is realized by means of increased robot programming through the given parameters, and a test piece spot welding test is carried out;
2) the test piece can be verified through a tension test and a tearing test of the test piece, and through statistical analysis of a large amount of data, if the current process parameter set value is not the optimal set value, the welding process parameters can be further optimized according to the statistical result of experimental data and the welding appearance quality.
Therefore, consistency verification of four groups of parameters is realized, and actual output values can be directly obtained by reading the self-measurement and output values of the actual position of the robot in the welding controller.
Referring to fig. 1 to 3, based on the prior art, the new functions of the subroutine are implemented by converting the measured position in the corresponding step one, measuring and verifying the position of consistency in the step two, and setting and measuring the parameters in the step four.
F4 and I4 correspond to robot set values;
f3 and I3 are the programmed positions of the newly added subprogram of the robot, and the calibrated accurate measurement values of an ammeter and a pressure gauge are used;
f2 and I2 are measured values of a current transformer of the robot at the programmed position of the robot new subprogram and welding pressure values corresponding to the output of a proportional valve;
f1 and I1 are measured values of current transformers of the robot at the actual spot welding workpiece (cab) position of the robot and welding pressure values corresponding to the output of a proportional valve;
the error between the output values of the parameter null point and the actual spot welding parameter is very small through the null point verification of the robot, the actual output value of the welding tongs is measured by adopting the calibrated current tester and the calibrated pressure tester, the welding parameter is linearized through a notebook computer, the parameter value read by controlling is ensured to be consistent with the set value and the actual measured value, and in addition, the automatic spot welding of the resistance spot welding test piece is realized.
And (3) current situation analysis:
1) the A7 automatic main wire splicing robot needs an operator to hold a test piece by hand to enter the safety net and operates the robot by another operator to perform welding test on the test piece when the automatic main wire splicing robot is used for making a current pressure test piece, so that the safety of the operator cannot be ensured, and serious potential safety hazards exist.
2) The robot is in motion, the parameter intuition is not strong, the parameter value checking needs an engineer to check and set by adopting control software, and the operation is complex.
3) The test piece test needs to be stopped in the whole line, the measurement time is long, and the single test time of each robot is about 1 hour, which affects the production.
The implementation measures are as follows:
1) an automatic test piece test board is additionally arranged, the test piece test board comprises two test piece spot welding positions of tension and tearing, and the robot automatically realizes the welding of a test piece at a preset position according to the test piece position.
2) The operator only needs to put the welding test piece into the corresponding position, and the primary fixation is realized through the permanent magnet, and the PLC program automatically realizes the thickness detection of the welding test piece and gives the corresponding welding process parameters.
3) The robot judges the position of the test piece on the corresponding platform, controls the platform fixing device to execute the action, and ensures the action to be executed accurately through signal feedback;
4) the touch screen can display corresponding parameters, and if the setting is wrong, the parameters of the touch screen welding test piece can be modified manually in time.
5) And the robot automatically completes the test piece spot welding of corresponding parameters according to the position and the parameters of the test piece before the electrode is ground in the grinding procedure.
6) After welding, the robot automatically classifies the welding test pieces with different parameters according to the test piece types and the test piece parameters, so that the test piece management in the later period is facilitated.
The measuring method well avoids the defects of two testing methods, inherits the advantages of the two measuring methods, can quickly and effectively realize parameter measurement and control, reduces the number of parameter measuring personnel from 6 to 2, reduces the operation time from 1 hour to 5 minutes for each robot, improves the working efficiency to more than 60 times, improves the accuracy of parameter measurement and control to 99 percent, is an operation method at the international level, and provides guiding significance for the control of industrial spot welding parameters.
For a complex combined system formed by a robot, a welding tongs controller and a measuring unit, no effective measuring and controlling method exists at home and abroad at present, the invention combines the advantages of the two traditional methods, I4/I3/I2/I1 and F4/F3/F2/F1 to realize linearization, well ensures the stability of welding parameters, designs and manufactures a fixed support for a tester, ends the history that a test piece cannot be tested, and improves the working efficiency by more than 60 times. The device can be applied to parameter control and measurement of similar combined systems in all industries.
The above description is only for the purpose of illustrating the preferred embodiments of the present invention and is not to be construed as limiting the invention, and any modifications, equivalents, improvements and the like that fall within the spirit and principle of the present invention are intended to be included therein.
Claims (3)
1. A robot resistance spot welding process parameter testing and controlling method is characterized in that,
s1, measurement position transfer verification: setting a testing station, performing corresponding displacement adjustment on the welding position of the welding robot, and performing welding setting on the welding robot;
s2, performing null point welding, respectively measuring a current parameter and a pressure parameter during welding, and recording the current parameter and the pressure parameter as a programmed position output parameter of the welding robot;
s3, carrying out actual measurement, respectively measuring a current parameter and a pressure parameter during welding by using a precisely calibrated current tester and a precisely calibrated pressure tester, and recording the current parameter and the pressure parameter as actual position output parameters of the welding robot;
s4, carrying out parameter linearization on the programmed position output parameter of S2 and the actual position output parameter of S3; calibrating the output slope of the current transformer and the proportional valve of the welding robot by taking the actual position output parameter of S3 as a standard, and ensuring that the actual position output parameter of the welding robot is consistent with the welding current measured by the robot through closed-loop feedback of the current transformer and the welding pressure output by the proportional valve;
s5, verifying the technological parameter set value, completing the welding test piece technological parameter verification through the welding test piece testing component, and guiding the technological setting according to the experimental data;
s4, calibrating the welding current, which comprises the following steps:
the method comprises the following steps of measuring the current of a welding robot, namely measuring the current value of a current transformer, specifically the secondary side alternating current of a transformer, wherein the measured current value is the measured value of the secondary side of the transformer;
adding a current tester at the lower electrode, directly measuring at the holding rod of the upper electrode and the lower electrode, calculating the absolute value of the measured value of the current tester and the measured value of the secondary side of the transformer, defining the robot output when the absolute value exceeds the error, and outputting a definition signal to prompt an operator to calibrate the current;
if the measured value of the current tester is IA-b and IA + a, the measured value of the secondary side of the transformer satisfies (IA-b)/k = IB1≤IB≤IB2If not, linearization is needed, namely the k value needs to be corrected;
wherein a and b are upper and lower deviation values of the process requirement; k is the slope of the linearization;
the current transformer achieves the effect of correcting the k value through linearization;
when the welding gun is a pneumatic welding gun, the welding pressure calibration method comprises the following steps:
f = P.S, wherein F is spot welding pressure, S is the sectional area of the execution cylinder, P is the air pressure value of the output side of the proportional valve, and the curve measurement of the set value of the proportional valve adopts a window comparison mode P _1 < P _ 2; p _1 and P _2 are respectively the lower limit upper limit pressure values of the air inlet source meeting the process output requirements;
calculating to obtain the required proportional valve output side air pressure values Pmin and Pmax and the theoretical feasible region of the change range of the proportional valve output side air pressure value P under two limit pressures according to the welding pressure upper deviation + b and lower deviation-a of the maximum value Fm and the minimum value Fn of the pressure required by the process and a formula F = P.S;
all pressure output within the process error range can be ensured only if Pmin is more than P _1 and more than or equal to 0 and Pmax is less than P _ 2;
according to the formula F = P.S = P.2 pi R, F welding clamp output pressure, P proportional valve output pressure control, S main cylinder cross-sectional area and R main cylinder radius;
when the welding gun is a servo welding gun, the welding pressure calibration method comprises the following steps:
F=T/L=9549×P/N•L=9549x1.732U•I•cosɕ/ N•L；
T＜T_limit；
wherein F is output pressure of the welding tongs, T is output torque of the motor, L is torque acting force arm, P is motor power, N is motor rotating speed, U is motor voltage, I is motor current, and cos ɕ is power factor;
the torque acting arm L, the motor power P, the motor rotating speed N, the motor voltage U, the motor current I and the power factor cos ɕ are all constants;
the method comprises the steps of obtaining an actually output torque curve through actual measurement of output welding pressure, adjusting output torque T of a motor through calibration of the slope of the torque curve, and further calibrating the welding pressure.
2. The method for testing and controlling parameters of a robotic resistance spot welding process of claim 1, wherein said welding settings in S1 include setting of welding parameters and welding track programming.
3. The method for testing and controlling parameters of a robotic resistance spot welding process of claim 1, wherein the step for S5 is:
1) defining test parameters through a welding tongs controller, realizing the setting of any welding parameters through a computer, realizing welding through the given parameters by means of increased robot programming, and carrying out a test piece spot welding test;
2) the test piece can be verified through a tension test and a tearing test of the test piece, and through statistical analysis of a large amount of data, if the current process parameter set value is not the optimal set value, the welding process parameters can be further optimized according to the statistical result of experimental data and the welding appearance quality;
the consistency verification of the actual position measurement and output value, the programmed position measurement and output value, the actual welding process parameter measurement value and the welding process parameter set value is realized, and the actual output value is directly obtained by reading the actual position self-measurement and output value of the robot in the welding controller.
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