CN110153534B - Multilayer and multi-path robot welding path planning method and system suitable for welding deformation - Google Patents
Multilayer and multi-path robot welding path planning method and system suitable for welding deformation Download PDFInfo
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- CN110153534B CN110153534B CN201910477618.XA CN201910477618A CN110153534B CN 110153534 B CN110153534 B CN 110153534B CN 201910477618 A CN201910477618 A CN 201910477618A CN 110153534 B CN110153534 B CN 110153534B
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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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- 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 utility model provides a multilayer multichannel robot welding path planning method and system that adapts to welding deformation, include: obtaining a laser stripe image formed on the surface of a welding workpiece, carrying out image processing to obtain the distance between two vertexes of the top end of the cross section of the welded groove of the i-1 th layer, and calculating the cross section area S of the i-th layer to be welded according to the geometric relationi(ii) a Planning the welding bead on the ith layer by adopting an equal-height filling strategy; determining the arc starting point coordinates, the position and the posture of a welding gun, the swing amplitude, the welding current and the welding speed of each welding bead on the layer; and (3) obtaining the distance between two top points of the cross section of the groove after all welding passes on the ith layer are welded by adopting a real-time visual detection method, calculating to obtain the cross section area of the welding pass on the subsequent layer, and then planning and welding the path of the welding pass on the layer. The method and the device can detect the distance between two vertexes in real time, and correct the path planning result in real time according to the change of the distance, so that the dynamic welding bead planning of the slope filling under the deformation condition can be realized, and the adaptability of the path planning strategy to the condition change is improved.
Description
Technical Field
The disclosure relates to the technical field of thick plate welding, in particular to a multilayer and multi-robot welding path planning method and system suitable for welding deformation.
Background
At present, spot welding robots and thin plate arc welding robots are widely used in industrial production, but in medium and thick plate welding production, the application of the robots is still limited considerably. One reason for this is that the accumulated deformation of the weldment is large along with the increase of the number of welding passes in the welding process of the thick plate, and the existing welding seam tracking technology is relatively immature and cannot correct the deviation in time. For example, when arc tracking is used, the detection software must detect the difference in balance between changes in the welding current on both sides of the groove, and one-sided tracking cannot be performed. Therefore, under multi-pass welding conditions, the root pass position can only be tracked by the arc, with the remaining pass positions being determined by offset with the first pass as a zero point. This method requires a considerably high groove machining accuracy. However, for medium-thickness plate workpieces, flame cutting blanking and groove machining are mostly adopted in view of machining cost, and the situation that the groove sizes and angles are inconsistent in the cutting process is very likely to occur. Meanwhile, in the welding process, along with the increase of heat input quantity, the workpiece is likely to generate thermal deformation, so that the position and the angle of the groove are changed, and errors with the preweld planning are caused.
For the problem that the error is easy to occur in the groove machining of the medium plate, a machining mode with higher precision is used for replacing the existing machining mode, such as groove machining robot or numerical control machine tool machining. Aiming at the problem that the welding of medium and heavy plates is easy to deform, the development of a visual tracking system of a welding seam is mainly used. The active visual tracking system for the welding seam scans the surface of a workpiece by using laser, shoots the surface image of the workpiece by using a CCD (charge coupled device) or CMOS (complementary metal oxide semiconductor) camera, and realizes the positioning of the workpiece and the correction of a welding bead track through an image processing algorithm and a control system.
The distance between two top points at the top end of the groove cross section is continuously changed due to welding deformation in the welding process. The change in distance results in a change in the total area of the weld layers, thereby causing a change in the total number of passes of the weld. Eventually leading to changes in the overall planning result.
Disclosure of Invention
The purpose of the embodiments of the present description is to provide a multilayer multi-path robot welding path planning method adapted to welding deformation, which detects the distance between two vertices at the top end of the groove cross section in real time, and corrects the welding path planning result in real time according to the change of the distance, so as to implement dynamic weld bead planning for filling the groove under the deformation condition, and improve the adaptability of the path planning strategy to the condition change.
The embodiment of the specification provides a multilayer multi-robot welding path planning method adaptive to welding deformation, which is realized by the following technical scheme:
the method comprises the following steps:
obtaining a laser stripe image formed on the surface of a welding workpiece, carrying out image processing to obtain the distance between two vertexes of the top end of the cross section of the welded groove of the i-1 th layer, and calculating the area S of the i-th layer to be welded according to the geometric relationi；
Planning the ith welding bead by adopting an equal-height filling strategy; determining the arc starting point coordinates, the position and the posture of a welding gun, the swing amplitude, the welding current and the welding speed of each welding bead on the layer;
obtaining the distance between two top points of the cross section of the groove after all welding passes of the ith layer are welded by adopting a real-time visual detection method, calculating to obtain the cross section area of the subsequent welding pass layer based on an equal-height filling strategy and a geometric relation, and then planning and welding the path of the welding pass layer;
and repeating the steps to complete the filling of the whole groove.
The embodiment of the specification provides a multilayer multi-robot welding path planning system based on real-time detection of welding deformation, which is realized by the following technical scheme:
the method comprises the following steps:
the vision sensor is arranged above the welding workpiece, and is used for acquiring a laser stripe image formed on the surface of the welding workpiece and transmitting the laser stripe image to the computer;
processing the image in a computer to obtain the distance between two vertexes at the top end of the cross section of the welded groove of the (i-1) th layerWhich relation calculates the cross-sectional area S of the ith layer to be weldedi；
Planning the ith welding bead by adopting an equal-height filling strategy; determining the arc starting point coordinates, the position and the posture of a welding gun, the swing amplitude, the welding current and the welding speed of each welding bead on the layer;
obtaining the distance between two top points of the cross section of the groove after all welding passes of the ith layer are welded by adopting a real-time visual detection method, calculating to obtain the cross section area of the subsequent layer of welding passes based on an equal-height filling strategy and a geometric relation, and then planning and welding the path of the layer of welding passes;
the computer transmits the dynamic welding path planning result of each time to the welding robot controller, and controls a welding gun of the welding robot to weld the layer of welding seam according to the new path planning result;
and repeating the process to complete the filling of the whole groove.
The present specification further provides a welding robot, including a controller and a welding gun, wherein the controller is configured to receive a dynamic welding path planning result, and the dynamic welding path planning result is obtained by:
obtaining a laser stripe image formed on the surface of a welding workpiece, carrying out image processing to obtain the distance between two vertexes of the top end of the cross section of the welded groove of the i-1 th layer, and calculating the cross section area S of the i-th layer to be welded according to the geometric relationi；
Planning the welding bead on the ith layer by adopting an equal-height filling strategy; determining the arc starting point coordinates, the position and the posture of a welding gun, the swing amplitude, the welding current and the welding speed of each welding bead on the layer;
obtaining the top end distance of the cross section of the groove after all welding passes on the ith layer are welded by adopting a real-time visual detection method, calculating to obtain the area of a subsequent layer of welding passes on the basis of an equal-height filling strategy and a geometric relation, and then planning and welding the path of the layer of welding passes;
and repeating the steps to complete the filling of the whole groove.
Compared with the prior art, the beneficial effect of this disclosure is:
the method and the device can detect the distance between two top points of the groove cross section in real time, and correct the path planning result in real time according to the change of the distance, so that the dynamic weld bead planning of the groove filling under the deformation condition can be realized, and the adaptability of the path planning strategy to the condition change is improved.
Drawings
The accompanying drawings, which are included to provide a further understanding of the disclosure, illustrate embodiments of the disclosure and together with the description serve to explain the disclosure and are not to limit the disclosure.
FIG. 1 is a schematic diagram of a V-groove cross-section fill of an embodiment of the present disclosure;
FIG. 2(a) -FIG. 2(b) are schematic diagrams of torch inclination angles of embodiments of the present disclosure;
FIG. 3 is a schematic view of a V-groove welding process according to an embodiment of the present disclosure;
FIG. 4 is a schematic view of V groove monitoring in an embodiment of the present disclosure;
FIG. 5 is a schematic view of a multi-layer multi-robot welding gun position according to an exemplary embodiment of the present disclosure;
FIG. 6 is a schematic view of a V-groove weld gun wall-strike model according to an embodiment of the disclosure;
FIG. 7 is a schematic diagram of V-groove coordinates for an embodiment of the present disclosure;
FIG. 8 is a schematic view of a plate thickness and a groove angle in an embodiment of the present disclosure;
9(a) -9 (b) schematic diagrams of a weaving process of a welding gun according to an embodiment of the present disclosure;
FIG. 10 is a schematic view of a welding gun weaving for a trapezoidal weld bead with a large weld width according to an exemplary embodiment of the present disclosure;
fig. 11 is a system schematic of an embodiment of the disclosure.
Detailed Description
It should be noted that the following detailed description is exemplary and is intended to provide further explanation of the disclosure. Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this disclosure belongs.
It is noted that the terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of example embodiments according to the present disclosure. As used herein, the singular forms "a", "an" and "the" are intended to include the plural forms as well, and it should be understood that when the terms "comprises" and/or "comprising" are used in this specification, they specify the presence of stated features, steps, operations, devices, components, and/or combinations thereof, unless the context clearly indicates otherwise.
Example of implementation 1
The embodiment discloses a multilayer multi-robot welding path planning method adaptive to welding deformation, and the general idea of the method is as follows: after the welding of the first layer of welding bead is finished, the distance between two top points of the top end of the cross section of the groove after the filling of the first layer is finished is obtained by adopting a real-time visual detection technology, the cross section area of the subsequent layer of welding bead is obtained by calculation based on an equal-height filling strategy and a geometric relation, and the planning of the welding path of the subsequent layer of welding bead is realized. The step is executed circularly, and the filling of the whole groove can be completed.
In the specific implementation, after the ith-1 layer is welded, the distance between two top points of the cross section of the groove is reduced due to welding deformation, the existing real-time visual detection technology is adopted to detect the distance between the two top points of the cross section of the groove after the ith-1 layer is welded, and the cross section area S of the to-be-welded ith layer is calculated according to the geometric relationi；
Planning the welding bead on the ith layer by adopting an equal-height filling strategy; determining the arc starting point coordinates, the position and the posture of a welding gun, the swing amplitude, the welding current, the welding speed and the like of each welding bead on the layer;
and (3) obtaining the distance between two top points of the cross section of the groove after all welding passes on the ith layer are welded by adopting a real-time visual detection method, calculating to obtain the cross section area of the subsequent layer of welding seam based on the contour filling strategy and the geometric relation, and then planning and welding the path of the welding pass on the layer.
And repeating the steps to complete the filling of the whole groove.
The key of the real-time detection planning method is to adopt a visual detection technology to detect the distance between two top points of the cross section of the groove in real time so as to reflect the real-time angular deformation. The distance between the two vertexes is constantly changed due to the existence of welding deformation during the welding process. The change in distance results in a change in the cross-sectional area of the weld layer, thereby causing a change in the total number of passes of the weld. Eventually leading to changes in the overall planning result. Therefore, only the distance between two vertexes needs to be detected in real time, and the path planning result is corrected in real time according to the change of the distance, so that the dynamic weld bead planning of slope filling under the deformation condition can be realized, and the adaptability of the path planning strategy to the condition change is improved.
In one embodiment, FIG. 1 is a schematic cross-sectional fill view of a V-groove, where the plate thickness is t and the groove angle is θ, and a butt joint is established as a coordinate system shown in FIG. 1. The method is to establish a weld bead planning model by adopting an equal-height filling strategy, and the height of a bottoming weld bead is hdThe height of each layer of welding bead on the second layer and above is h. The first pass cross section was fitted with a triangle (trapezoid when there was a groove gap). The initial welding bead and the middle welding bead of the second layer and the above layers adopt rhombic fitting, and the area of the initial welding bead and the middle welding bead is set as SrThe cross section of the final welding bead adopts trapezoidal fitting, and the area is StFor a diamond weld bead, the welding torch position is on the perpendicular bisector of the long diagonal of the diamond, the welding torch inclination angle is the angle between the welding torch and the perpendicular direction, α is set, as shown in fig. 2(a), the star in fig. 2(a) indicates the arc starting point position, and for a trapezoidal weld bead, the welding torch position is on the center line, as shown in fig. 2(b), the star in fig. 2(b) indicates the arc starting point position.
The central idea of the contour filling strategy is that the heights of all layers are equal, the heights of the welding seams of the backing weld and the filling weld are selected according to actual production experience, generally speaking, the technological requirements of the backing weld welding process and the filling weld are greatly different, and therefore the heights of the welding seams are also different. And then, according to the total height of the groove, the total number of layers required for completing groove filling can be calculated. Because the shape of the welding seam is simplified into the diamond shape, the cross section area of the single diamond welding seam is determined after the layer height is determined. Then, the total area of the cross section of the layer to be welded can be calculated, and the number of welding seams required for filling the layer can be calculated by dividing the total area by the area of a single welding seam. The calculation flow is shown in fig. 3.
From the thickness t of the base metal plate, the height of the backing bead is hdAnd the height of the filling weld bead is h, and the total number of layers n required for filling the groove can be obtained according to the formula (1):
when n is not an integer, in order to ensure that the groove is filled, the minimum integer n which is greater than the calculation result of the formula (1) is takenzMeanwhile, when a large integer is taken, the total cross-sectional area of the weld metal is larger than that of the groove, so that the weld is filled with bulges, and extra height is generated. Therefore, we need to correct the layer height of the weld, and take the corrected layer height as hz，hzCan be calculated from equation (2):
referring to FIG. 4, assuming that the (i-1) layer has been welded, before the ith layer, the distance between two vertices at the top of the groove cross section is determined by visual inspection, and the measured value is diThen the length d of the bottom side of the ith layer can be calculatedibLength of top side dit：
According to the similar proportion relation, the following steps are carried out:
according to the trapezoidal area calculation formula, the total cross section area S of the weld joint of the ith layeriComprises the following steps:
in which i is e [2, n ∈ [ ]z]。
Each layer has a height of hzLength l and area S of rhombus weld beadrRespectively as follows:
calculating (S)i/Sr) The integer part of Q is marked as N, and the decimal part is marked as C. The number of the diamond welding beads is determined according to the decimal C so as to ensure that the final trapezoidal welding bead of each layer has proper fusion width, 0.4 is taken as a critical value in the text, and tests show that when the critical value is 0.4, the welding bead is better formed. If C is more than or equal to 0.4, the number r of rhombic welding passes on the ith layeriN, the final trapezoidal bead area is assumed to be St＝C*SrIf C is<0.4, the number r of rhombic welding passes on the ith layeriN-1, the final trapezoidal bead area is St＝(C+1)*Sr。
During path planning, the position of the welding gun is determined:
in FIG. 5, let y be the abscissa and the ordinate of the ith pass of the ith weld beadij、zij。
The abscissa and ordinate of the arc starting point of the backing weld bead are as follows: y is11＝0，z11＝0。
For each welding layer above the backing weld bead, according to mathematical derivation, the abscissa of each layer of diamond weld beads except for the last trapezoidal weld bead is as follows:
in which i is e [2, n ∈ [ ]z]，j∈[1,ri]M is a correction factor considering the shape of the molten pool and the swing of the welding gun, and is generally 1-3 mm.
The abscissa of the starting point of the last trapezoidal welding bead on the ith layer is as follows:
in which i is e [2, n ∈ [ ]z]，j＝ri+1, M is a correction factor considering the shape of the molten pool and the swing of the welding gun, and is generally 1-3 mm.
The ordinate of the upper weld bead on the ith layer is as follows:
zij＝hd+(i-2)hz(12)
in which i is e [2, n ∈ [ ]z]，j∈[1,ri+1]。
And during path planning, planning the inclination angle of the welding gun:
in order to ensure the formation of the weld joint and make the actual shape of the cross section of the weld joint as close as possible to the fitted geometric figure, the inclination angle α of the welding gun needs to be planned when welding the diamond-shaped weld beadrSo that the welding gun is positioned on the midperpendicular of the rhombus long diagonal and the welding wire points to an arc starting point, as shown in figure 2(a), the inclination angle α of the welding gun of the ith layer of rhombus welding bead can be obtained through mathematical derivationriComprises the following steps:
in the formula [ theta ]iAnd the bevel angle of the i-1 st layer after welding is finished.
The welding gun inclination angles of all the trapezoidal welding beads are 0 degree.
During path planning, detection of wall collision of a welding gun:
the welding bead near the root of the groove of the thick plate has large depth and small space, so that a welding gun is easy to contact and collide with the side wall of the groove, and the accessibility is poor. In order to avoid the situation, an angular bisector of a connecting line between a welding bead arc starting point and two vertexes of the upper surface of the groove is generally taken as a welding gun position in the welding planning, and a welding gun inclination angle is determined. Although the method avoids the collision between the welding gun and the side wall of the groove, the inclination angle of the welding gun needs to be frequently changed when a thick plate and an extra-thick plate are welded. Therefore, the method establishes a model for detecting whether the welding gun touches the groove side wall or not. The rhombus long diagonal perpendicular bisector is used as the inclined position of the welding gun under the normal condition, once the welding gun is touched, the inclination angle of the welding gun is changed, and the inclination angle of the welding gun does not need to be changed when the welding gun is not collided. Therefore, the inclination angle of the welding gun does not need to be changed frequently, which is more favorable for automatic welding and is also favorable for fitting the actual cross section shape of the welding bead with a rhombus.
FIG. 6 is a schematic view of a model for detecting wall contact of a welding gun simplified into a cylinder in which a dot-and-dash line lsIs the center line of the welding wire, namely the center line of the cylinder; thread lbThe outer contour edge of the welding gun nozzle is positioned; thread lrThe bevel sidewall edge. If the welding gun does not touch the side wall, only the welding gun is required to be ensured not to contact the side wall when each layer of diamond welding bead closest to the trapezoidal welding bead is welded, namely the line l in the figure 6bAnd line lrDo not intersect in the groove. Let a straight line lbAnd lsSlope kbStraight line lrSlope krRadius of nozzle of welding gun is rq。
The ith-1 layer is welded, the ith layer is a layer to be welded, and the bevel angle is thetaiAccording to the geometric relationship of FIG. 4, θiIn order to realize the purpose,
bevel angle of thetaiAnd the welding gun is positioned on the angular bisector of the diamond welding bead, and the mathematical relationship shows thatbAt an angle of y-axis
And lrAt an angle of y-axis
Can obtain lbSlope kb，lrSlope krComprises the following steps:
when in use
I.e. thetai>At 60 DEG, the steel sheet does not collide with the wall regardless of the thickness of the steel sheet.
If theta<60 degrees, as shown in figure 6, a coordinate system is established, and a straight line l can be obtainedrThe equation of (a) is:
straight line l of welding wiresThe equation is:
from the functional relationship, a straight line l can be obtainedbThe equation of (a) is:
the formula (17) is associated with the formula (19) to determine the value of the ordinate z, and the welding torch can be prevented from touching the groove as long as the plate thickness t satisfies t < z.
According to practical experience, in the multi-layer and multi-path robot welding of the thick plate, the number of each welding path layer does not exceed the number of the layers. In the attached figure 6, the number of welding tracks is equal to the number of layers of the layer where the welding tracks are located, meanwhile, the heights of the second layer and each layer of welding tracks are consistent, and the cross sections of all the diamond welding tracks are consistent, so that a welding gun can be ensured not to touch the wall when the diamond welding tracks of the bottom layer are welded as long as the welding gun does not touch the side wall of the groove.
Under the condition that the weldment is thick and the bevel angle is small, the space at the bottom of the weldment is small, and the second layer and even the third layer can be filled up only by one trapezoidal welding bead, as shown in fig. 7, so that the starting point coordinate of the first rhombic welding bead is needed to be used for calculation. The coordinates (y) of the starting point of the first diamond welding beadi1,zi1) With the formula (17), the intercept b value can be found to be:
the line l can be obtained by combining the formula (17) and the formula (19) and substituting the value bbAnd line lrThe intersection ordinate z is:
the welding gun can be ensured not to touch the side wall of the groove only by ensuring that the z value in the formula (21) is larger than the plate thickness t. As can be seen from equation (21), the value of the vertical axis z of the intersection is determined by the bevel angle θiFirst diamond bead coordinate (y)i1,zi1) And radius r of welding gun nozzleqAnd (6) determining. For gas metal arc welding, the radius of a nozzle of a welding gun is generally 5-11 mm. To more intuitively illustrate the above relationship, assuming a torch tip radius of 10mm, FIG. 8 shows the relationship at zi1When the values are different, the relation between the bevel angle and the upper limit value of the plate thickness is obtained.
According to FIG. 8, if zi1The value is 15mm, and even if the groove angle reaches 50 °, the maximum allowable plate thickness during welding does not exceed 30 mm. Meanwhile, when the groove angle exceeds 40 °, the upper limit of the allowable plate thickness is sharply increased. Therefore, when welding a thick plate, the groove angle can be increased appropriately to ensure the accessibility of the welding gun for the lower weld bead. Moreover, aiming at the backing weld bead and the bottom trapezoidal weld bead, the welding heat input can be properly increased on the premise of ensuring that the weld is not burnt through, and the welding height can be rapidly increased by increasing the deposition of welding metal because the space of the groove bottom layer is smallerAnd secondly, for thick plates, the larger welding heat input can ensure the penetration of the backing weld bead, and the defect of incomplete penetration is avoided.
In path planning, regarding welding gun swing planning:
increase welder swing in welding process, can increase the welding bead width, avoid the inhomogeneous condition of welding seam shaping to a certain extent. Meanwhile, the welding gun swings to reduce the height of the welding seam to a certain extent, the mechanical property of the welding seam metal is improved, and multilayer and multi-pass welding is facilitated.
The numerical value of the swing amplitude cannot be too large or too small, when the swing amplitude is too large, a welding gun can touch the side wall, and the fusion depth can be too small to meet the technical requirements; too small a swing can result in sidewall unfused defects. Therefore, a suitable swing must be selected. Fig. 9(a) -9 (b) show the swinging process of the welding gun. For a diamond weld pass, the weld gun is located on its long diagonal mid-vertical. Because of the adoption of the rhombus fitting welding bead, the height h of the welding beadzOnce determined, the long diagonal AC length is also determined, and the swing R for the ith diamond pass is:
in the formula [ theta ]iThe bevel angle is the bevel angle after the welding of the (i-1) th layer is finished, and m is a correction factor considering the shape of a molten pool and is generally 2-3 mm.
For the trapezoidal weld bead, the total area of the weld layer is divided by the area of the single diamond weld bead, and then the cross section area of the trapezoidal weld bead is calculated according to the remaining decimal part. When the fractional part C is less than 0.4, the area of the trapezoidal part is St＝(C+1)*SrIn this case, a weld bead indicated by an arrow in fig. 10 may occur, the weld bead has a large melt width, and proper torch swing welding is required to obtain good bead formation, and the torch swing R of the i-th trapezoidal weld bead is,
in the formula [ theta ]iIs the bevel angle h after the welding of the i-1 st layer is finishedzHeight of the weld layer, hdFor the backing weld height, riThe number of rhombic welding passes on the ith layer is m is a correction factor considering the shape of the molten pool, and is generally 2-3 mm.
Example II
The embodiment of the specification provides a multilayer multi-robot welding path planning system based on real-time detection of welding deformation, which is realized by the following technical scheme:
the method comprises the following steps:
the vision sensor is arranged above the welding workpiece, and is used for acquiring a laser stripe image formed on the surface of the welding workpiece and transmitting the laser stripe image to the computer;
processing the image in a computer to obtain the distance between two top points of the cross section of the welded groove on the i-1 th layer, and calculating the cross section area S of the i-th layer to be welded according to the geometric relationi；
Planning the welding bead on the ith layer by adopting an equal-height filling strategy; determining the arc starting point coordinates, the position and the posture of a welding gun, the swing amplitude, the welding current and the welding speed of each welding bead on the layer;
obtaining the distance between two top points of the cross section of the groove after all welding passes of the ith layer are welded by adopting a real-time visual detection method, calculating to obtain the cross section area of the subsequent layer of welding passes based on an equal-height filling strategy and a geometric relation, and then planning and welding the path of the layer of welding passes;
the computer transmits the dynamic welding path planning result of each time to the welding robot controller, and controls a welding gun of the welding robot to weld the layer of welding seam according to the new path planning result;
and repeating the process to complete the filling of the whole groove.
The coordinate calculation formula of the dynamic welding path planning result in the embodiment is referred to as a specific calculation formula in the first embodiment, and will not be described in detail here.
Example III
Embodiments of the present disclosure provide a welding robot, including a controller and a welding gun, where the controller is configured to receive a dynamic welding path planning result, and the dynamic welding path planning result is obtained by:
obtaining a laser stripe image formed on the surface of a welding workpiece, carrying out image processing to obtain the distance between two vertexes of the top end of the cross section of the welded groove of the i-1 th layer, and calculating the cross section area S of the i-th layer to be welded according to the geometric relationi；
Planning the welding bead on the ith layer by adopting an equal-height filling strategy; determining the arc starting point coordinates, the position and the posture of a welding gun, the swing amplitude, the welding current and the welding speed of each welding bead on the layer;
obtaining the distance between two top points of the cross section of the groove after all welding passes of the ith layer are welded by adopting a real-time visual detection method, calculating to obtain the cross section area of the subsequent welding pass layer based on an equal-height filling strategy and a geometric relation, and then planning and welding the path of the welding pass layer;
and repeating the steps to complete the filling of the whole groove.
The coordinate calculation formula of the dynamic welding path planning result in the embodiment is referred to as a specific calculation formula in the first embodiment, and will not be described in detail here.
It is to be understood that throughout the description of the present specification, reference to the term "one embodiment", "another embodiment", "other embodiments", or "first through nth embodiments", etc., is intended to mean that a particular feature, structure, material, or characteristic described in connection with the embodiment or example is included in at least one embodiment or example of the present invention. In this specification, the schematic representations of the terms used above do not necessarily refer to the same embodiment or example. Furthermore, the particular features, structures, materials, etc. described may be combined in any suitable manner in any one or more embodiments or examples.
The above description is only a preferred embodiment of the present disclosure and is not intended to limit the present disclosure, and various modifications and changes may be made to the present disclosure by those skilled in the art. Any modification, equivalent replacement, improvement and the like made within the spirit and principle of the present disclosure should be included in the protection scope of the present disclosure.
Claims (8)
1. The method for planning the welding path of the multilayer and multi-path robot adapting to welding deformation is characterized by comprising the following steps:
obtaining a laser stripe image formed on the surface of a welding workpiece, carrying out image processing to obtain the distance between two vertexes of the top end of the cross section of the welded groove of the i-1 th layer, and calculating the cross section area S of the i-th layer to be welded according to the geometric relationi；
Planning the welding bead on the ith layer by adopting an equal-height filling strategy; determining the arc starting point coordinates, the position and the posture of a welding gun, the swing amplitude, the welding current and the welding speed of each welding bead on the layer;
obtaining the distance between two top points of the cross section of the groove after all welding passes of the ith layer are welded by adopting a real-time visual detection method, calculating to obtain the cross section area of the subsequent layer of welding passes based on an equal-height filling strategy and a geometric relation, and then planning and welding the path of the layer of welding passes;
repeating the steps to complete the filling of the whole groove;
for the V-groove, the plate thickness is t, the groove angle is theta, the butt joint is provided, and the backing weld bead height is hdThe height of each welding bead on the second layer and above is h, the cross section of the welding bead on the first layer is fitted in a triangle shape, the cross sections of the initial welding bead and the middle welding bead on the second layer and above are fitted in a diamond shape, and the area of the cross section is SrThe cross section of the final welding bead adopts trapezoidal fitting, and the area is StFor the diamond welding bead, the welding gun is positioned on the perpendicular bisector of the long diagonal of the diamond during welding, the inclination angle of the welding gun is the included angle between the welding gun and the perpendicular direction and is set as α, and for the trapezoidal welding bead, the welding gun is positioned on the center line of the welding gun;
assuming that the layer (i-1) is welded, before the layer (i), the distance between two top points at the top end of the cross section of the groove is determined by adopting a visual detection technology, and the measured value is set as diThe height of the welding layer after correction is taken as hzThen the length d of the bottom side of the ith layer can be calculatedibLength of top side dit：
According to the similar proportion relation, the following steps are carried out:
2. the method as claimed in claim 1, wherein the total cross-sectional area S of the weld seam of the ith layer is determined by the total cross-sectional area S of the weld seam of the ith layeriComprises the following steps:
in which i is e [2, n ∈ [ ]z]，nzIs the smallest integer greater than the total number of layers required to fill the groove.
3. The method for planning a welding path of a multi-layer multi-path robot adapted to welding deformation as set forth in claim 2, wherein a side length l and an area S of a diamond-shaped beadrRespectively as follows:
calculating (S)i/Sr) Ratio Q of (A) to (B), the whole of QThe number part is marked as N, the decimal part is marked as C, the number of the diamond welding beads is determined according to the decimal C, so that the final trapezoidal welding bead of each layer has proper fusion width, 0.4 is taken as a critical value, and tests show that the welding seam is better formed when the critical value is 0.4; if C is more than or equal to 0.4, the number r of rhombic welding passes on the ith layeriN, it can be inferred that the final trapezoidal bead cross-sectional area is St＝C*SrIf C is<0.4, the number r of rhombic welding passes on the ith layeriN-1, the cross-sectional area of the final trapezoidal bead is St＝(C+1)*Sr；θiIs a bevel angle.
4. The method for planning the welding path of a multi-layer and multi-path robot adapted to the welding deformation of claim 3, wherein the abscissa and the ordinate of the ith and the jth welding passes are respectively yij、zij；
The abscissa and ordinate of the arc starting point of the backing weld bead are as follows: y is11＝0，z11＝0；
For each welding layer above the backing weld bead, according to mathematical derivation, the abscissa of each layer of diamond weld beads except for the last trapezoidal weld bead is as follows:
in which i is e [2, n ∈ [ ]z]，j∈[1,ri]M is a correction factor considering the shape of the molten pool and the swinging of the welding gun;
the abscissa of the starting point of the last trapezoidal welding bead on the ith layer is as follows:
in which i is e [2, n ∈ [ ]z]，j＝ri+1, M is a correction factor considering the shape of the molten pool and the swing of the welding gun;
the ordinate of the upper weld bead on the ith layer is as follows:
zij＝hd+(i-2)hz
in which i is e [2, n ∈ [ ]z]，j∈[1,ri+1]；θiAngle of bevel, riThe number of diamond-shaped welding passes of the ith layer.
5. The method for planning a welding path of a multi-layer and multi-robot adapted to welding deformation according to claim 1, wherein the inclination angle of the welding gun is planned by:
the inclination angle α of the welding gun needs to be planned when welding the diamond-shaped welding beadrSo that the welding gun is positioned on the midperpendicular of the rhombus long diagonal, the welding wire points to an arc starting point, and the inclination angle α of the welding gun of the ith layer of rhombus welding beadriComprises the following steps:
in the formula [ theta ]iFor the bevel angle, the calculation formula is:
the welding gun inclination angles of all the trapezoidal welding beads are 0 degree.
6. The method as claimed in claim 1, wherein the perpendicular bisector of the long diagonal of the diamond is used as the tilting position of the welding torch, and the tilting angle of the welding torch is changed when the welding torch is touched, and the tilting angle of the welding torch is not changed when the welding torch is not touched.
7. Multilayer multichannel robot welding path planning system based on welding deformation real-time detection, characterized by includes:
the vision sensor is arranged above the welding workpiece, and is used for acquiring a laser stripe image formed on the surface of the welding workpiece and transmitting the laser stripe image to the computer;
processing the image in a computer to obtain the distance between two top points of the cross section of the welded groove on the i-1 th layer, and calculating the cross section area S of the i-th layer to be welded according to the geometric relationi；
Planning the welding bead on the ith layer by adopting an equal-height filling strategy; determining the arc starting point coordinates, the position and the posture of a welding gun, the swing amplitude, the welding current and the welding speed of each welding bead on the layer;
obtaining the distance between two top points of the cross section of the groove after all welding passes on the ith layer are welded by adopting a real-time visual detection method, calculating to obtain the cross section area of a subsequent layer of welding joint based on an equal-height filling strategy and a geometric relation, and then planning and welding the path of the welding pass on the layer;
the computer transmits the dynamic welding path planning result of each time to the welding robot controller, and controls a welding gun of the welding robot to weld the layer of welding seam according to the new path planning result;
for the V-groove, the plate thickness is t, the groove angle is theta, the butt joint is provided, and the backing weld bead height is hdThe height of each welding bead on the second layer and above is h, the cross section of the welding bead on the first layer is fitted in a triangle shape, the cross sections of the initial welding bead and the middle welding bead on the second layer and above are fitted in a diamond shape, and the area of the cross section is SrThe cross section of the final welding bead adopts trapezoidal fitting, and the area is StFor the diamond welding bead, the welding gun is positioned on the perpendicular bisector of the long diagonal of the diamond during welding, the inclination angle of the welding gun is the included angle between the welding gun and the perpendicular direction and is set as α, and for the trapezoidal welding bead, the welding gun is positioned on the center line of the welding gun;
assuming that the layer (i-1) is welded, before the layer (i), the distance between two top points at the top end of the cross section of the groove is determined by adopting a visual detection technology, and the measured value is set as diThe height of the welding layer after correction is taken as hzThen the length d of the bottom side of the ith layer can be calculatedibLength of top side dit：
According to the similar proportion relation, the following steps are carried out:
8. a welding robot comprising a controller and a welding gun, the controller configured to receive dynamic welding path planning results, characterized in that the dynamic welding path planning results are obtained by:
obtaining a laser stripe image formed on the surface of a welding workpiece, carrying out image processing to obtain the distance between two vertexes of the top end of the cross section of the welded groove of the i-1 th layer, and calculating the cross section area S of the i-th layer to be welded according to the geometric relationi；
Planning the welding bead on the ith layer by adopting an equal-height filling strategy; determining the arc starting point coordinates, the position and the posture of a welding gun, the swing amplitude, the welding current and the welding speed of each welding bead on the layer;
obtaining the distance between two top points of the cross section of the groove after all welding passes of the ith layer are welded by adopting a real-time visual detection method, calculating to obtain the cross section area of the subsequent layer of welding passes based on an equal-height filling strategy and a geometric relation, and then planning and welding the path of the layer of welding passes;
for the V-groove, the plate thickness is t, the groove angle is theta, the butt joint is provided, and the backing weld bead height is hdThe height of each welding bead on the second layer and above is h, the cross section of the welding bead on the first layer is fitted in a triangle shape, the cross sections of the initial welding bead and the middle welding bead on the second layer and above are fitted in a diamond shape, and the area of the cross section is SrThe cross section of the final welding bead adopts trapezoidal fitting, and the area is StFor the diamond welding bead, the welding gun is positioned on the perpendicular bisector of the long diagonal of the diamond during welding, the inclination angle of the welding gun is the included angle between the welding gun and the perpendicular direction and is set as α, and for the trapezoidal welding bead, the welding gun is positioned on the center line of the welding gun;
suppose thatAfter the layer (i-1) is welded, before the layer (i), the distance between two top points of the cross section of the groove is determined by adopting a visual detection technology, and the measured value is set as diThe height of the welding layer after correction is taken as hzThen the length d of the bottom side of the ith layer can be calculatedibLength of top side dit：
According to the similar proportion relation, the following steps are carried out:
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