CN111152221A - Welding robot control system and control method thereof - Google Patents
Welding robot control system and control method thereof Download PDFInfo
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- CN111152221A CN111152221A CN202010008184.1A CN202010008184A CN111152221A CN 111152221 A CN111152221 A CN 111152221A CN 202010008184 A CN202010008184 A CN 202010008184A CN 111152221 A CN111152221 A CN 111152221A
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B25—HAND TOOLS; PORTABLE POWER-DRIVEN TOOLS; MANIPULATORS
- B25J—MANIPULATORS; CHAMBERS PROVIDED WITH MANIPULATION DEVICES
- B25J9/00—Programme-controlled manipulators
- B25J9/16—Programme controls
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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
- B23K37/00—Auxiliary devices or processes, not specially adapted to a procedure covered by only one of the preceding main groups
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B25—HAND TOOLS; PORTABLE POWER-DRIVEN TOOLS; MANIPULATORS
- B25J—MANIPULATORS; CHAMBERS PROVIDED WITH MANIPULATION DEVICES
- B25J11/00—Manipulators not otherwise provided for
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B25—HAND TOOLS; PORTABLE POWER-DRIVEN TOOLS; MANIPULATORS
- B25J—MANIPULATORS; CHAMBERS PROVIDED WITH MANIPULATION DEVICES
- B25J9/00—Programme-controlled manipulators
- B25J9/16—Programme controls
- B25J9/1679—Programme controls characterised by the tasks executed
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Abstract
The invention discloses a welding robot control system and a control method thereof, which at least comprises a welding robot system, wherein the welding robot system comprises: a signal input module; an intelligent decision module; the detection and correction unit carries out online detection on the workpiece, obtains an adjusting parameter and a position parameter according to the detected data and uses the adjusting parameter and the position parameter as a compensation basis for the next processing; the welding equipment control unit is used for controlling the robot to cooperatively operate with the welding equipment; a command output module that converts the adjustment instruction into an output signal and outputs the output signal to the robot and the welding equipment to perform an action corresponding to the output signal; and the information monitoring module is used for monitoring the monitoring data generated by the welding robot system and providing the monitoring data for a user to use. The welding robot system with high integration is realized in a single system mode, and the welding robot system can be simultaneously suitable for arc welding and laser welding to improve the quality and the efficiency of a welding process.
Description
Technical Field
The invention belongs to the field of robots, relates to a welding robot, and particularly relates to a welding robot control system and a control method thereof.
Background
Most existing welding automation schemes adopt a multi-system architecture and are connected in series through an additional central control system, such as a Programmable Logic Controller (PLC). The multi-system scheme needs to consider the development of different systems for equipment manufacturers, and the development cost is very high; when the system is abnormal, the problem is difficult to clearly clear because the system architecture is complex when the problem is to be checked; in addition, the maintenance cost of the multi-system solution is also quite high. For operators, the operators need to learn the operation modes of a plurality of systems at the same time, the learning cost is high, long time is needed to get the hands, and high labor cost is needed.
Disclosure of Invention
The invention aims to overcome the defects of the prior art and provide a welding robot control system.
In order to achieve the purpose, the invention adopts the technical scheme that: a welding robot control system comprising at least a welding robot system, the welding robot system comprising:
the signal input module is used for receiving original data and processing the original data to obtain measured data;
the intelligent decision-making module comprises an intelligent teaching unit, a tracking adjusting unit, a detection correcting unit and a welding equipment control unit which are matched, wherein the intelligent teaching unit is used for providing at least one function so that a user can adjust the path track of at least one robot according to the function, and the tracking adjusting unit adjusts and controls at least one welding equipment in real time according to the measurement data so as to optimize and adjust process parameters in an online mode according to the welding bead state of a workpiece in real time to obtain an adjusting instruction and a position instruction; the detection and correction unit carries out online detection on the workpiece, obtains an adjusting parameter and a position parameter according to the detected data and uses the adjusting parameter and the position parameter as a compensation basis for the next processing; the welding equipment control unit is used for controlling the robot to cooperatively operate with the welding equipment;
a command output module that converts the adjustment instruction into an output signal and outputs the output signal to the robot and the welding equipment to perform an action corresponding to the output signal;
and the information monitoring module is used for monitoring the monitoring data generated by the welding robot system and providing the monitoring data for a user to use.
Preferably, the raw data is obtained by measuring a signal between the workpiece and an end effector by an external sensing element.
Optimally, the functions comprise a visual alignment function, a visual picture preview function or/and an automatic high-adjusting function.
Optimally, the signal input module comprises a signal acquisition unit and a signal processing unit which are matched with each other; the command output module comprises a motion planning unit, a force control unit and a signal output unit which are matched with each other; the information monitoring module comprises an information collecting unit, a data analyzing unit and a communication unit which are matched with each other.
Optimally, the welding robot control system further comprises an external server which is matched with the information monitoring module and used for converting the monitoring data into quantitative indexes.
Still another object of the present invention is to provide a welding robot control method, which includes the steps of:
sensing the original data;
acquiring and processing the original data to obtain measurement data;
performing decision making function according to the measurement data and converting the decision making function into an adjusting instruction and a position instruction respectively;
converting the adjusting instruction into an output signal and outputting the output signal to drive at least one welding device, and simultaneously converting the position instruction into a driving instruction to drive at least one robot, so that the welding device and the robot cooperate to operate a workpiece;
and analyzing the measurement data to obtain monitoring data for monitoring.
Optimally, the robot is provided with an end effector, and the operation of the welding equipment and the robot on the workpiece in cooperation at least comprises three different application scenes of before welding, during welding and after welding.
Further, the pre-weld application scenario includes the steps of:
measuring the position between the end effector and the workpiece to obtain the original data;
acquiring and processing the original data to obtain the position instruction;
performing instruction planning according to the position instruction and outputting a driving instruction;
and enabling the robot to execute a point position adjusting program according to the driving instruction.
Further, the application scenario during welding includes the following steps:
sensing the workpiece and the end effector to obtain the original data;
acquiring and processing the original data to obtain the measured data;
respectively executing a first program and a second program according to the measurement data, wherein the first program comprises the following steps: collecting the measurement data, analyzing and processing the measurement data to obtain the monitoring data, and transmitting the monitoring data to a user to realize real-time monitoring in the welding process, wherein the second program comprises the following steps: the method comprises the steps of detecting relevant information in real time in the welding process according to the measurement data to obtain an adjusting instruction and a position instruction, controlling the welding equipment to perform online adjustment on the workpiece according to the adjusting instruction, converting the adjusting instruction subjected to online adjustment into an output signal, performing a welding process according to the output signal, performing command planning according to the position instruction, outputting a driving instruction and performing offset adjustment on the robot according to the driving instruction.
Further, the application scenario during welding includes the following steps:
sensing the workpiece and the end effector to obtain the original data;
acquiring and processing the original data to obtain the measured data;
respectively executing a third process and a fourth process according to the measurement data, wherein the third process comprises the following steps: collecting the measurement data, analyzing the measurement data to obtain the monitoring data, and transmitting the monitoring data to a user to realize real-time monitoring in the welding process, wherein the fourth procedure comprises the following steps: the method comprises the steps of detecting relevant information in real time in the welding process according to the measurement data to obtain an adjusting parameter and a position parameter, correcting the relevant parameter of at least one welding device according to the adjusting parameter, converting the corrected relevant parameter of the at least one welding device into an output signal, carrying out a welding processing correction process according to the output signal, carrying out command planning correction according to the position parameter and outputting a corrected driving command, and correcting the path track of the robot according to the driving command to obtain a processed and corrected workpiece.
Due to the application of the technical scheme, compared with the prior art, the invention has the following advantages: the welding robot control system disclosed by the invention realizes a highly integrated welding robot system in a single system mode by adopting the matching of the signal input module, the intelligent decision module, the command output module and the information monitoring module, and can be simultaneously suitable for arc welding and laser welding to improve the quality and efficiency of a welding process.
The control method of the welding robot obtains the adjusting instruction and the position instruction by converting the obtained measurement data, outputs and drives the welding equipment and the robot, analyzes the data and obtains monitoring data, realizes the cooperative control of the welding equipment and the robot, and can convert the data into quantitative indexes for reference of a user.
Drawings
FIG. 1 is a block diagram of a welding robot control system of the present invention;
FIG. 2 is a block diagram of the welding robot system of the present invention;
FIG. 3 is a schematic flow chart of a control method of the welding robot according to the present invention;
FIG. 4A is a schematic flow chart of the control system of the welding robot of the present invention before welding;
FIG. 4B is a block diagram of the control system of the welding robot of the present invention before welding;
FIG. 5A is a schematic view of a control system of a welding robot according to the present invention during welding;
FIG. 5B is a block diagram of the control system of the welding robot of the present invention during welding;
FIG. 6A is a schematic view of another process of the control system of the welding robot of the present invention during welding;
FIG. 6B is another block diagram of the control system of the welding robot of the present invention during welding;
FIG. 7A is a schematic view of the control system of the welding robot of the present invention after welding;
fig. 7B is a block diagram of the control system of the welding robot of the present invention after welding.
Detailed Description
The following detailed description of preferred embodiments of the invention is provided:
the welding robot control system 1 shown in fig. 1 mainly includes a welding robot system 2, an external sensing element 50, a welding device 60, a robot 70, an external plant-wide monitoring system 80, an external server 90, and the like.
The welding robot system 2 comprises a signal input module 10, an intelligent decision module 20, a command output module 30 and an information monitoring module 40, wherein the signal input module 10 is respectively connected with the intelligent decision module 20 and the information monitoring module 40, and the intelligent decision module 20 is connected with the command output module 30; the external sensing device 50 is connected to the signal input module 10 of the welding robot system 2, the command output module 30 is connected to the welding equipment 60 and the robot 70, respectively, and the information monitoring module 40 is connected to the external factory-integrated monitoring system 80 and the external server 90, respectively. In the present embodiment, the number of the welding apparatuses 60 and the number of the robots 70 are at least one, and may be multiple; such as one welding apparatus 60 may cooperate with one robot 70, multiple welding apparatuses 60 may cooperate with one robot 70, or one welding apparatus 60 may cooperate with multiple robots 70, etc. As shown in fig. 1, the signal input module 10 is used for receiving raw data and processing the raw data to obtain measured data. In the present embodiment, the raw data is obtained by measuring the signal between the workpiece (not shown) and the end effector (not shown) by the external sensing device 50 (i.e. the external sensor); the signal may be distance, angle, current, voltage or capacitance.
Fig. 2 is a block diagram of the welding robot system 2, wherein the signal input module 10 includes a signal acquisition unit 110 and a signal processing unit 120 connected to each other, the signal acquisition unit 110 is used for acquiring raw data transmitted from the external sensing element 50, and the signal processing unit 120 processes the raw data to form measured data. The signal input module 10 provides an acquisition interface for the external sensing device 50, and supports the input of different signal sources such as the existing standard communication protocol, the traditional analog signal, and the I/O signal; and also integrates signal processing functions such as signal amplification, filtering, etc. into the signal input module 10. The signal input module 10 can provide an interface for the whole welding robot control system 1 and the external sensing element 50 to communicate with each other without additionally installing peripheral devices such as a communication conversion module, a signal amplifier, etc.
The intelligent decision module 20 is designed for the welding industry, and can realize the intelligent decision function under the premise of matching with the external sensing element 50 (i.e. receiving the measurement data transmitted from the signal processing unit 120). The intelligent decision module 20 includes a matching intelligent teaching unit 210, a tracking adjustment unit 220, a detection correction unit 230, a welding equipment control unit 240, and the like. The following description is directed to the various units in the intelligent decision module 20.
The smart teaching unit 210: the system 2 for welding robot integrates the external sensing element 50 to provide visual alignment, visual image preview, automatic height adjustment and other functions to assist the user in point position teaching, improve the error problem caused by direct alignment manually (such as naked eyes, etc.), and adjust the path trajectory of the robot 70 to align with the weld bead as much as possible;
the tracking adjustment unit 220: in order to improve the welding quality, the welding robot control system 1 can integrate the information of the welding robot system 2 and the external sensing element 50, compensate the processing path and the posture of the robot 70 in real time; meanwhile, the welding peripheral equipment can be adjusted in real time according to the measurement data sensed by the external sensing element 50, so that the optimal adjustment of the process parameters is carried out in an online manner according to the welding bead state of the workpiece in real time to obtain an adjustment instruction and a position instruction;
the detection correction unit 230: the welding robot control system 1 integrates sensors such as an industrial camera, a web camera and/or a laser range finder, and detects the quality of a weld bead after the welding process is completed. By using the welding robot control system 1 disclosed by the invention, on-line detection of a welding finished product can be realized on the premise of not using an additional machine to assist measurement, and an adjustment parameter and a position parameter are obtained according to measurement data sensed by the external sensing element 50, so that the relevant parameters of the welding equipment 60 and the path plan of the robot 80 are respectively corrected and used as a compensation basis for the next processing;
welding apparatus control unit 240: the welding equipment control unit 240 provides welding equipment control functions such as a welding head, a galvanometer, a laser source and/or a welding gun, and provides command outputs such as analog input/output (AD-DA), digital input/output (DI-DO), PWM signal output, XY2-100 and the like; due to the single system integration, besides greatly reducing the complexity and cost of the system configuration, the robot 70 and the welding equipment 60 with various functions can be cooperatively controlled.
The command output module 30 at least comprises a motion planning unit 310, a force control unit 320 and a signal output unit 330. The motion planning unit 310 converts the adjustment result transmitted by the intelligent decision module 20 into a position command signal, which can be a path of the robot 70 for processing the workpiece, so that the motion planning unit 310 can optimize the motion trajectory of the robot 70 for processing the workpiece according to the adjustment result. Therefore, the command output module 30 converts the adjustment result into output signals such as position, force and analog, and transmits the output signals to the robot 70 through the signal output unit 330, so that the robot 70 can perform actions corresponding to the signals after receiving the signals.
The signal monitoring module 40 at least comprises a data collecting unit 410, a data analyzing unit 420 and a communication unit 430 which are matched; the data collection unit 410 collects and monitors all data related to the welding process during the welding process, and analyzes the data using the data analysis unit 420 to allow a user to easily monitor the process state. The communication unit 430 outputs the monitoring data to the external plant-wide monitoring system 80 and the external server 90 for use. The external server 90 may be a cloud hard disk or a general computer host, and when the external server 90 receives the monitoring data transmitted from the communication unit 430, the external server 90 performs quantization processing on the monitoring data.
According to the welding robot control system 1, as shown in fig. 3, the present invention also provides a welding robot control method, comprising the steps of:
step S1: sensing the original data; in this step, the raw data is obtained by sensing a signal between the workpiece and the end effector using the external sensing element 50;
step S2: obtaining and processing the original data to obtain the measured data; in this step, the original data obtained in step S1 is obtained by the signal obtaining unit 110 of the signal input module 10, and then the original data is processed by the signal processing unit 120 to be converted into measurement data;
step S3: performing decision function according to the measured data and converting to obtain an adjusting instruction and a position instruction; in this step, the intelligent decision module 20 is used to make decisions on the measurement data, and the tracking adjustment unit 220 is used to convert the measurement data into adjustment commands and position commands;
step S4: converts the adjustment command into an output signal and outputs the output signal to drive the at least one welding device 60, and converts the position command into a drive command to drive the at least one robot 70; in this step, the adjustment command is transmitted from the intelligent decision module 20 to the command output module 30, and is set by the user; the motion planning unit 310 and the force control unit 320 in the command output module 30 will convert the adjustment command into output signals of position, force, analogy, etc. and transmit the output signals from the signal output unit 330 to the welding equipment 60 and the robot 70;
step S5: the welding device 60 and the robot 70 process the workpiece according to the output signal;
step S6: analyzing the measurement data to obtain monitoring data and transmitting the monitoring data to a monitoring system for monitoring; in this step, the measurement data is transmitted from the signal input module 10 to the signal monitoring module 40, the data collection unit 410 collects the measurement data, the data analysis unit 420 analyzes the measurement data to obtain monitoring data, the communication unit 430 transmits the monitoring data to the external whole plant monitoring system 80, and the external whole plant monitoring system 80 monitors the measurement data.
The following is also set forth for three different application scenarios of the welding robot control system 1 during pre-welding, during welding and after welding of the welding process (it is to be noted that the units of the modules in fig. 1 and 2 can be used for execution during the three different application scenarios before welding, during welding and after welding, and therefore the units used in the pre-welding application scenario are listed in fig. 4B, the functions of which are the same as those described above, and only the functions performed by the units in the different welding scenarios are described here).
Since the distance control between the end effector and the workpiece surface is a very important issue, and the workpieces are mostly special-shaped workpieces, the welding seam path is a complex spatial curve, so that the process of point position teaching needs a lot of time. In addition, after the machining path is planned by off-line programming software (such as CAD/CAM), fine adjustment of the machining path during the machining process is required due to the feeding error, and manual teaching and correction for the shape of the workpiece are also required, which also takes a lot of time. As shown in fig. 4A and 4B, in order to solve the time and labor cost at this stage, the welding robot control system 1 executes intelligent teaching at the scene stage before welding, and provides visual auxiliary teaching and automatic height adjustment functions by combining the visual system and the height measurement module, so as to implement a high-efficiency point location teaching process, and the operation steps are as follows:
step S11: measuring the position between the end effector and the workpiece to obtain original data; in this step, the distance between the workpiece and the end effector is measured by the external sensing element 50 to obtain raw data;
step S12: acquiring and processing original data to obtain a position instruction; in this step, the external sensing device 50 transmits the raw data of the measured distance to the signal acquiring unit 110, and transmits the raw data to the signal processing unit 120 for processing and converting the raw data into the measured data, and the intelligent teaching unit 210 in the intelligent decision module 20 converts the measured data into the position command;
step S13: performing instruction planning according to the position instruction and outputting a driving instruction; in this step, the signal processing unit 120 transmits the processed measurement data to the intelligent teaching unit 210, and the intelligent teaching unit 210 is used to make decisions and provide an automatic up function to assist the user in point location teaching, so as to adjust the path trajectory of the robot 70 and the alignment of the weld bead in an intelligent manner, thereby reducing errors caused by manual work;
step S14: enabling the robot to execute a point position adjusting program according to the driving instruction; in this step, the intelligent teaching unit 210 transmits the driving command to the motion planning unit 310, and outputs a position command corresponding to the driving command to the robot 70 (as shown in fig. 1) after performing command planning, so that the robot 70 can execute according to the driving command with the position command; therefore, the robot 70 can move along the normal plane vector of the current workpiece according to the driving command without changing the current rotation posture, and the robot 70 can automatically adjust the distance between the end effector and the surface of the workpiece, thereby realizing the automatic height adjustment function.
In order to improve the welding quality, the welding robot control system 1 provides a tracking adjustment function in an application scene during welding, and combines a height measurement module and a weld seam tracking system to realize a three-dimensional weld seam tracking function, so that the position and size change of a weld seam can be monitored in real time, the path track and the processing posture of the robot 70 can be changed in real time, and the welding quality can be optimized. In addition, the welding robot control system 1 also combines the special welding module, adjusts the output of the welding equipment 60 such as welding, laser source and welding head according to the motion situation of the actual robot 70, and realizes the interactive control and adjustment function of the robot 70 and the welding equipment 60 to improve the welding effect. In addition, the information monitoring module 40 can be used for collecting data information in the adjusting process, and the current welding process state is displayed in real time after the data is analyzed, so that the function of monitoring the welding quality in real time is realized.
The operation steps of the application scene of the welding robot control system 1 during welding are shown in fig. 5A and 5B, which mainly illustrate that the information such as the position of the weld joint and the width of the weld bead can be monitored in real time during welding, and the welding equipment 60 and the robot 70 can be adjusted simultaneously according to the information to optimize the welding process; the method comprises the following specific steps:
step S21: sensing the workpiece and the end effector to obtain original data; in this step, the external sensing device 50 measures the signal between the workpiece and the end effector to obtain the original data;
step S22: obtaining and processing the original data to obtain measurement data; in this step, the external sensing device 50 also transmits the measured raw data to the signal acquiring unit 110, and transmits the raw data to the signal processing unit 120 for processing to obtain the measured data; in the present application, a first process (step A1) and a second process (step A2) may be performed, respectively, based on the metrology data;
the first process is the steps on the left side of the drawing in FIG. 5A, after obtaining the measurement data in step S22, the following steps are performed:
step A11: collecting the measurement data; in this step, the data collection unit 410 is used to collect the above mentioned measurement data and monitor all the data related to the welding process during the welding process;
step A12: analyzing and processing the measurement data to obtain monitoring data; in this step, the data analysis unit 420 is used to analyze the data, such as what kind of signals of distance, angle, current, voltage and capacitance the monitoring data belongs to;
step A13: transmitting the monitoring data to a user to realize real-time monitoring in the welding process; in this step, the communication unit 430 is used to output the monitoring data (or the monitoring result) to the user (e.g. the external whole plant monitoring system 80);
the second process is the same as the right step in fig. 5A, and after the raw data is obtained and processed to obtain the measured data in step S22, the second process is entered to perform the following steps:
step A21: monitoring relevant information in real time during welding (namely during welding) according to the measured data to obtain an adjusting instruction and a position instruction; in this step, the tracking adjustment unit 220 is used to adjust the measurement data and convert the measurement data into an adjustment command and a position command; the tracking adjustment unit 220 transmits the adjustment command to the welding equipment control unit 240 and the position command to the motion planning unit 310 for subsequent steps;
step a23 (when the tracking adjustment unit 220 transmits an adjustment command to the welding equipment control unit 240, step a23 is performed): controlling welding equipment to perform online adjustment on the workpiece according to the adjustment instruction; that is, after the welding equipment control unit 240 receives the adjustment instruction transmitted by the tracking adjustment unit 220, the welding equipment is adjusted on-line according to the adjustment instruction, and the adjustment is performed on different process parameters such as the size of the weld bead, the processing speed, the offset of the workpiece, and the like; step A24: converting the online adjusted regulating instruction into an output signal; in this step, the signal output unit 330 is used to convert the adjustment command into an output signal, which may be in the form of an analog signal, an industrial communication protocol, a digital signal, or an XY2-10 communication protocol; step A25: performing a welding process according to the output signal; in this step, the signal output unit 330 transmits an output signal to the welding apparatus 60, and the welding apparatus 60 performs a welding process according to this output signal;
step a26 (when the tracking modulation unit 220 sends the position command to the motion planning unit 310, proceed to step a 26): performing instruction planning according to the position instruction and outputting a driving instruction; in this step, after the motion planning unit 310 receives the position command, it performs command planning and outputs a driving command to the robot 70; step A27: performing offset adjustment on the robot 70 according to the driving instruction; in this step, the robot 70 adjusts the machining path and the attitude in accordance with the drive command to perform the offset adjustment.
In this application, in order to ensure the quality of the welding product, the welding robot control system 1 provides detection and correction in another application scene during welding, it utilizes the vision system and the height measurement module, after the welding is completed, detects the welding processing result, measures the welding path deviation, the welding bead flaw, and to the movement track of the robot 70, the welding process parameter is correspondingly corrected, if the processing error exceeds the tolerance range, the welding robot control system 1 can carry out secondary processing according to the processing program and the process parameter after the detection and correction. After the processing is completed, the information monitoring module 40 can be further used to diagnose the status of the current welding process in real time and collect information for the user to monitor. As shown in fig. 6A and fig. 6B, mainly illustrating that the welding device 60 and the robot 70 can be adjusted simultaneously to perform multiple machining corrections during the welding process to obtain a welded product with an error within a tolerance range, the specific steps are as follows:
step S31: obtaining original data through the sensing device and the end effector; in this step, signals between the workpiece and the end effector are measured by the external sensing element 50 to obtain raw data;
step S32: obtaining and processing the original data to obtain measurement data; in this step, the external sensing device 50 also transmits the original measured distance data to the signal acquiring unit 110, and transmits the original measured distance data to the signal processing unit 120 to process the original measured distance data to obtain measured distance data; in the present application, the third process (step A3) and the fourth process (step A4) can be performed according to the metrology data;
the third process is the step to the left of the drawing in FIG. 6A, after obtaining the measurement data in step S32, the following steps are followed:
step A31: collecting the measurement data;
step A32: analyzing and processing the measurement data to obtain monitoring data; in this step, these data are analyzed (for example, what type of monitoring data is) by the data analysis unit 420;
step A33: transmitting the monitoring data to a user to realize real-time monitoring in the welding process; in this step, the communication unit 430 is used to output the monitoring data (or the monitoring result) to the user (for example, the external whole plant monitoring system 80) to realize the real-time monitoring function during the welding process;
the fourth process is the same as the right step in fig. 6A, after obtaining and processing the original data to obtain the measured data in step S32, the fourth process is entered to perform the following steps:
step A41: detecting relevant information in real time in the welding process according to the measured data to obtain an adjusting parameter and a position parameter; in this step, the measurement data is adjusted by the detection and correction unit 230 and converted into adjustment parameters and position parameters; for example, the detection and correction unit 230 compares the received measurement data (e.g., the bead width a) with a predetermined bead width (e.g., the bead width B), and converts the measurement data into an adjustment parameter and a position parameter according to the error information between the bead width a and the bead width B; the detection and correction unit 230 transmits the adjustment parameters to the welding equipment control unit 240 and the position parameters to the motion planning unit 310 for subsequent steps;
step a43 (when the detection and correction unit 230 transmits the adjustment parameter to the welding equipment control unit 240): correcting relevant parameters of the welding equipment according to the adjusting parameters; in this step, the adjustment parameters are used to automatically edit the processing program and modify the relevant parameters of the welding equipment 60;
step A44: converting the corrected relevant parameters of the welding equipment into output signals; in this step, the signal output unit 330 is used to convert the adjustment command into an output signal, which may be in the form of an analog signal, an industrial communication protocol, a digital signal, or an XY2-10 communication protocol;
step A45: carrying out welding processing correction technology according to the output signal; in this step, the signal output unit 330 transmits the output signal to the welding device 60, and the welding device 60 performs the welding process correction process according to the output signal;
step a46 (when the tracking adjustment unit 220 transmits the position parameters to the motion planning unit 310): carrying out instruction planning correction according to the position parameters and outputting a corrected driving instruction; in this step, after the motion planning unit 310 receives the position parameters, it will perform the command plan modification and output the modified driving command to the robot 70;
step A47: correcting the path trajectory of the robot 70 according to the corrected driving command; in this step, the robot 70 adjusts the machining path and the attitude according to the corrected drive command;
next, step S33: obtaining a welding finished product after processing and correction; in this step, the welded product obtained in the steps S31, S32, a4 (i.e., the fourth procedure), a 41-a 47 after the machining and correction processes meets the tolerance range.
After the welding process is finished, the welding robot control system 1 transmits the monitoring data to the external server 90 in the welding application scenario, and the external server 90 converts the monitoring data into the quantitative index, as shown in fig. 7A and 7B, the following steps (specifically, refer to step S21, step S22, step a1, step a11, step a12, and step a13 in fig. 5A):
step S41: sensing the workpiece and the end effector to obtain original data;
step S42: obtaining and processing the original data to obtain measurement data;
step S43: collecting the measurement data;
step S44: analyzing the measured data to obtain monitoring data;
step S45: transmitting the monitoring data to a user to realize real-time monitoring in the welding process;
step S46: converting the monitoring data into a quantitative index; in this step, the communication unit 430 outputs the monitoring data (or the monitoring result) to the external server 90, and the external server 90 converts the monitoring data into a quantitative index; for example, the external server 90 quantifies the welding voltage feedback information into a welding quality index, by which the user can adjust the relevant parameters of the welding process.
Therefore, according to the above steps, the welding robot control system 1 can integrate the intelligent control system, the welding system and the robot system into a single system to realize the functions of signal sensing, intelligent teaching, tracking adjustment, detection correction and/or robot control, etc., and can simultaneously apply the welding process of each stage of the welding industry to increase the applicability of industrial value.
The above embodiments are merely illustrative of the technical concept and features of the present invention, and the purpose thereof is to enable those skilled in the art to understand the content of the present invention and implement the invention, and not to limit the scope of the invention, and all equivalent changes or modifications made according to the spirit of the present invention should be covered by the scope of the present invention.
Claims (10)
1. A welding robot control system which includes at least a welding robot system, characterized in that the welding robot system comprises:
the signal input module is used for receiving original data and processing the original data to obtain measured data;
the intelligent decision-making module comprises an intelligent teaching unit, a tracking adjusting unit, a detection correcting unit and a welding equipment control unit which are matched, wherein the intelligent teaching unit is used for providing at least one function so that a user can adjust the path track of at least one robot according to the function, and the tracking adjusting unit adjusts and controls at least one welding equipment in real time according to the measurement data so as to optimize and adjust process parameters in an online mode according to the welding bead state of a workpiece in real time to obtain an adjusting instruction and a position instruction; the detection and correction unit carries out online detection on the workpiece, obtains an adjusting parameter and a position parameter according to the detected data and uses the adjusting parameter and the position parameter as a compensation basis for the next processing; the welding equipment control unit is used for controlling the robot to cooperatively operate with the welding equipment;
a command output module that converts the adjustment instruction into an output signal and outputs the output signal to the robot and the welding equipment to perform an action corresponding to the output signal;
and the information monitoring module is used for monitoring the monitoring data generated by the welding robot system and providing the monitoring data for a user to use.
2. The welding robot control system according to claim 1, characterized in that: the raw data is obtained by measuring a signal between the workpiece and an end effector by an external sensing element.
3. The welding robot control system according to claim 1, characterized in that: the functions comprise a visual alignment function, a visual picture preview function or/and an automatic height-adjusting function.
4. The welding robot control system according to claim 1, characterized in that: the signal input module comprises a signal acquisition unit and a signal processing unit which are matched with each other; the command output module comprises a motion planning unit, a force control unit and a signal output unit which are matched with each other; the information monitoring module comprises an information collecting unit, a data analyzing unit and a communication unit which are matched with each other.
5. The welding robot control system according to claim 1, characterized in that: the system also comprises an external server which is matched with the information monitoring module and used for converting the monitoring data into quantitative indexes.
6. A welding robot control method is characterized by comprising the following steps:
sensing the original data;
acquiring and processing the original data to obtain measurement data;
performing decision making function according to the measurement data and converting the decision making function into an adjusting instruction and a position instruction respectively;
converting the adjusting instruction into an output signal and outputting the output signal to drive at least one welding device, and simultaneously converting the position instruction into a driving instruction to drive at least one robot, so that the welding device and the robot cooperate to operate a workpiece;
and analyzing the measurement data to obtain monitoring data for monitoring.
7. The welding robot control method according to claim 6, characterized in that: the robot is provided with an end effector, and the operation of the welding equipment and the robot on the workpiece in a cooperative mode at least comprises three different application scenes including before welding, during welding and after welding.
8. The welding robot control method according to claim 7, wherein the pre-welding application scenario comprises the steps of:
measuring the position between the end effector and the workpiece to obtain the original data;
acquiring and processing the original data to obtain the position instruction;
performing instruction planning according to the position instruction and outputting a driving instruction;
and enabling the robot to execute a point position adjusting program according to the driving instruction.
9. The welding robot control method according to claim 7, wherein the welding-time application scenario includes the steps of:
sensing the workpiece and the end effector to obtain the original data;
acquiring and processing the original data to obtain the measured data;
executing a first program and a second program according to the decibels of the measured data, wherein the first program comprises the following steps: collecting the measurement data, analyzing and processing the measurement data to obtain the monitoring data, and transmitting the monitoring data to a user to realize real-time monitoring in the welding process, wherein the second program comprises the following steps: the method comprises the steps of detecting relevant information in real time in the welding process according to the measurement data to obtain an adjusting instruction and a position instruction, controlling the welding equipment to perform online adjustment on the workpiece according to the adjusting instruction, converting the adjusting instruction subjected to online adjustment into an output signal, performing a welding process according to the output signal, performing command planning according to the position instruction, outputting a driving instruction and performing offset adjustment on the robot according to the driving instruction.
10. The welding robot control method according to claim 7, wherein the welding-time application scenario includes the steps of:
sensing the workpiece and the end effector to obtain the original data;
acquiring and processing the original data to obtain the measured data;
respectively executing a third process and a fourth process according to the measurement data, wherein the third process comprises the following steps: collecting the measurement data, analyzing the measurement data to obtain the monitoring data, and transmitting the monitoring data to a user to realize real-time monitoring in the welding process, wherein the fourth procedure comprises the following steps: the method comprises the steps of detecting relevant information in real time in the welding process according to the measurement data to obtain an adjusting parameter and a position parameter, correcting the relevant parameter of at least one welding device according to the adjusting parameter, converting the corrected relevant parameter of the at least one welding device into an output signal, carrying out a welding processing correction process according to the output signal, carrying out command planning correction according to the position parameter and outputting a corrected driving command, and correcting the path track of the robot according to the driving command to obtain a processed and corrected workpiece.
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