CN111347129B - Calibration device and calibration method for robot welding gun and laser sensor - Google Patents

Calibration device and calibration method for robot welding gun and laser sensor Download PDF

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Publication number
CN111347129B
CN111347129B CN202010231746.9A CN202010231746A CN111347129B CN 111347129 B CN111347129 B CN 111347129B CN 202010231746 A CN202010231746 A CN 202010231746A CN 111347129 B CN111347129 B CN 111347129B
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robot
welding gun
axis
laser sensor
signal
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CN111347129A (en
Inventor
景岩
魏世海
陈昱杉
饶洪华
梁桉洋
秦伟铭
杨心江
隋志高
张家林
石长柏
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Xixian New Area Big Bear Constellation Intelligent Technology Co ltd
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Shaanxi Silk Road Robot Intelligent Manufacturing Research Institute Co ltd
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K9/00—Arc welding or cutting
    • B23K9/12—Automatic feeding or moving of electrodes or work for spot or seam welding or cutting
    • B23K9/127—Means for tracking lines during arc welding or cutting
    • B23K9/1272—Geometry oriented, e.g. beam optical trading
    • B23K9/1274—Using non-contact, optical means, e.g. laser means
    • 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
    • B25J9/1656—Programme controls characterised by programming, planning systems for manipulators
    • B25J9/1664—Programme controls characterised by programming, planning systems for manipulators characterised by motion, path, trajectory planning
    • 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
    • B25J9/1694—Programme controls characterised by use of sensors other than normal servo-feedback from position, speed or acceleration sensors, perception control, multi-sensor controlled systems, sensor fusion
    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01B—MEASURING LENGTH, THICKNESS OR SIMILAR LINEAR DIMENSIONS; MEASURING ANGLES; MEASURING AREAS; MEASURING IRREGULARITIES OF SURFACES OR CONTOURS
    • G01B11/00—Measuring arrangements characterised by the use of optical techniques
    • G01B11/002—Measuring arrangements characterised by the use of optical techniques for measuring two or more coordinates
    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01B—MEASURING LENGTH, THICKNESS OR SIMILAR LINEAR DIMENSIONS; MEASURING ANGLES; MEASURING AREAS; MEASURING IRREGULARITIES OF SURFACES OR CONTOURS
    • G01B11/00—Measuring arrangements characterised by the use of optical techniques
    • G01B11/24—Measuring arrangements characterised by the use of optical techniques for measuring contours or curvatures
    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01B—MEASURING LENGTH, THICKNESS OR SIMILAR LINEAR DIMENSIONS; MEASURING ANGLES; MEASURING AREAS; MEASURING IRREGULARITIES OF SURFACES OR CONTOURS
    • G01B21/00—Measuring arrangements or details thereof, where the measuring technique is not covered by the other groups of this subclass, unspecified or not relevant
    • G01B21/02—Measuring arrangements or details thereof, where the measuring technique is not covered by the other groups of this subclass, unspecified or not relevant for measuring length, width, or thickness
    • G01B21/04—Measuring arrangements or details thereof, where the measuring technique is not covered by the other groups of this subclass, unspecified or not relevant for measuring length, width, or thickness by measuring coordinates of points

Abstract

The utility model provides a calibration arrangement of welder of robot and laser sensor, includes the bottom plate, installs the cone that longitudinal section is big-end-up structure on the bottom plate, and circumference evenly distributed has four signal posts on the bottom plate all around of cone, all installs the photoelectric sensor who is connected with the robot on the signal post. The method has the advantages of effectively and accurately solving the problem of manual intervention in the calibration of the laser welding seam tracking sensor and realizing the automatic operation of the whole calibration process.

Description

Calibration device and calibration method for robot welding gun and laser sensor
Technical Field
The invention relates to the field of robot arc welding, in particular to a calibration device for a robot welding gun and a laser sensor.
Background
The laser sensor is widely applied to the field of robot welding and used for correcting the deviation of a welding track in real time in the welding process. In order to accurately apply the parameters of the laser sensor to the trajectory deviation correction of the robot, the calibration of the hand and the eye must be performed first after the laser sensor is installed. The calibration methods which are commonly used at present are many, but all require specific calibration tools and must be manually intervened. Therefore, a calibration method capable of realizing automatic calibration without human intervention is urgently needed.
Disclosure of Invention
The invention aims to solve the technical problem of the prior art and provides a calibration device for a robot welding gun and a laser sensor, which can automatically perform a calibration process without human intervention.
The technical problem to be solved by the invention is realized by the following technical scheme. The invention relates to a calibration device for a robot welding gun and a laser sensor, which is characterized in that: the calibration method comprises a bottom plate, wherein a cone with a vertical section of a big-end-up structure is arranged on the bottom plate, four signal columns are uniformly distributed on the bottom plate around the cone in the circumferential direction, photoelectric sensors connected with a robot are arranged on the signal columns, the height of each photoelectric sensor is 8-12mm higher than the top point of the cone, transmitting columns are arranged between the oppositely arranged signal columns, and receiving columns correspondingly matched with the transmitting columns are arranged between the oppositely arranged signal columns, and the calibration method is realized by the following steps: (1) installing a laser sensor at the outer end of a welding gun of the welding robot, establishing communication between the laser sensor and the welding robot, and fixing a bottom plate on a workbench, wherein the included angle between the bottom plate and the x and y axes of a robot coordinate system is less than 10 degrees; (2) vertically arranging a robot welding gun on a bottom plate, moving the robot welding gun to the position in the negative direction of an x axis, wherein the distance from the edge of the bottom plate to the edge of the bottom plate is less than 30mm, the y coordinate is close to the y coordinate at the vertex of a cone as much as possible, the deviation is not more than plus or minus 20mm, the height of the tip of a welding wire of the robot welding gun is 2-10mm lower than the light height of a photoelectric sensor, and recording or covering the point as P0Moving a robot welding gun to a safe point by using a manual teaching method; (4) the robot runs a program for automatically completing hand-eye calibration, obtains the relative position relation between a welding gun and a laser sensor, outputs the value of a vector T as a calibration result, and reads a motion starting point P0(x0,y0,z0) The robot welding gun starts from a safety point and movesTo P0The position of the robot welding gun moves 10-20mm in the positive direction of the y axis and then moves in the positive direction of the x axis at the speed of 2-10mm/s, the robot detects that the signal of the first photoelectric sensor is changed from 0 to 1, the photoelectric sensor outputs a signal of 0 under the condition that no object blocks the light, the light of the photoelectric sensor is blocked by the object and outputs a signal of 1, and the current position P is recordeda(xa,ya,z0) When the robot detects that the signal of the second photoelectric sensor changes from 0 to 1, the current position P is recordedb(xb,yb,z0) Robot torch Return to P0The position of the robot welding gun is 10-20mm in the negative direction of the y axis, the robot welding gun moves in the positive direction of the x axis at the speed of 2-10mm/s, the signal of the first photoelectric sensor detected by the robot is changed from 0 to 1, and the current position P is recorded immediatelyc(xc,yc,z0) When the robot detects that the signal of the second photoelectric sensor changes from 0 to 1, the current position Pd (x) is recordedd,yd,z0) (ii) a (5) Robot slave PdThe position moves to the positive direction of the z axis, the signal of the photoelectric sensor detected by the robot is changed from 1 to 0, and the z axis coordinate z of the current position is recorded immediatelys(ii) a (6) Robot torch back to P0When the position of the robot is detected, the laser sensor starts to continuously scan, the mode is set to output the coordinates (x, z) of the highest point on the contour line, the robot welding gun moves towards the positive direction of the x axis, the speed is 2-10mm/s, the robot control system compares the data of one laser sensor with the z value in the previous group of data when receiving the data of the laser sensor, if the current z value is larger, the current data and the coordinate value of the current robot are recorded, the previous group of data is cleared, until the previous z value is larger, the current data are not recorded, the previous group of data are reserved, the laser sensor stops scanning, the coordinates of the highest point of the contour line are recorded as (x, z), and the coordinates of the current robot are recorded as (x, z)2,y2,z2) The laser sensor stops scanning, and the robot returns to a safety point; (7) solving for P1Solving for P2＝(x2,y2+x,z2+ z), laser sensor to torch space vector T ═ P1-P2The welding gun moves in the positive direction of the x-axis along 2 pathsIntersecting the light ray of the photoelectric sensor at Pa,Pb,Pc,PdFour points, P1Point is a straight line PaPdAnd a straight line PbPcThe equations of the two straight lines are solved according to the coordinates recorded by the robot, and the equations are respectively as follows;
straight line PaPdThe equation of (c): y ═ ya-yd)/(xa-xd)*(x-xa)+ya
Straight line PbPcThe equation of (c): y ═ ya-yd)/(xb-xc)*(x-xb)+ya
Solving the coordinates of point P1 according to the above equation:
x1＝((ya-yd)/(xa-xd)*xa-(ya-yd)/(xb-xc)*xb)/((ya-yd)/(xa-xd)-(ya-yd)/(xb-xc))
y1＝(ya-yd)/(xa-xd)*(x1-xa)+ya
since the laser line height is 10mm higher than the cone apex, P is1The z-coordinate of the point is: z is a radical of1＝zs-10，
The above formula is written in the program, when P is obtaineda,Pb,Pc,PdAnd the height value zsThen, automatically solve for P1The coordinates of (a).
In the technical scheme of the calibration device for the robot welding gun and the laser sensor, the further preferable technical scheme is characterized in that:
1. the connecting lines of the 2 groups of oppositely arranged signal columns are mutually vertical and intersect at the vertex of the vertebral body;
2. the height of the photoelectric sensor is 10mm higher than the top of the cone;
3. in the step (4), the robot welding gun moves 20mm in the positive direction of the y axis and then moves in the positive direction of the x axis at the speed of 5 mm/s;
4. in the step (4), the robot welding gun moves 20mm to the negative direction of the y axis, and then moves to the positive direction of the x axis at the speed of 5 mm/s;
5. and (5) moving the robot welding gun in the step (6) to the positive direction of the x axis at the speed of 5 mm/s.
Compared with the prior art, the method has the advantages that the scheme is effective and accurate, the problem of manual intervention in the calibration of the laser welding seam tracking sensor is solved, and the automatic operation of the whole calibration process is realized.
Drawings
In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings required in the description of the embodiments or the prior art will be briefly introduced below, it is obvious that the drawings in the following description are only some embodiments of the present invention, and for those skilled in the art, other drawings can be obtained according to the drawings without creative efforts.
FIG. 1 is a schematic structural diagram of the present invention.
Fig. 2 is a schematic diagram of automatic calibration of a robot welding gun.
Detailed Description
The technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the drawings in the embodiments of the present invention, and it is obvious that the described embodiments are only a part of the embodiments of the present invention, and not all of the embodiments. All other embodiments, which can be derived by a person skilled in the art from the embodiments given herein without making any creative effort, shall fall within the protection scope of the present invention.
Embodiment 1, a calibration device for a robot welding gun and a laser sensor comprises a bottom plate 1, wherein a cone 2 with a vertical section of a big-end-up structure is arranged on the bottom plate 1, four signal columns 3 are uniformly distributed on the bottom plate around the cone 2 in the circumferential direction, photoelectric sensors connected with a robot are arranged on the signal columns 3, the height of each photoelectric sensor is 8-12mm higher than the top of the cone, transmitting columns are arranged between the oppositely arranged signal columns respectively, and the photoelectric sensors are opposite to the transmitting columnsThe calibration method of the receiving column to be matched is realized by the following steps: (1) installing a laser sensor at the outer end of a welding gun of the welding robot, establishing communication between the laser sensor and the welding robot, and fixing a bottom plate on a workbench, wherein the included angle between the bottom plate and the x and y axes of a robot coordinate system is less than 10 degrees; (2) vertically arranging a robot welding gun on a bottom plate, moving the robot welding gun to the position in the negative direction of an x axis, wherein the distance from the edge of the bottom plate to the edge of the bottom plate is less than 30mm, the y coordinate is close to the y coordinate at the vertex of a cone as much as possible, the deviation is not more than plus or minus 20mm, the height of the tip of a welding wire of the robot welding gun is 2-10mm lower than the light height of a photoelectric sensor, and recording or covering the point as P0Moving a robot welding gun to a safe point by using a manual teaching method; (4) the robot runs a program for automatically completing hand-eye calibration, obtains the relative position relation between a welding gun and a laser sensor, outputs the value of a vector T as a calibration result, and reads a motion starting point P0(x0,y0,z0) The robot welding gun starts from a safety point and moves to P0The position of the robot welding gun moves 10-20mm in the positive direction of the y axis and then moves in the positive direction of the x axis at the speed of 2-10mm/s, the robot detects that the signal of the first photoelectric sensor is changed from 0 to 1, the photoelectric sensor outputs a signal of 0 under the condition that no object blocks the light, the light of the photoelectric sensor is blocked by the object and outputs a signal of 1, and the current position P is recordeda(xa,ya,z0) When the robot detects that the signal of the second photoelectric sensor changes from 0 to 1, the current position P is recordedb(xb,yb,z0) Robot torch Return to P0The position of the robot welding gun is 10-20mm in the negative direction of the y axis, the robot welding gun moves in the positive direction of the x axis at the speed of 2-10mm/s, the signal of the first photoelectric sensor detected by the robot is changed from 0 to 1, and the current position P is recorded immediatelyc(xc,yc,z0) When the robot detects that the signal of the second photoelectric sensor changes from 0 to 1, the current position Pd (x) is recordedd,yd,z0) (ii) a (5) Robot slave PdThe position moves to the positive direction of the z axis, the robot detects that the signal of the photoelectric sensor is changed from 1 to 0, and the z axis seat which records the current position at onceMark zs(ii) a (6) Robot torch back to P0When the position of the robot is detected, the laser sensor starts to continuously scan, the mode is set to output the coordinates (x, z) of the highest point on the contour line, the robot welding gun moves towards the positive direction of the x axis, the speed is 2-10mm/s, the robot control system compares the data of one laser sensor with the z value in the previous group of data when receiving the data of the laser sensor, if the current z value is larger, the current data and the coordinate value of the current robot are recorded, the previous group of data is cleared, until the previous z value is larger, the current data are not recorded, the previous group of data are reserved, the laser sensor stops scanning, the coordinates of the highest point of the contour line are recorded as (x, z), and the coordinates of the current robot are recorded as (x, z)2,y2,z2) The laser sensor stops scanning, and the robot returns to a safety point; (7) solving for P1Solving for P2＝(x2,y2+x,z2+ z), laser sensor to torch space vector T ═ P1-P2The welding gun moves in the positive direction of the x axis along 2 paths and intersects with the light ray of the photoelectric sensor at Pa,Pb,Pc,PdFour points, P1Point is a straight line PaPdAnd a straight line PbPcThe equations of the two straight lines are solved according to the coordinates recorded by the robot, and the equations are respectively as follows;
straight line PaPdThe equation of (c): y ═ ya-yd)/(xa-xd)*(x-xa)+ya
Straight line PbPcThe equation of (c): y ═ ya-yd)/(xb-xc)*(x-xb)+ya
Solving the coordinates of point P1 according to the above equation:
x1＝((ya-yd)/(xa-xd)*xa-(ya-yd)/(xb-xc)*xb)/((ya-yd)/(xa-xd)-(ya-yd)/(xb-xc))
y1＝(ya-yd)/(xa-xd)*(x1-xa)+ya
since the laser line height is 10mm higher than the cone apex, P is1The z-coordinate of the point is: z is a radical of1＝zs-10，
The above formula is written in the program, when P is obtaineda,Pb,Pc,PdAnd the height value zsThen, automatically solve for P1The coordinates of (a). The utility model discloses the bottom plate is square rigidity bottom plate, and the length of side is 200mm, and is 5-10mm thick, and the cone is the cone, places in the center department of bottom plate, and its base circle diameter is 100mm, and height 20mm, the material is not limited. Install photoelectric sensor on the signal post, highly than the high 10mm on cone summit to avoid light to be sheltered from by the cone, photoelectric sensor is supplied power by the 24V power, and is connected the output with the IO integrated circuit board of robot. The laser sensor is a laser welding seam tracking sensor.
Embodiment 2, in the calibration apparatus and the calibration method for the robot welding gun and the laser sensor described in embodiment 1: the calibration method comprises a bottom plate, wherein a cone with a vertical section of a big-end-up structure is arranged on the bottom plate, four signal columns are uniformly distributed on the bottom plate around the cone in the circumferential direction, photoelectric sensors connected with a robot are arranged on the signal columns, the height of each photoelectric sensor is 8mm higher than the top point of the cone, transmitting columns are arranged between the oppositely arranged signal columns respectively, and receiving columns correspondingly matched with the transmitting columns are arranged, and the calibration method is realized by the following steps: (1) installing a laser sensor at the outer end of a welding gun of the welding robot, establishing communication between the laser sensor and the welding robot, and fixing a bottom plate on a workbench, wherein the included angle between the bottom plate and the x and y axes of a robot coordinate system is less than 10 degrees; (2) vertically arranging a robot welding gun on a bottom plate, moving the robot welding gun to the position in the negative direction of an x axis, wherein the distance from the edge of the bottom plate to the edge of the bottom plate is less than 30mm, the y coordinate is close to the y coordinate at the vertex of a cone as much as possible, the deviation does not exceed plus or minus 20mm, the height of the tip of a welding wire of the robot welding gun is 2mm lower than the light height of a photoelectric sensor, and recording or covering the point as P0Moving a robot welding gun to a safe point by using a manual teaching method; (4) the robot runs to automatically complete the procedure of calibrating the hand and the eye, and obtains the welding gunRelative position relation with the laser sensor, the output vector T value is the calibration result, and the motion starting point P is read0(x0,y0,z0) The robot welding gun starts from a safety point and moves to P0The position, the robot welder moves 10mm to the y axle positive direction, moves to the x axle positive direction again, and the speed is 2mm/s, and the robot detects that first photoelectric sensor's signal changes from 0 to 1, and under the condition that no object shelters from light, photoelectric sensor output signal 0, photoelectric sensor's light is sheltered from output signal by the object and is 1, records current position Pa(xa,ya,z0) When the robot detects that the signal of the second photoelectric sensor changes from 0 to 1, the current position P is recordedb(xb,yb,z0) Robot torch Return to P0The position, the robot welding gun moves 10mm to the y-axis negative direction, the robot welding gun moves to the x-axis positive direction again, the speed is 2mm/s, the robot detects that the signal of the first photoelectric sensor changes from 0 to 1, and the current position P is recorded immediatelyc(xc,yc,z0) When the robot detects that the signal of the second photoelectric sensor changes from 0 to 1, the current position Pd (x) is recordedd,yd,z0) (ii) a (5) Robot slave PdThe position moves to the positive direction of the z axis, the signal of the photoelectric sensor detected by the robot is changed from 1 to 0, and the z axis coordinate z of the current position is recorded immediatelys(ii) a (6) Robot torch back to P0The position, the laser sensor starts to continuously scan, the mode is set as the coordinate (x, z) of the highest point on the output contour line, the robot welding gun moves towards the positive direction of the x axis, the speed is 2mm/s, the robot control system compares the data of one photoelectric sensor with the z value in the previous group of data when receiving the data of one photoelectric sensor, if the current z value is larger, the current data and the coordinate value of the current robot are recorded, the previous group of data is cleared, until the previous z value is larger, the current data are not recorded, the previous group of data are reserved, the sensor stops scanning, the coordinate of the highest point contour line is recorded as (x, z), the coordinate of the current robot is recorded as (x, z), and the coordinate of the current robot is recorded as (x, z)2,y2,z2) When the sensor stops scanning, the robot returns to a safety point; (7) solving for P1Solving for P2＝(x2,y2+x,z2+ z), laser sensor to torch space vector T ═ P1-P2The welding gun moves in the positive direction of the x axis along 2 paths and intersects with the light ray of the photoelectric sensor at Pa,Pb,Pc,PdFour points, P1Point is a straight line PaPdAnd a straight line PbPcThe equations of the two straight lines are solved according to the coordinates recorded by the robot, and the equations are respectively as follows;
straight line PaPdThe equation of (c): y ═ ya-yd)/(xa-xd)*(x-xa)+ya
Straight line PbPcThe equation of (c): y ═ ya-yd)/(xb-xc)*(x-xb)+ya
Solving the coordinates of point P1 according to the above equation:
x1＝((ya-yd)/(xa-xd)*xa-(ya-yd)/(xb-xc)*xb)/((ya-yd)/(xa-xd)-(ya-yd)/(xb-xc))
y1＝(ya-yd)/(xa-xd)*(x1-xa)+ya
since the laser line height is 10mm higher than the cone apex, P is1The z-coordinate of the point is: z is a radical of1＝zs-10，
The above formula is written in the program, when P is obtaineda,Pb,Pc,PdAnd the height value zsThen, automatically solve for P1The coordinates of (a).
Embodiment 3, the calibration apparatus and the calibration method for the robot welding gun and the laser sensor according to embodiment 1 or 2 are as follows: comprises a bottom plate, a cone with a vertical section of a big-end-up structure is arranged on the bottom plate, four signal columns are uniformly distributed on the bottom plate around the cone in the circumferential direction, and the signal columns are all arranged on the robotThe height of the photoelectric sensor is 12mm higher than the top of the cone, the oppositely arranged signal columns are respectively provided with an emitting column and a receiving column correspondingly matched with the emitting column, and the calibration method is realized by the following steps: (1) installing a laser sensor at the outer end of a welding gun of the welding robot, establishing communication between the laser sensor and the welding robot, and fixing a bottom plate on a workbench, wherein the included angle between the bottom plate and the x and y axes of a robot coordinate system is less than 10 degrees; (2) vertically arranging a robot welding gun on a bottom plate, moving the robot welding gun to the position in the negative direction of an x axis, wherein the distance from the edge of the bottom plate to the edge of the bottom plate is less than 30mm, the y coordinate is close to the y coordinate at the vertex of a cone as much as possible, the deviation is not more than plus or minus 20mm, the height of the tip of a welding wire of the robot welding gun is 10mm lower than the light height of a photoelectric sensor, and recording or covering the point as P0Moving a robot welding gun to a safe point by using a manual teaching method; (4) the robot runs a program for automatically completing hand-eye calibration, obtains the relative position relation between a welding gun and a laser sensor, outputs the value of a vector T as a calibration result, and reads a motion starting point P0(x0,y0,z0) The robot welding gun starts from a safety point and moves to P0The position, the robot welder moves 20mm to the y axle positive direction, moves to the x axle positive direction again, and the speed is 10mm/s, and the robot detects that the signal of first photoelectric sensor changes from 0 to 1, and under the condition that no object shelters from light, photoelectric sensor output signal 0, photoelectric sensor's light is sheltered from output signal by the object and is 1, records current position Pa(xa,ya,z0) When the robot detects that the signal of the second photoelectric sensor changes from 0 to 1, the current position P is recordedb(xb,yb,z0) Robot torch Return to P0The position, the robot welding gun moves 20mm to the y-axis negative direction, the robot welding gun moves to the x-axis positive direction again, the speed is 10mm/s, the signal of the first photoelectric sensor detected by the robot changes from 0 to 1, and the current position P is recorded immediatelyc(xc,yc,z0) When the robot detects that the signal of the second photoelectric sensor changes from 0 to 1, the current position Pd (x) is recordedd,yd,z0) (ii) a (5) Machine with a rotatable shaftPerson from PdThe position moves to the positive direction of the z axis, the signal of the photoelectric sensor detected by the robot is changed from 1 to 0, and the z axis coordinate z of the current position is recorded immediatelys(ii) a (6) Robot torch back to P0The position, the laser sensor starts to continuously scan, the mode is set as the coordinate (x, z) of the highest point on the output contour line, the robot welding gun moves towards the positive direction of the x axis, the speed is 10mm/s, the robot control system compares the data of one photoelectric sensor with the z value in the previous group of data when receiving the data of one photoelectric sensor, if the current z value is larger, the current data and the coordinate value of the current robot are recorded, the previous group of data is cleared, until the previous z value is larger, the current data are not recorded, the previous group of data are reserved, the sensor stops scanning, the coordinate of the highest point contour line is recorded as (x, z), the coordinate of the current robot is recorded as (x, z), and the coordinate of the current robot is recorded as (x, z)2,y2,z2) When the sensor stops scanning, the robot returns to a safety point; (7) solving for P1Solving for P2＝(x2,y2+x,z2+ z), laser sensor to torch space vector T ═ P1-P2The welding gun moves in the positive direction of the x axis along 2 paths and intersects with the light ray of the photoelectric sensor at Pa,Pb,Pc,PdFour points, P1Point is a straight line PaPdAnd a straight line PbPcThe equations of the two straight lines are solved according to the coordinates recorded by the robot, and the equations are respectively as follows;
straight line PaPdThe equation of (c): y ═ ya-yd)/(xa-xd)*(x-xa)+ya
Straight line PbPcThe equation of (c): y ═ ya-yd)/(xb-xc)*(x-xb)+ya
Solving the coordinates of point P1 according to the above equation:
x1＝((ya-yd)/(xa-xd)*xa-(ya-yd)/(xb-xc)*xb)/((ya-yd)/(xa-xd)-(ya-yd)/(xb-xc))
y1＝(ya-yd)/(xa-xd)*(x1-xa)+ya
since the laser line height is 10mm higher than the cone apex, P is1The z-coordinate of the point is: z is a radical of1＝zs-10，
The above formula is written in the program, when P is obtaineda,Pb,Pc,PdAnd the height value zsThen, automatically solve for P1The coordinates of (a).
Embodiment 4, the calibration apparatus and the calibration method for the robot welding gun and the laser sensor according to embodiment 1, 2 or 3 are as follows: the calibration method comprises a bottom plate, wherein a cone with a vertical section of a big-end-up structure is arranged on the bottom plate, four signal columns are uniformly distributed on the bottom plate around the cone in the circumferential direction, photoelectric sensors connected with a robot are arranged on the signal columns, the height of each photoelectric sensor is 10mm higher than the top point of the cone, transmitting columns are arranged between the oppositely arranged signal columns respectively, and receiving columns correspondingly matched with the transmitting columns are arranged, and the calibration method is realized by the following steps: (1) installing a laser sensor at the outer end of a welding gun of the welding robot, establishing communication between the laser sensor and the welding robot, and fixing a bottom plate on a workbench, wherein the included angle between the bottom plate and the x and y axes of a robot coordinate system is less than 10 degrees; (2) vertically arranging a robot welding gun on a bottom plate, moving the robot welding gun to the position in the negative direction of an x axis, wherein the distance from the edge of the bottom plate to the edge of the bottom plate is less than 30mm, the y coordinate is close to the y coordinate at the vertex of a cone as much as possible, the deviation is not more than plus or minus 20mm, the height of the tip of a welding wire of the robot welding gun is 10mm lower than the light height of a photoelectric sensor, and recording or covering the point as P0Moving a robot welding gun to a safe point by using a manual teaching method; (4) the robot runs a program for automatically completing hand-eye calibration, obtains the relative position relation between a welding gun and a laser sensor, outputs the value of a vector T as a calibration result, and reads a motion starting point P0(x0,y0,z0) The robot welding gun starts from a safety point and moves to P0The position of the robot welding gun moves 20mm in the positive direction of the y axis and then moves to the x axisMoving in the positive direction at the speed of 5mm/s, changing the signal of the first photoelectric sensor detected by the robot from 0 to 1, outputting the signal of 0 by the photoelectric sensor under the condition that no object blocks the light, outputting the signal of 1 by the light blocked by the object, and recording the current position Pa(xa,ya,z0) When the robot detects that the signal of the second photoelectric sensor changes from 0 to 1, the current position P is recordedb(xb,yb,z0) Robot torch Return to P0The position, the robot welding gun moves 20mm to the y-axis negative direction, the robot welding gun moves to the x-axis positive direction again, the speed is 5mm/s, the signal of the first photoelectric sensor detected by the robot changes from 0 to 1, and the current position P is recorded immediatelyc(xc,yc,z0) When the robot detects that the signal of the second photoelectric sensor changes from 0 to 1, the current position Pd (x) is recordedd,yd,z0) (ii) a (5) Robot slave PdThe position moves to the positive direction of the z axis, the signal of the photoelectric sensor detected by the robot is changed from 1 to 0, and the z axis coordinate z of the current position is recorded immediatelys(ii) a (6) Robot torch back to P0The position, the laser sensor starts to continuously scan, the mode is set as the coordinate (x, z) of the highest point on the output contour line, the robot welding gun moves towards the positive direction of the x axis, the speed is 5mm/s, the robot control system compares the data of one photoelectric sensor with the z value in the previous group of data when receiving the data of one photoelectric sensor, if the current z value is larger, the current data and the coordinate value of the current robot are recorded, the previous group of data is cleared, until the previous z value is larger, the current data are not recorded, the previous group of data are reserved, the sensor stops scanning, the coordinate of the highest point contour line is recorded as (x, z), the coordinate of the current robot is recorded as (x, z), and the coordinate of the current robot is recorded as (x, z)2,y2,z2) When the sensor stops scanning, the robot returns to a safety point; (7) solving for P1Solving for P2＝(x2,y2+x,z2+ z), laser sensor to torch space vector T ═ P1-P2The welding gun moves in the positive direction of the x axis along 2 paths and intersects with the light ray of the photoelectric sensor at Pa,Pb,Pc,PdThe number of the four points is four,P1point is a straight line PaPdAnd a straight line PbPcThe equations of the two straight lines are solved according to the coordinates recorded by the robot, and the equations are respectively as follows;
straight line PaPdThe equation of (c): y ═ ya-yd)/(xa-xd)*(x-xa)+ya
Straight line PbPcThe equation of (c): y ═ ya-yd)/(xb-xc)*(x-xb)+ya
Solving the coordinates of point P1 according to the above equation:
x1＝((ya-yd)/(xa-xd)*xa-(ya-yd)/(xb-xc)*xb)/((ya-yd)/(xa-xd)-(ya-yd)/(xb-xc))
y1＝(ya-yd)/(xa-xd)*(x1-xa)+ya
since the laser line height is 10mm higher than the cone apex, P is1The z-coordinate of the point is: z is a radical of1＝zs-10，
The above formula is written in the program, when P is obtaineda,Pb,Pc,PdAnd the height value zsThen, automatically solve for P1The coordinates of (a).
Embodiment 5, the calibration apparatus and the calibration method for the robot welding gun and the laser sensor according to any one of embodiments 1 to 4 are: the connecting lines of the 2 groups of oppositely arranged signal columns are mutually vertical and intersect at the vertex of the vertebral body.
Embodiment 6, the calibration apparatus and the calibration method for the robot welding gun and the laser sensor according to any one of embodiments 1 to 5, wherein: the height of the photoelectric sensor is 10mm higher than the top of the cone.
Embodiment 7, the calibration apparatus and the calibration method for the robot torch and the laser sensor according to any one of embodiments 1 to 6, wherein: in the step (4), the robot welding gun moves 20mm in the positive direction of the y axis and then moves in the positive direction of the x axis at the speed of 5 mm/s.
Embodiment 8, the calibration apparatus and the calibration method for the robot welding gun and the laser sensor according to any one of embodiments 1 to 7, wherein: and (4) moving the robot welding gun to the y-axis negative direction for 20mm, and moving the robot welding gun to the x-axis positive direction at the speed of 5 mm/s.
Embodiment 9, the calibration apparatus and the calibration method for the robot welding gun and the laser sensor according to any one of embodiments 1 to 8, wherein: and (5) moving the robot welding gun in the step (6) to the positive direction of the x axis at the speed of 5 mm/s.
The principle of the invention is as follows: the laser welding seam tracking sensor is arranged at the outer end of a welding gun of the robot and keeps a relatively fixed distance with the welding gun, and the hand eyes of the welding gun and the laser welding seam tracking sensor are calibrated to obtain the relative position relation of the welding gun and the laser welding seam tracking sensor, namely the space vector T from the laser sensor to the welding gun is solved. Thus, the coordinate P of the target point output by the laser welding seam tracking sensor is the coordinate of the target point relative to the welding gun through vector addition P + T. The invention adopts a photoelectric sensor to detect the welding wire to judge that the welding gun reaches the key position on the calibration plate, and solves the coordinate of the cone vertex of the calibration device relative to the welding gun by using the geometric relation. The mode for searching the highest point coordinate used by the laser sensor. In this mode, the laser sensor will continuously send the coordinates (x, z) of the point of maximum z value in the scanned profile. In the invention, the vertex of the cone is the highest point of the calibration device, so when the laser sensor scans over the cone, the z value in the output coordinate is the maximum only when the laser sensor just passes through the vertex of the cone, and the coordinate is the coordinate of the vertex of the cone relative to the laser sensor.
In step (4), whether the robot welding gun moves to the positive direction of the y axis or the negative direction of the y axis first is not strictly regulated. And the robot welding gun moves towards the x axis, the robot welding gun moves to the position of the x axis negative direction of the calibration device in the manual teaching step, so that the welding gun moves towards the x axis positive direction to start the calibration operation, and if the robot welding gun moves to the position of the x axis positive direction of the calibration device in the manual teaching step, the robot welding gun moves towards the x axis negative direction in the manual teaching step to start the calibration operation. Therefore, the XY coordinate system in step (4) may be performed in any one of the first, second, third and fourth quadrants.
The above are only specific embodiments of the present invention, but the scope of the present invention is not limited thereto, and any person skilled in the art can substitute or change the technical solution and the concept of the present invention within the scope of the present invention disclosed by the present invention, and all the persons skilled in the art belong to the scope of the present invention.

Claims (6)

1. The utility model provides a calibration device of welder of robot and laser sensor which characterized in that: comprises a bottom plate, a cone with a vertical section of a structure with a big top and a small bottom is arranged on the bottom plate, four signal columns are uniformly distributed on the bottom plate at the periphery of the cone in the circumferential direction, photoelectric sensors connected with a robot are arranged on the signal columns, the height of each photoelectric sensor is 8-12mm higher than the top of the cone, transmitting columns and receiving columns correspondingly matched with the transmitting columns are respectively arranged between the oppositely arranged signal columns,
the calibration method is realized by the following steps:
(1) installing a laser sensor at the outer end of a welding gun of the welding robot, establishing communication between the laser sensor and the welding robot, and fixing a bottom plate on a workbench, wherein the included angle between the bottom plate and the x and y axes of a robot coordinate system is less than 10 degrees;
(2) vertically arranging a robot welding gun on a bottom plate, moving the robot welding gun to the position in the negative direction of an x axis, wherein the distance from the edge of the bottom plate to the edge of the bottom plate is less than 30mm, the y coordinate is close to the y coordinate at the vertex of a cone as much as possible, the deviation is not more than plus or minus 20mm, the height of the tip of a welding wire of the robot welding gun is 2-10mm lower than the light height of a photoelectric sensor, and recording or covering the point as P0The point(s) is (are) such that,
(3) moving the robot welding gun to a safety point by using a manual teaching method;
(4) the robot runs a program for automatically completing the calibration of the hand and the eye, obtains the relative position relationship between the welding gun and the laser sensor,the output vector T value is the calibration result, and the motion starting point P is read0(x0,y0,z0) The robot welding gun starts from a safety point and moves to P0The position of the robot welding gun moves 10-20mm in the positive direction of the y axis and then moves in the positive direction of the x axis at the speed of 2-10mm/s, the robot detects that the signal of the first photoelectric sensor is changed from 0 to 1, the photoelectric sensor outputs a signal of 0 under the condition that no object blocks the light, the light of the photoelectric sensor is blocked by the object and outputs a signal of 1, and the current position P is recordeda(xa,ya,z0) When the robot detects that the signal of the second photoelectric sensor changes from 0 to 1, the current position P is recordedb(xb,yb,z0) Robot torch Return to P0The position of the robot welding gun is 10-20mm in the negative direction of the y axis, the robot welding gun moves in the positive direction of the x axis at the speed of 2-10mm/s, the signal of the first photoelectric sensor detected by the robot is changed from 0 to 1, and the current position P is recorded immediatelyc(xc,yc,z0) When the robot detects that the signal of the second photoelectric sensor changes from 0 to 1, the current position Pd (x) is recordedd,yd,z0)；
(5) Robot slave PdThe position moves to the positive direction of the z axis, the signal of the photoelectric sensor detected by the robot is changed from 1 to 0, and the z axis coordinate z of the current position is recorded immediatelys；
(6) Robot torch back to P0When the position of the robot is detected, the laser sensor starts to continuously scan, the mode is set to output the coordinates (x, z) of the highest point on the contour line, the robot welding gun moves towards the positive direction of the x axis, the speed is 2-10mm/s, the robot control system compares the data of one laser sensor with the z value in the previous group of data when receiving the data of the laser sensor, if the current z value is larger, the current data and the coordinate value of the current robot are recorded, the previous group of data is cleared, until the previous z value is larger, the current data are not recorded, the previous group of data are reserved, the laser sensor stops scanning, the coordinates of the highest point of the contour line are recorded as (x, z), and the coordinates of the current robot are recorded as (x, z)2,y2,z2) When the laser sensor stops scanning, the robotReturning to a safety point;
(7) solving for P1Solving for P2＝(x2,y2+x,z2+ z), laser sensor to torch space vector T ═ P1-P2The welding gun moves in the positive direction of the x axis along 2 paths and intersects with the light ray of the photoelectric sensor at Pa,Pb,Pc,PdFour points, P1Point is a straight line PaPdAnd a straight line PbPcThe equations of the two straight lines are solved according to the coordinates recorded by the robot, and the equations are respectively as follows;
straight line PaPdThe equation of (c): y ═ ya-yd)/(xa-xd)*(x-xa)+ya
Straight line PbPcThe equation of (c): y ═ ya-yd)/(xb-xc)*(x-xb)+ya
Solving the coordinates of point P1 according to the above equation:
x1＝((ya-yd)/(xa-xd)*xa-(ya-yd)/(xb-xc)*xb)/((ya-yd)/(xa-xd)-(ya-yd)/(xb-xc))
y1＝(ya-yd)/(xa-xd)*(x1-xa)+ya
since the laser line height is 10mm higher than the cone apex, P is1The z-coordinate of the point is: z is a radical of1＝zs-10，
The above formula is written in the program, when P is obtaineda,Pb,Pc,PdAnd the height value zsThen, automatically solve for P1The coordinates of (a).
2. The calibration device for the robot welding gun and the laser sensor according to claim 1, wherein: the connecting lines of the 2 groups of oppositely arranged signal columns are mutually vertical and intersect at the vertex of the vertebral body.
3. The calibration device for the robot welding gun and the laser sensor according to claim 1, wherein the height of the photoelectric sensor is 10mm higher than the top of the cone.
4. The calibration device for the robot welding gun and the laser sensor according to claim 1, wherein in the step (4), the robot welding gun moves 20mm in the positive direction of the y axis and then moves in the positive direction of the x axis at a speed of 5 mm/s.
5. The calibration device for the robot welding gun and the laser sensor according to claim 1, wherein: and (4) moving the robot welding gun to the y-axis negative direction for 20mm, and moving the robot welding gun to the x-axis positive direction at the speed of 5 mm/s.
6. The calibration device for the robot welding gun and the laser sensor according to claim 1, wherein: and (5) moving the robot welding gun in the step (6) to the positive direction of the x axis at the speed of 5 mm/s.
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