CN111702304A - Control system and method for automatic positioning of contact tip for submerged arc welding - Google Patents

Control system and method for automatic positioning of contact tip for submerged arc welding Download PDF

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Publication number
CN111702304A
CN111702304A CN202010579380.4A CN202010579380A CN111702304A CN 111702304 A CN111702304 A CN 111702304A CN 202010579380 A CN202010579380 A CN 202010579380A CN 111702304 A CN111702304 A CN 111702304A
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axis
welding
plc
pipe joint
entering
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CN111702304B (en
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李靖
唐建明
张继彪
时蓓玲
胡灵斌
夏月
汪峥
赵利忠
华军明
韦奋祥
陆泽城
胡斌
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CCCC Third Harbor Engineering 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
    • B23K9/24—Features related to electrodes
    • B23K9/26—Accessories for electrodes, e.g. ignition tips
    • 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
    • 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
    • B23K9/18—Submerged-arc welding

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  • Physics & Mathematics (AREA)
  • Plasma & Fusion (AREA)
  • Mechanical Engineering (AREA)
  • Arc Welding In General (AREA)
  • Butt Welding And Welding Of Specific Article (AREA)

Abstract

The invention discloses a control system and a method for automatically positioning a contact tube for submerged arc welding. The control system includes: a support frame; the rolling frame is connected with the supporting frame in a shaft mode and used for placing a pipe joint to be welded; a plurality of roller driving motors for driving the rolling frames to rotate by driving the rollers; the rotary encoder is used for measuring the rotary arc length of the pipe joint to be welded; the two-dimensional scanning sensor is arranged on the machine head and used for measuring coordinate data of M points on the upper edge of the left groove of the welding bead; according to the coordinate data of M points on the upper edge of the left groove of the welding bead and the rotating arc length of the pipe joint, calculating and sending the PLC of the position information of the contact nozzle to be moved; and the two-dimensional action mechanism is arranged on the support frame above the roll-on-roll-off frame and drives the machine head to move along the X-axis direction and the Y-axis direction according to the received information of the position to be moved of the contact nozzle. The invention realizes the high-precision positioning of the contact tube for submerged arc welding.

Description

Control system and method for automatic positioning of contact tip for submerged arc welding
Technical Field
The invention relates to the technical field of automatic positioning of a contact tube.
Background
Submerged arc welding is mainly used for welding various steel plate structures at present, the welded steel mainly comprises carbon structural steel, stainless steel, heat-resistant steel, composite steel thereof and the like, and submerged arc welding is most widely applied to shipbuilding, boilers, chemical containers, bridges, hoisting machinery, metallurgical machinery manufacturing industry, marine structures and nuclear power equipment. The welding mode is mainly manual or semi-automatic, the distance from the contact tip to a workpiece is difficult to accurately control, the stability of electric arc is directly caused, and the welding quality and the welding efficiency are influenced.
The invention discloses a positioning scheme for a stacker, which is disclosed in the patent of 'an automatic stereoscopic warehouse point location control system and a control method thereof' (application number: 201510154842.7). the scheme can only solve the problems of X-axis and Y-axis driving and large object positioning, but the measurement precision and the application environment can not meet the requirements of submerged arc welding application.
The name of "an automatic gate control method based on trilateral positioning" (application number: 201410447404.5) discloses a trilateral positioning method, which measures the distance of a moving object based on a signal transmitted by a wireless signal base station and determines the space position of the moving object by calculation, and the method has the advantages of slow response speed, low measurement precision and incapability of meeting the requirements of industrial control
As described above, the conventional technique cannot meet the requirement of high positioning accuracy of the contact tip for submerged arc welding.
Disclosure of Invention
The invention aims to provide a control system and a control method for automatically positioning a contact tube for submerged arc welding, which realize high-precision positioning of the contact tube for submerged arc welding.
The technical scheme for realizing the purpose is as follows:
the invention discloses a control system for automatically positioning a contact tube for submerged arc welding, which is used for controlling the contact tube on a machine head to move and establishing a three-dimensional rectangular coordinate system by taking the original position of the contact tube as the original point, and comprises the following steps:
a support frame;
the rolling frame is used for placing a pipe joint to be welded;
4 sets of roller driving motors controlled by a PLC, which drive the rollers to drive the roll-on rack to rotate;
the rotary encoder is used for measuring the rotary arc length of the pipe joint to be welded;
the two-dimensional scanning sensor is arranged on the machine head and used for measuring coordinate data of M points on the upper edge of the left groove of the welding bead;
according to the coordinate data of M points on the upper edge of the left groove of the welding bead and the rotating arc length of the pipe joint, calculating and sending the PLC of the position information of the contact nozzle to be moved;
and the two-dimensional action mechanism is arranged on the support frame above the roll-on-roll-off frame and drives the machine head to move along the X-axis direction and the Y-axis direction according to the received information of the position to be moved of the contact nozzle.
Preferably, the two-dimensional motion mechanism includes:
a Y-axis perpendicular to the ground;
the Y-axis driver is fixedly connected with the machine head;
a Y-axis servo motor which is controlled by the PLC and is used for driving the Y-axis driver to move along the Y-axis direction;
the X axis is coupled to the support frame;
the X axis is coupled to the support frame; and
and the X-axis servo motor is controlled by the PLC and is used for driving the X-axis driver to move along the X-axis direction.
Preferably, the two-dimensional motion mechanism further includes:
the X encoder is arranged on the X-axis servo motor and used for measuring the moving position of the machine head along the X-axis direction; and
and the Y encoder is arranged on the Y-axis servo motor and is used for measuring the moving position of the machine head along the Y-axis direction.
Preferably, the method further comprises the following steps: a plurality of frequency converters connecting the PLC and each roller driving motor;
and the PLC controls the output of the corresponding roller driving motor through the frequency converter.
The control method of the control system for automatically positioning the contact tube for submerged arc welding comprises the following steps:
step S1, reading welding voltage, current, welding speed, welding bead number, rotation speed v (m/S) of a pipe joint to be welded, sampling frequency f (HZ) of a two-dimensional sensor, welding process requirements and total length L of a welding bead by a PLC;
steps S2, S3, and S4 are performed simultaneously:
step S2, data processing:
S21，n＝0；
s22, judging whether the rotating speed v of the pipe joint to be welded is equal to 0, if so, returning to S21; otherwise, entering the next step;
s23, detecting whether the scanning time t is equal to n/f, if yes, entering the next step, otherwise, circulating S23;
s24, reading the measured data of the two-dimensional scanning sensor at the moment to obtain an、bnThe value of (d);
s25, reading the data S of the rotary encodernAnd calculate cn＝l+sn。
S26, construction Mn(an,bn,cn) And put into a queue, n is n + 1;
s27, judging whether the system operation flag bit is equal to 1, if yes, returning to S23, and if not, entering the next step;
step S3, positioning the handpiece, including:
s31, reading the data S of the rotary encoder;
s32, judging whether S is larger than l, if so, entering the next step, and if not, returning to the previous step; the distance from the contact nozzle to the two-dimensional scanning sensor is l (m);
s33, judging whether S is equal to c in the queue head coordinate data M (a, b, c), if yes, entering the next step, and if not, repeating S33;
s34, calling the coordinate of the M point at the moment, and positioning the position of the welding bead at the moment through S;
s35, according to the welding process requirement, using anCalculating an x-axis target value Dx; use of bnCalculating a y-axis target value Dy;
s36, the PLC sends pulse signals to the Y-axis servo motor and the X-axis servo motor to respectively drive the Y-axis driver to move to Dy and the X-axis driver to move to Dx;
s37, welding, and judging whether the system operation flag bit is equal to 1, if yes, returning to S33, and if not, entering the next step;
step S4, stop control:
s41, judging whether S is smaller than L, judging whether the system fault is 1 or the stop bit is 1, if yes, entering the next step, otherwise, repeating S41;
s42, judging that the system operation identification bit is set to 0;
and step S5, stopping welding of the welding machine.
The invention has the beneficial effects that: according to the invention, the position data information scanned by the two-dimensional scanning sensor and the data information of the rotary encoder for measuring the rotation angle of the roll-on frame are processed to obtain the position information of the contact nozzle to be moved, and the machine head for mounting the contact nozzle is driven by the two-dimensional action mechanism to move, so that the high-precision positioning of the contact nozzle for submerged arc welding is realized.
Drawings
FIG. 1 is a block diagram of a control system for automatic positioning of a contact tip for submerged arc welding in accordance with the present invention;
FIG. 2 is a side view of the control system for automatic positioning of a contact tip for submerged arc welding of the present invention;
FIG. 3 is a circuit diagram of the control system for automatic positioning of the contact tip for submerged arc welding of the present invention;
FIG. 4 is a schematic diagram of a two-dimensional scanning sensor measuring M points on the upper edge of a left groove in the present invention;
FIG. 5 is a flowchart of a method for controlling the automatic positioning of a submerged arc welding contact tip according to the present invention.
Detailed Description
The invention will be further explained with reference to the drawings.
Referring to fig. 1-3, the present invention provides a control system for automatically positioning a contact tube for submerged arc welding, which is used for controlling the movement of a contact tube 1 on a machine head, and establishing a three-dimensional rectangular coordinate system with the original position of the contact tube 1 as an origin, and comprises: the device comprises a support frame 2, a rolling frame 3, a plurality of rollers 4, 4 sets of roller driving motors 5, a rotary encoder 6, a two-dimensional scanning sensor 7, a PLC (programmable logic controller) 8 and a two-dimensional action mechanism.
The support frame 2 is used for installing relevant devices such as a machine head and a submerged arc welding machine. The roll-on frame 3 is used for placing pipe joints to be welded.
The 4 sets of roller driving motors 5 drive the rolling frame 3 to rotate by driving each roller 4.
The rotary encoder 6 is used for measuring the rotating arc length of the pipe joint to be welded. The two-dimensional scanning sensor 7 is mounted on the machine head, moves along with the machine head, and is used for measuring coordinate data of M points on the upper edge of the left groove of the welding bead. And the PLC 8 calculates to obtain the information of the position to be moved of the contact nozzle according to the coordinate data of the M point on the upper edge of the left groove of the welding bead and the rotating arc length of the pipe joint. The two-dimensional action mechanism is arranged on the support frame 2 above the rolling frame 3, and drives the machine head (driving the contact nozzle 1) to move along the X-axis direction and the Y-axis direction according to the received information of the position to be moved of the contact nozzle, so that the high-precision positioning of the contact nozzle 1 is realized. Specifically, the two-dimensional motion mechanism includes: a Y-axis 9 vertical to the ground, an X-axis 10, a Y-axis driver 11, an X-axis driver 12, a Y-axis servomotor 13 and an X-axis servomotor 14.
The Y-axis driver 11 is fixedly connected to the handpiece. The Y-axis servo motor 13 is controlled by the PLC 8 and drives the Y-axis driver 11 to move in the Y-axis direction.
The X-axis 10 is journalled to the support frame 2. An X-axis drive 12 is fixedly connected to the handpiece. The X-axis servo motor 14 is controlled by the PLC 8 and drives the X-axis driver 12 to move in the X-axis direction.
In addition, an X encoder and a Y encoder are provided. The X encoder is connected to an X-axis servomotor 14 for measuring the position of the head moving in the X-axis direction. The Y encoder is connected to a Y axis servomotor 13 for measuring the position of the head moving in the Y axis direction.
The PLC 8 is connected with each roller driving motor 5 through a plurality of frequency converters 15, and the PLC 8 controls the output of the corresponding roller driving motor 5 through the frequency converters 15.
The two-dimensional scanning sensor 7 emits laser, after the laser is reflected after meeting a workpiece, the distance from the laser to a pipe joint to be welded is calculated, and therefore the measurement of the distance of a single point is completed, because a deflection plate is installed in the two-dimensional scanning sensor 7, the rotation angle of the deflection plate is 45 degrees, two-dimensional data of a groove with a certain width is measured, and because the pipe joint is selectively installed on the roll-on frame 3, the rotation arc length of the pipe joint measured by the rotary encoder 6 is used as coordinate data in the Z direction, and a space three-dimensional coordinate system is constructed, as shown in fig. 4. According to the graph, the Y-axis coordinate is increased and then decreased along with the increase of the X-axis coordinate, when the Y-axis coordinate is increased to a critical value, a left characteristic point (an upper edge M point of a left groove) is reached, then scanning data is groove internal data, the left characteristic point coordinate can be obtained, and the upper edge M point of the left groove is stored in a register as important data for positioning the contact tip. A certain distance exists between the two-dimensional scanning sensor 7 and the contact tube 1, so a certain data buffer area needs to be established to store basic data of the point location of the contact tube, the distance from the contact tube 1 to the two-dimensional scanning sensor 7 is set to be l (m), the rotating speed of the roll-on rack 3 is set to be v (m/s), the sampling frequency of the two-dimensional scanning sensor 7 is set to be f (hz), and the data quantity D needing to be stored into the buffer area can be expressed by a formula (1):
Figure BDA0002552604780000051
the data processing of the buffer is carried out in a queue manner, following FIFO (first in first out), the new left characteristic point coordinate is always inserted into the tail of the linked list, and the reading is always started from the head of the linked list, one coordinate is read each time, one coordinate is released, and the reading and releasing instructions are determined by signals sent to the PLC by the rotary encoder 6. The radius of the pipe joint to be welded is R, a plane rectangular coordinate system is established by taking the initial position of the contact nozzle as the origin, and a certain moment is tnThe radian of the rotary encoder is snThe left characteristic point coordinate is Mn(an,bn,cn) Wherein c isn＝l+snFor determining the reading a at the time of weldingnAnd bnThe numerical value position, the data is inserted into the tail of the queue, and the data at the next sampling moment is inserted into the tail of the queue along with the rotation of the roll-on rack until MnMove to the head of the team when the contact tip reaches tnThe radian of the groove plane scanned by the two-dimensional scanning sensor 7 at any moment is l + snI.e. cn，MnThe coordinates of the point are taken out from the head of the queue for X, Y-axis servo motor to read and release, and the contact tip 1 is positioned by this data.
Let the coordinate of the contact tip be Nn-1(xn-1,yn-1,zn-1) The left characteristic point coordinate is Mn-1(an-1,bn-1,cn-1) The coordinates of the repositioned contact tip are Nn(xn,yn,zn) Then the coordinates satisfy:
Figure BDA0002552604780000061
let the distance between the welding position of the welding track and the direction of the left characteristic point X, Y be pi、qiThen, there are:
Figure BDA0002552604780000062
Nn(xn,yn,zn) May also be expressed as;
Figure BDA0002552604780000063
therefore, the X-axis servo motor 14 drives the X-axis driver 12 to move a along the positive X-axis directionn-an-1, a Y-axis servo motor 13 drives a Y-axis driver 11 to move b along the positive direction of the Y axisn-bn-1The contact tube 1 is driven to realize the dynamic positioning at the moment, and the contact tube 1 reaches the coordinate Nn(an+pi,bn+qi,l+sn). The welding positions are different for different welding passes, and the welding position needs to pass through z according to the requirements of the welding processnAnd judging the current welding path position, and obtaining the distance between the welding position at the moment and the direction of the left characteristic point X, Y.
Based on the above principle, as shown in fig. 5, the method for controlling the automatic positioning of the contact tip for submerged arc welding according to the present invention comprises the steps of:
in step S1, the PLC 8 reads the welding voltage, current, welding speed, number of weld beads, rotation speed v (m/S) of the pipe joint to be welded, two-dimensional sensor sampling frequency f (hz), welding process requirement, and total length L of weld beads.
Steps S2, S3, and S4 are performed simultaneously.
Step S2, data processing:
S21，n＝0；
s22, judging whether the rotating speed v of the pipe joint to be welded is equal to 0, if so, returning to S21; otherwise, entering the next step;
s23, detecting whether the scanning time t is equal to n/f, if yes, entering the next step, otherwise, circulating S23;
s24, reading the measured data of the two-dimensional scanning sensor 7 at the moment to obtain an、bnThe value of (d);
s25, reading the data S of the rotary encoder 6nAnd calculate cn＝l+sn。
S26, construction Mn(an,bn,cn) And put into a queue, n is n + 1;
and S27, judging whether the system operation flag bit is equal to 1, if so, returning to S23, otherwise, entering the next step.
Step S3, positioning the handpiece, including:
s31, reading the data S of the rotary encoder 6;
s32, judging whether S is larger than l, if so, entering the next step, and if not, returning to the previous step; the distance from the contact tip 1 to the two-dimensional scanning sensor 7 is l (m);
and S33, judging whether S is equal to c in the queue head coordinate data M (a, b and c), if so, entering the next step, and if not, repeating S33.
S34, calling the coordinate of the M point at the moment, and positioning the position of the welding bead at the moment through S;
s35, according to the welding process requirement, using anCalculating an x-axis target value Dx; use of bnAnd calculating a y-axis target value Dy.
S36, the PLC 8 sends pulse signals to the Y-axis servo motor 13 and the X-axis servo motor 14 to respectively drive the Y-axis driver 11 to move to Dy and the X-axis driver 12 to move to Dx;
and S37, welding and judging whether the system operation flag bit is equal to 1, if so, returning to S33, and if not, entering the next step.
Step S4, stop control:
s41, judging whether S is smaller than L, judging whether the system fault is 1 or the stop bit is 1, if yes, entering the next step, otherwise, repeating S41;
and S42, judging that the system operation identification bit is set to 0.
And step S5, stopping welding of the welding machine.
The above embodiments are provided only for illustrating the present invention and not for limiting the present invention, and those skilled in the art can make various changes and modifications without departing from the spirit and scope of the present invention, and therefore all equivalent technical solutions should also fall within the scope of the present invention, and should be defined by the claims.

Claims (5)

1. The utility model provides a control system of contact tube automatic positioning for submerged arc welding for the contact tube on the control aircraft nose moves, establishes three-dimensional rectangular coordinate system with contact tube initial position as the origin, its characterized in that includes:
a support frame;
the rolling frame is used for placing a pipe joint to be welded;
4 sets of roller driving motors controlled by a PLC, which drive the rollers to drive the roll-on rack to rotate;
the rotary encoder is used for measuring the rotary arc length of the pipe joint to be welded;
the two-dimensional scanning sensor is arranged on the machine head and used for measuring coordinate data of M points on the upper edge of the left groove of the welding bead;
according to the coordinate data of M points on the upper edge of the left groove of the welding bead and the rotating arc length of the pipe joint, calculating and sending the PLC of the position information of the contact nozzle to be moved;
and the two-dimensional action mechanism is arranged on the support frame above the roll-on-roll-off frame and drives the machine head to move along the X-axis direction and the Y-axis direction according to the received information of the position to be moved of the contact nozzle.
2. The system of claim 1, wherein the two-dimensional motion mechanism comprises:
a Y-axis perpendicular to the ground;
the Y-axis driver is fixedly connected with the machine head;
a Y-axis servo motor which is controlled by the PLC and is used for driving the Y-axis driver to move along the Y-axis direction;
the X axis is coupled to the support frame;
the X axis is coupled to the support frame; and
and the X-axis servo motor is controlled by the PLC and is used for driving the X-axis driver to move along the X-axis direction.
3. The system of claim 2, wherein the two-dimensional motion mechanism further comprises:
the X encoder is arranged on the X-axis servo motor and used for measuring the moving position of the machine head along the X-axis direction; and
and the Y encoder is arranged on the Y-axis servo motor and is used for measuring the moving position of the machine head along the Y-axis direction.
4. The system of claim 1, further comprising: a plurality of frequency converters connecting the PLC and each roller driving motor;
and the PLC controls the output of the corresponding roller driving motor through the frequency converter.
5. The method for controlling a system for controlling automatic positioning of a contact tip for submerged arc welding according to claim 1, comprising:
step S1, reading welding voltage, current, welding speed, welding bead number, rotation speed v (m/S) of a pipe joint to be welded, sampling frequency f (HZ) of a two-dimensional sensor, welding process requirements and total length L of a welding bead by a PLC;
steps S2, S3, and S4 are performed simultaneously:
step S2, data processing:
S21，n＝0；
s22, judging whether the rotating speed v of the pipe joint to be welded is equal to 0, if so, returning to S21; otherwise, entering the next step;
s23, detecting whether the scanning time t is equal to n/f, if yes, entering the next step, otherwise, circulating S23;
s24, reading the measured data of the two-dimensional scanning sensor at the moment to obtain an、bnThe value of (d);
s25, reading the data S of the rotary encodernAnd calculate cn＝l+sn；
S26, construction Mn(an,bn,cn) And put into a queue, n is n + 1;
s27, judging whether the system operation flag bit is equal to 1, if yes, returning to S23, and if not, entering the next step;
step S3, positioning the handpiece, including:
s31, reading the data S of the rotary encoder;
s32, judging whether S is larger than l, if so, entering the next step, and if not, returning to the previous step; the distance from the contact nozzle to the two-dimensional scanning sensor is l (m);
s33, judging whether S is equal to c in the queue head coordinate data M (a, b, c), if yes, entering the next step, and if not, repeating S33;
s34, calling the coordinate of the M point at the moment, and positioning the position of the welding bead at the moment through S;
s35, according to the welding process requirement, using anCalculating an x-axis target value Dx; use of bnCalculating a y-axis target value Dy;
s36, the PLC sends pulse signals to the Y-axis servo motor and the X-axis servo motor to respectively drive the Y-axis driver to move to Dy and the X-axis driver to move to Dx;
s37, welding, and judging whether the system operation flag bit is equal to 1, if yes, returning to S33, and if not, entering the next step;
step S4, stop control:
s41, judging whether S is smaller than L, judging whether the system fault is 1 or the stop bit is 1, if yes, entering the next step, otherwise, repeating S41;
s42, judging that the system operation identification bit is set to 0;
and step S5, stopping welding of the welding machine.
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CN86108654A (en) * 1985-12-20 1987-07-29 库卡焊接设备及机器人股份公司 The method and apparatus of detection and tracking angle welding when gas shielded arc welding connects
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