CN111843299A - Swing welding data analysis method applied to multilayer and multi-pass welding of robot - Google Patents
Swing welding data analysis method applied to multilayer and multi-pass welding of robot Download PDFInfo
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- CN111843299A CN111843299A CN202010616541.2A CN202010616541A CN111843299A CN 111843299 A CN111843299 A CN 111843299A CN 202010616541 A CN202010616541 A CN 202010616541A CN 111843299 A CN111843299 A CN 111843299A
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- 238000003466 welding Methods 0.000 title claims abstract description 140
- 238000000034 method Methods 0.000 title claims abstract description 34
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- 239000013598 vector Substances 0.000 claims description 69
- 239000011159 matrix material Substances 0.000 claims description 31
- 230000009466 transformation Effects 0.000 claims description 19
- 239000011324 bead Substances 0.000 claims description 7
- 238000009941 weaving Methods 0.000 claims description 5
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- 238000004891 communication Methods 0.000 abstract description 2
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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
- 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
- B23K31/00—Processes relevant to this subclass, specially adapted for particular articles or purposes, but not covered by only one of the preceding main groups
- B23K31/12—Processes relevant to this subclass, specially adapted for particular articles or purposes, but not covered by only one of the preceding main groups relating to investigating the properties, e.g. the weldability, of materials
- B23K31/125—Weld quality monitoring
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Abstract
The invention discloses a swing welding data analysis method applied to multilayer and multi-pass welding of a robot, which is connected with a robot controller in modes of Ethernet TCP/IP communication and the like to acquire pose data of the robot in real time; after the welding of the base path is finished, calculating a user coordinate system of the multilayer multi-pass welding according to the pose data of the welding gun of the base path and the characteristics of the multilayer multi-pass welding; and in the welding process of other welding passes, obtaining the offset and deflection angle of each pass relative to the base path in the multilayer multi-pass welding for a user to consult and record to form a process library.
Description
Technical Field
The invention relates to an auxiliary welding technology, in particular to a swing welding data analysis method applied to multilayer and multi-pass welding of a robot.
Background
In a robot welding process experiment, the traditional method for acquiring swing welding data of multilayer multi-pass welding operation is as follows: in the welding process, parameters such as welding current, welding voltage and the like of a welding power supply panel are manually recorded, after each welding is finished, a steel ruler is manually used for measuring a space deviation value at the tail end of a welding gun, and meanwhile, a posture deflection angle value of the welding gun is estimated according to experience. Therefore, the traditional method has the problems of large error, low process experiment efficiency and the like. In order to intuitively and efficiently monitor information such as a welding working path, a swing mode, a swing characteristic, welding current, welding voltage and the like of the robot and facilitate experiment personnel to dynamically adjust the position and the posture of a welding gun to observe a welding effect, equipment/a method supporting a real-time monitoring function of parameters such as the position and the posture of the tail end of the robot, the welding current, the welding voltage and the like is needed.
Disclosure of Invention
The invention aims to provide a swing welding data analysis method applied to multilayer and multi-pass welding of a robot.
The technical scheme for realizing the purpose of the invention is as follows: a swing welding data analysis method applied to multilayer and multi-pass welding of a robot comprises the following steps:
s1, selecting a plane where a multi-layer and multi-pass welding base path welding bead is located to establish a user coordinate system, and determining a plane equation and a plane normal vector of the base path based on discrete welding gun position data in the base path welding bead; determining a welding direction vector based on the arc starting point position data and the arc extinguishing point position data;
s2, establishing a user coordinate system based on a normal vector of a plane, a welding direction vector in the plane and an arc starting point position, and determining a transformation matrix of the user coordinate system relative to a world coordinate system;
and S3, in the process of welding other welding tracks, determining the position and the posture in the user coordinate system of the current welding gun based on the position and the posture of the real-time welding gun, namely the offset and the deflection angle of each welding path relative to the base path.
Further, in step S1, a least square method is adopted to fit the welding plane of the base path; wherein, the arc starting point Q1As the origin of the user coordinate system, the arc starting point and the arc extinguishing point Q 2As a welding direction vector
Plane normal vector fitted by least square method
Further, the establishing the user coordinate system in step S2 includes:
with an arcing point Q1As origin, welding direction vector
As the X-axis, plane normal vector
As Z-axis, unit vector
And unit vector
Outer product of (2)
Establishing a user coordinate system as a Y axis by unit vector
Vector quantity
Sum vector
As basis vectors of the user coordinate system, wherein:
the plane equation is: a is0x+a1y+a2
Based on the least square method formula to obtain
Solving the system of equations to obtain a0、a1、a2And the normal vector of the plane
In the formula, L is
Length of (2), Q1x、Q1y、Q1zAre respectively point Q1Coordinate values in the world coordinate system, Q2x、Q2y、Q2zAre respectively point Q2Coordinate values in the world coordinate system.
Further, the step S2 is to calculate a transformation matrix of the user coordinate system with respect to the world coordinate system, specifically:
Upx＝[1 0 0]T
Upy＝[0 1 0]T
Upz＝[0 0 1]T
UOweld＝[0 0 0]T
wherein the content of the first and second substances,Wpx、Wpy、Wpz、WOweldunit vectors respectively being welding direction vectors in world coordinate system
Unit vector
Unit vector of plane normal vector
And the coordinates Q of the arc starting point in the world coordinate system1；Upx、Upy、Upz、UOweldAre respectively asThe X-axis base vector, the Y-axis base vector, the Z-axis base vector and the coordinates of the arc starting point in the user coordinate system under the user coordinate system;UTWis a transformation matrix of the user coordinate system relative to the world coordinate system.
Further, in step S3, a homogeneous matrix corresponding to the position and posture data is obtained according to the real-time position and posture of the welding gun in the world coordinate system; based on the homogeneous matrix and the relative transformation matrix of the welding gun in the world coordinate system, the homogeneous matrix of the welding gun in the user coordinate system is obtained:
UPArc＝UTW WPArc
in the formula, x, y and z are coordinate values of the welding gun in a world coordinate system respectively, and alpha, beta and gamma are attitude angles of the welding gun in the world coordinate system respectively; c alpha and s alpha respectively represent cos alpha and sin alpha; c beta and s beta respectively represent cos beta and sin beta; c gamma and s gamma respectively represent cos gamma and sin gamma;WPArca homogeneous matrix of the welding gun in a world coordinate system;UPArca homogeneous matrix of the welding gun in a user coordinate system;UTWfor transformation matrices of the user coordinate system relative to the world coordinate system
Compared with the prior art, the invention has the following remarkable advantages:
(1) the invention supports various brands of robots, and is verified by the KUKA robot; for the robot supporting the Ethernet TCP/IP communication protocol or the PROFINET protocol, the acquisition and analysis of multilayer and multichannel welding data can be realized;
(2) automatically analyzing data, and automatically extracting arc starting points and arc extinguishing points from the acquired data; for multilayer multi-pass welding, the base path is especially important; the invention calculates the user coordinate system of multilayer multi-pass welding according to the welding data (position and posture) of the base path, and calculates the position and posture of each pass of welding bead in the user coordinate system, namely the offset and deflection angle.
The present invention is described in further detail below with reference to the attached drawing figures.
Drawings
Fig. 1 is a schematic view of a bead arrangement of multilayer multi-pass welding.
Fig. 2 is a schematic diagram of a transformation relationship of a user coordinate system relative to a world coordinate system.
FIG. 3 is a flow chart of a weld analysis of the present invention.
Detailed Description
At present, the ship welding in China basically adopts a manual welding mode mainly comprising workers, and the welding efficiency and safety are low; in addition, due to the particularity of ship welding, the application scenes of multilayer and multi-pass welding are very rich.
The invention establishes a user coordinate system by a series of discrete and compact position and posture data on a base path of multi-layer and multi-pass welding, and calculates the offset and the rotation angle of each welding pass relative to the base path. And after the base path data is acquired, automatically calculating the parameters of the user coordinate system. And in the welding process of the upper welding bead, calculating and displaying the offset and deflection angle of the current welding gun in real time. After the welding of the current path is finished, experimenters can quickly position the welding data of any welding position in a data analysis system according to the distance between the experimenters and a welding starting point.
As shown in fig. 1 and 2, the method for analyzing the swing welding data applied to the multi-layer and multi-pass welding of the robot of the present invention comprises the following steps:
Step 1: establishing a fitted plane equation
The general expression of the equation for a plane in three-dimensional space is:
Ax+By+Cz+D＝0(C≠0) (1)
order to
The plane equation is simplified as:
z＝a0x+a1y+a2(2)
according to the least squares method, the error value is:
for point set { (x)i,yi,zi) If S is minimized, the best fit plane of the point set can be obtained. To minimize S, it should be satisfied
The following results were obtained:
solving a linear equation system to obtain a0、a1、a2Further, the plane equation fitted to the point set and the normal vector of the plane are obtained
Step 2: establishing a homogeneous transformation matrix of a user working coordinate system relative to a world coordinate system
In the present invention, the starting point of the base path is assumed to be the arc starting point, the end point is assumed to be the arc extinguishing point, and the vector formed by the two points is the welding direction (the same applies to the weaving welding mode). And calculating a transformation matrix of the user coordinate system of the multilayer multi-pass welding relative to the world coordinate system according to the unit normal vector of the fitting plane, the unit vector of the welding direction and the arc starting point coordinate.
Assuming a unit vector of welding travel as an X-axis base vector of a user coordinate system
The unit normal vector of the fitting plane is the Z-axis base vector of the user coordinate system
According to the right-hand rule, the Y-axis basis vector of the user coordinate system is the outer product of the Z-axis basis vector and the X-axis basis vector.
In the formula (5), L is
The die of (1).
Under a user coordinate system, unit vectors of an X axis, a Y axis and a Z axis are respectively as follows:Upx＝[1 0 0]T，Upy＝[0 1 0]T，Upz＝[0 0 1]T. Obtaining the relationship between the description of the coordinate axis direction vector of the user coordinate system in the user coordinate system and the description in the world coordinate system according to a homogeneous transformation formula:
combining formula (5) to obtain
Wpx，Wpy，Wpz，WOweldThe coordinate of the X-axis unit vector, the Y-axis unit vector, the Z-axis unit vector and the origin of the world coordinate system are respectively in the world coordinate system. Will be provided withUpx，Upy，Upz，UOweldSubstituting, the left side of equation 8 is the identity matrix.Wpx，Wpy，Wpz，WOweldHave been calculated. Therefore, the temperature of the molten metal is controlled,
up to this point, a transformation matrix of the user coordinate system with respect to the world coordinate system has been obtained.
And step 3: calculating the offset and deflection angle of each weld pass relative to the base path
The Euler angle is used to determine a set of independent angle parameters of the fixed point rotation rigid body position, and consists of a nutation angle alpha, a precession angle beta and a self-rotation angle gamma. According to transformation matrix of user coordinate system relative to world coordinate systemUTWAnd calculating the position and the posture of any point of the welding path in the user coordinate system. The Z-Y-Z Euler angle is used in the invention to describe the attitude of the welding gun.
Obtaining a rotation transformation matrix according to a Z-Y-Z Euler angle formula:
in the formula (11), alpha, beta and gamma are attitude angles of the welding gun in a world coordinate system respectively; c alpha and s alpha respectively represent cos alpha and sin alpha; c beta and s beta respectively represent cos beta and sin beta; and c gamma and s gamma respectively represent cos gamma and sin gamma.
Then a homogeneous matrix describing the position and attitude of the welding gun is
From equation (8), a homogeneous matrix of the pose of the welding gun in the user coordinate systemUPArcAnd pose homogeneous matrix in world coordinate systemWPArcThe following relationships exist:
UPArc＝UTW WPArc(13)
according to the transformation matrix of the user coordinate system relative to the world coordinate system solved in the step 2 and the pose data of the welding gun in the world coordinate system, the pose homogeneous matrix of the welding gun in the user coordinate system can be obtainedUPArcAnd further solving the position and attitude data of the welding gun in the user coordinate system (Upx，Upy，Upz，Upα，Upβ，Upγ) I.e. offset and deflection angle with respect to the base path.
Exemplary embodiments of the present invention will be described in detail below with reference to the accompanying drawings.
Examples
The embodiment provides a swing welding data analysis method applied to multilayer and multi-pass welding of a robot. With reference to fig. 3, the method comprises the following steps:
1) selecting the first data point as an arc starting point Q1The last data point is the arc extinguishing point Q2And unit vector of welding direction
Arcing point Q1Is the origin of the user coordinate system;
2) fitting a plane equation and a unit normal vector of the plane by using a least square method according to all position data of the base path
3) Vector quantity
Vector quantity
And vector
Outer product of (2)
Vector quantity
As base vectors of the user coordinate system;
4) a transformation matrix of the user coordinate system relative to the world coordinate system is calculated.
And 3, the robot continues to perform multi-layer and multi-pass welding, and the data analysis system calculates the position and posture data of the welding gun in the user coordinate system according to the current position and posture of the welding gun in the world coordinate system, namely the offset and deflection angle of each welding pass relative to the base path.
And 4, after the robot finishes multi-layer and multi-pass welding, the data analysis system stores all welding path data into a database, and stores the offset and deflection angle data of each welding pass into a process library.
Claims (5)
1. A swing welding data analysis method applied to multilayer and multi-pass welding of a robot is characterized by comprising the following steps:
S1, selecting a plane where a multi-layer and multi-pass welding base path welding bead is located to establish a user coordinate system, and determining a plane equation and a plane normal vector of the base path based on discrete welding gun position data in the base path welding bead; determining a welding direction vector based on the arc starting point position data and the arc extinguishing point position data;
s2, establishing a user coordinate system based on a normal vector of a plane, a welding direction vector in the plane and an arc starting point position, and determining a transformation matrix of the user coordinate system relative to a world coordinate system;
and S3, in the process of welding other welding tracks, determining the position and the posture in the user coordinate system of the current welding gun based on the position and the posture of the real-time welding gun, namely the offset and the deflection angle of each welding path relative to the base path.
2. The weaving welding data analysis method applied to multilayer and multipass welding of a robot as set forth in claim 1, wherein the welding plane of the base path is fitted with the least square method in step S1; wherein, the arc starting point Q1As the origin of the user coordinate system, the arc starting point and the arc extinguishing point Q2As a welding direction vector
Plane normal vector fitted by least square method
3. The weaving welding data analysis method applied to multi-pass welding with multiple layers by a robot as set forth in claim 2, wherein the establishing the user coordinate system in step S2 includes:
With an arcing point Q1As origin, welding direction vector
As the X-axis, plane normal vector
As Z-axis, unit vector
And unit vector
Outer product of (2)
Establishing a user coordinate system as a Y axis by unit vector
Vector quantity
Sum vector
As basis vectors of the user coordinate system, wherein:
the plane equation is: a is0x+a1y+a2
Based on the least square method formula to obtain
Solving the system of equations to obtain a0、a1、a2And the normal vector of the plane
In the formula, L is
Length of (2), Q1x、Q1y、Q1zAre respectively point Q1Coordinate values in the world coordinate system, Q2x、Q2y、Q2zAre respectively point Q2Coordinate values in the world coordinate system.
4. The weaving welding data analysis method applied to multi-pass welding with multiple layers by robot as claimed in claim 3, wherein said step S2 is to calculate a transformation matrix of the user coordinate system relative to the world coordinate system, specifically:
Upx＝[1 0 0]T
Upy＝[0 1 0]T
Upz＝[0 0 1]T
UOweld＝[0 0 0]T
wherein the content of the first and second substances,Wpx、Wpy、Wpz、WOweldunit vectors respectively being welding direction vectors in world coordinate system
Unit vector
Unit vector of plane normal vector
And the coordinates Q of the arc starting point in the world coordinate system1；Upx、Upy、Upz、UOweldRespectively representing the coordinates of an X-axis base vector, a Y-axis base vector, a Z-axis base vector and an arc starting point in a user coordinate system;UTWis a transformation matrix of the user coordinate system relative to the world coordinate system.
5. The weaving welding data analysis method applied to multilayer and multipass welding of a robot as claimed in claim 1, wherein in step S3, a homogeneous matrix corresponding to position and posture data one to one is obtained with real-time position and posture of the welding gun in a world coordinate system; based on the homogeneous matrix and the relative transformation matrix of the welding gun in the world coordinate system, the homogeneous matrix of the welding gun in the user coordinate system is obtained:
UPArc＝UTW WPArc
In the formula, x, y and z are coordinate values of the welding gun in a world coordinate system respectively, and alpha, beta and gamma are attitude angles of the welding gun in the world coordinate system respectively; c alpha and s alpha respectively represent cos alpha and sin alpha; c beta and s beta respectively represent cos beta and sin beta; c gamma and s gamma respectively represent cos gamma and sin gamma;WPArca homogeneous matrix of the welding gun in a world coordinate system;UPArca homogeneous matrix of the welding gun in a user coordinate system;UTWis a transformation matrix of the user coordinate system relative to the world coordinate system.
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Cited By (2)
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| CN113042940A (en) * | 2021-03-25 | 2021-06-29 | 中车青岛四方机车车辆股份有限公司 | Standardized programming method and system for welding robot |
| CN115033842A (en) * | 2022-06-17 | 2022-09-09 | 合肥工业大学 | Fitting method and fitting system for spatial 6-degree-of-freedom pose transformation data |
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Effective date of registration: 20220920 Address after: 222061 No.18, Shenghu Road, Haizhou District, Lianyungang City, Jiangsu Province Patentee after: The 716th Research Institute of China Shipbuilding Corp. Patentee after: JIANGSU JARI TECHNOLOGY GROUP Co.,Ltd. Patentee after: CSIC Information Technology Co.,Ltd. Address before: 222001 No.18 Shenghu Road, Lianyungang City, Jiangsu Province Patentee before: 716TH RESEARCH INSTITUTE OF CHINA SHIPBUILDING INDUSTRY Corp. Patentee before: JIANGSU JARI TECHNOLOGY GROUP Co.,Ltd. |
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Address after: 222061 No.18, Shenghu Road, Haizhou District, Lianyungang City, Jiangsu Province Patentee after: The 716th Research Institute of China Shipbuilding Corp. Patentee after: JIANGSU JARI TECHNOLOGY GROUP Co.,Ltd. Patentee after: China Shipbuilding Digital Information Technology Co.,Ltd. Address before: 222061 No.18, Shenghu Road, Haizhou District, Lianyungang City, Jiangsu Province Patentee before: The 716th Research Institute of China Shipbuilding Corp. Patentee before: JIANGSU JARI TECHNOLOGY GROUP Co.,Ltd. Patentee before: CSIC Information Technology Co.,Ltd. |