CN112276431A - Current collecting device and current collecting method - Google Patents
Current collecting device and current collecting method Download PDFInfo
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- CN112276431A CN112276431A CN202010952383.8A CN202010952383A CN112276431A CN 112276431 A CN112276431 A CN 112276431A CN 202010952383 A CN202010952383 A CN 202010952383A CN 112276431 A CN112276431 A CN 112276431A
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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
- B23K37/02—Carriages for supporting the welding or cutting element
- B23K37/0252—Steering means
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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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- G—PHYSICS
- G01—MEASURING; TESTING
- G01R—MEASURING ELECTRIC VARIABLES; MEASURING MAGNETIC VARIABLES
- G01R19/00—Arrangements for measuring currents or voltages or for indicating presence or sign thereof
- G01R19/0092—Arrangements for measuring currents or voltages or for indicating presence or sign thereof measuring current only
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Abstract
The embodiment of the invention discloses a current collecting device and a current collecting method, wherein the current collecting device is used for collecting the current value in a cable to be detected between a controller and a welding gun in real time, wherein the current value is the current value when the welding gun swings to two ends; the current value is sent to the controller, so that the controller calculates the path correction data in the horizontal direction and the path correction data in the vertical direction according to the deviation value and the trend characteristic of the current value when the welding gun swings to two ends, and corrects the movement track of the welding gun according to the path correction data in the horizontal direction and the path correction data in the vertical direction.
Description
Technical Field
The invention relates to the technical field of control, in particular to a current collecting device and a current collecting method.
Background
Automated welding is typically a robot or other automated device that controls the welding torch of a welding machine to move across the joint between two workpieces, melting the welding wire to fill the weld, and joining the two workpieces together.
At present, automatic welding equipment generally controls a welding gun to move according to a preset motion track, and when a size error of a welding seam of a workpiece is larger, the welding gun performs welding according to the motion of a set track, so that the conditions of wrong welding, welding missing and weak welding are caused.
Disclosure of Invention
In view of the above problems, embodiments of the present invention are proposed to provide a current collecting device and a current collecting method that overcome or at least partially solve the above problems.
In a first aspect, an embodiment of the present invention provides a current collecting device, where the current collecting device includes:
the device comprises a current acquisition unit, a power input unit, a metal shielding shell and a cable access port unit; the current acquisition unit is used for acquiring the current value of the cable to be detected between the controller and the electric welding gun; the current acquisition unit is positioned in the metal shielding shell, the power input unit is used for providing power for the current acquisition unit, and an interface of the power input unit and the cable access interface unit are arranged on the surface of the metal shielding shell; the cable access interface unit is used for connecting a network cable and is connected with the controller, so that the controller is used for controlling the welding gun.
Optionally, the current collecting unit comprises a tested current cable penetrating hole and a cable locking mechanism, so that the cable to be tested is fixed on the current collecting unit.
Optionally, an interference fit is adopted between the cable locking mechanism and the metal shielding shell.
Optionally, two fixing holes are formed in one side of the cable locking mechanism, and the cable locking mechanism and the metal shielding shell are connected together through the fixing holes by bolts.
Optionally, the device further comprises an analog-to-digital conversion unit and a hall sensor, wherein the analog-to-digital conversion unit and the hall sensor are located in the metal shielding shell, and the hall sensor is connected with the current acquisition unit.
Optionally, the power input unit is used for converting 220V ac power into 24V dc power.
In a second aspect, an embodiment of the present invention provides a current collecting method, where the method includes:
collecting a current value in a cable to be detected between a controller and a welding gun, wherein the current value is the current value when the welding gun swings to two ends;
and sending the current value to a controller, so that the controller calculates path correction data in the horizontal direction and path correction data in the vertical direction according to the deviation value and the trend characteristic of the current value when the welding gun swings to two ends, and corrects the motion track of the welding gun according to the path correction data in the horizontal direction and the path correction data in the vertical direction.
Optionally, the method further comprises:
modifying configuration parameters of the welding gun, wherein the configuration parameters at least comprise one or more of a path correction maximum offset, a tracking type (center line tracking and height tracking), a sensitivity of path correction in the left-right direction and a sensitivity of path correction in the height direction, and the tracking type comprises center line tracking and height tracking.
Optionally, the controller calculates path correction data in a horizontal direction and path correction data in a vertical direction according to the deviation value and the trend characteristic of the current value when the welding gun swings to the two ends, and corrects the welding gun motion trajectory according to the path correction data in the horizontal direction and the path correction data in the vertical direction, including:
the controller calculates by adopting a Kalman filtering model according to the current value when the welding gun swings to two ends, and obtains a current deviation value and a trend characteristic;
respectively calculating path correction data in the horizontal direction and path correction data in the vertical direction according to the current deviation value and the trend characteristic;
and correcting the motion track of the welding gun according to the path correction data in the horizontal direction and the path correction data in the vertical direction.
Optionally, the calculating the path correction data in the horizontal direction and the path correction data in the vertical direction according to the current deviation value and the trend characteristic respectively includes:
performing PID adjustment according to the difference value of the left predicted current and the right predicted current to obtain path correction data in the horizontal direction;
and carrying out PID adjustment according to the difference value of the predicted current and the average current to obtain path correction data in the vertical direction.
The embodiment of the invention provides a current collecting device and a current collecting method, wherein a current value in a cable to be detected between a controller and a welding gun is collected in real time through the current collecting device, wherein the current value is the current value when the welding gun swings to two ends; the current value is sent to the controller, so that the controller calculates the path correction data in the horizontal direction and the path correction data in the vertical direction according to the deviation value and the trend characteristic of the current value when the welding gun swings to two ends, and corrects the movement track of the welding gun according to the path correction data in the horizontal direction and the path correction data in the vertical direction.
Drawings
FIG. 1 is a block diagram of an embodiment of a current collection device according to the present invention;
FIG. 2 is a block diagram of an embodiment of a current collection system of the present invention;
FIG. 3 is a flow chart of the steps of one embodiment of a current collection method of the present invention;
FIG. 4 is a flow chart of steps of yet another current collection method embodiment of the present invention;
FIG. 5 is a flow chart of steps in yet another embodiment of a current collection method of the present invention;
FIG. 6 is a flow chart of steps in another current collection method embodiment of the present invention;
FIG. 7 is a flow chart of steps of yet another current collection method embodiment of the present invention;
FIG. 8 is a schematic illustration of a travel path of the weld gun of the present invention;
FIG. 9a is a schematic illustration of torch center point tracking of the present invention;
fig. 9b is a schematic illustration of the torch height tracking of the present invention.
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.
Referring to fig. 1, a block diagram of a current collecting device according to an embodiment of the present invention is shown, and the device may specifically include the following modules: the device comprises a current acquisition unit 10, a power input unit 20, a metal shielding shell 30 and a cable access port unit 40; wherein:
the current collecting unit 10 is used for collecting the current value of the cable to be detected between the controller and the electric welding gun; the current acquisition unit is positioned in the metal shielding shell;
the power input unit 20 is used for providing power for the current acquisition unit;
an interface of the power input unit 20 and the cable access interface unit 40 are disposed on the surface of the shield case 30;
the cable access interface unit 40 is used for connecting a network cable and is connected with a controller, so that the controller is used for controlling the welding gun.
Specifically, the current collection device provided by the embodiment of the invention can solve the problems of quick field installation and current collection quality guarantee, and the whole current collection device only needs to be connected to a 24V power supply and an ethercat (Ethernet control automation technology) special network cable and a cable to be measured to pass through a measuring hole. The whole device comprises the following 4 parts: the device comprises a current acquisition unit 10, a power input unit 20, a metal shielding shell 30 and a cable access port unit 40, wherein the surface of the metal shielding shell 30 is provided with an interface of the power input unit 20 and the cable access interface unit 40, and the cable access interface unit 40 is an ethercat cable access port.
According to the current collecting device provided by the embodiment of the invention, the current value of the cable to be detected between the controller and the electric welding gun is collected in real time through the current collecting device, wherein the current value is the current value when the electric welding gun swings to two ends; the current value is sent to the controller, so that the controller calculates the path correction data in the horizontal direction and the path correction data in the vertical direction according to the deviation value and the trend characteristic of the current value when the welding gun swings to two ends, and corrects the movement track of the welding gun according to the path correction data in the horizontal direction and the path correction data in the vertical direction.
The current collecting device provided by the above embodiment is further described in an additional embodiment of the present invention.
Optionally, the current collecting unit comprises a tested current cable penetrating hole and a cable locking mechanism, so that the cable to be tested is fixed on the current collecting unit.
The current acquisition unit comprises a detected current cable penetrating hole and a cable locking mechanism so as to prevent the cable from being separated from the current acquisition module in the moving process.
Optionally, an interference fit is adopted between the cable locking mechanism and the metal shielding shell.
The cable locking mechanism and the metal shielding shell are in interference fit, so that the locking mechanism and the metal shielding shell are reliably connected.
Optionally, two fixing holes are formed in one side of the cable locking mechanism, and the cable locking mechanism and the metal shielding shell are connected together through the fixing holes by bolts.
The front face of the locking mechanism is provided with two fixing holes which can be connected with the metal shielding shell through a fixing port by bolts, so that the cable can not fall off from the current collecting device even in severe collision.
Optionally, the device further comprises an analog-to-digital conversion unit and a hall sensor, wherein the analog-to-digital conversion unit and the hall sensor are located in the metal shielding shell, and the hall sensor is connected with the current acquisition unit.
Specifically, the metal shielding shell shields strong electromagnetic interference from an electric arc of the welding machine, the analog-to-digital conversion module and the Hall sensor are surrounded by the metal shielding shell, so that signals output by the Hall sensor are not interfered by external electromagnetic interference, and the analog-to-digital conversion module can acquire purer current signals.
Optionally, the power input unit is used for converting 220V ac power into 24V dc power.
Fig. 2 is a block diagram of a current collection system according to an embodiment of the present invention, which includes a welding machine, a controller, and a current collection device, where the current collection device collects a current between the welding machine and the controller, and the controller controls a movement trajectory of a welding gun of the welding machine by adjusting the current.
Fig. 3 is a flowchart of steps of an embodiment of a current collection method according to the present invention, in which AC220V is input into an AC/DC transformer, AC220V is converted into DC24V, the measured current is converted by a hall sensor, a control signal of 0-5V is generated, and the control signal and DC24V are input into a current collection unit, the current collection unit is connected to a controller by an EtherCAT, and a welding torch is controlled by the controller.
The embodiment of the invention is a current acquisition module which is composed of an EtherCAT (or CANopen, the same kind of real-time bus) communication module, a Hall sensor, a power supply input module and an analog quantity module, and can acquire current more quickly and in more real time.
According to the current collecting device provided by the embodiment of the invention, the current value of the cable to be detected between the controller and the electric welding gun is collected in real time through the current collecting device, wherein the current value is the current value when the electric welding gun swings to two ends; the current value is sent to the controller, so that the controller calculates the path correction data in the horizontal direction and the path correction data in the vertical direction according to the deviation value and the trend characteristic of the current value when the welding gun swings to two ends, and corrects the movement track of the welding gun according to the path correction data in the horizontal direction and the path correction data in the vertical direction.
An embodiment of the invention provides a current collection method based on the current collection device.
Referring to fig. 4, a flow chart of steps of an embodiment of a current collection method of the present invention is shown, and the method may specifically include the following steps:
s401, collecting a current value in a cable to be detected between a controller and a welding gun, wherein the current value is the current value when the welding gun swings to two ends;
specifically, the current collection device collects current values in a cable between the controller and the electric welding gun, including the current values collected when the welding gun moves to both ends of the weld.
S402, sending the current value to a controller, enabling the controller to calculate path correction data in the horizontal direction and path correction data in the vertical direction according to the deviation value and trend characteristics of the current value when the welding gun swings to two ends, and correcting the motion track of the welding gun according to the path correction data in the horizontal direction and the path correction data in the vertical direction.
Specifically, the current collecting device sends the collected current value to the controller, the controller performs deviation calculation according to the current values at different positions to obtain a deviation value, further, the deviation value and the trend characteristic are calculated according to a Kalman filtering algorithm, path correction data in the horizontal direction and path correction data in the vertical direction are calculated, and the welding gun motion track is corrected according to the path correction data in the horizontal direction and the path correction data in the vertical direction.
According to the current collecting method provided by the embodiment of the invention, the current value in the cable to be detected between the controller and the electric welding gun is collected in real time through the current collecting device, wherein the current value is the current value when the electric welding gun swings to two ends; the current value is sent to the controller, so that the controller calculates the path correction data in the horizontal direction and the path correction data in the vertical direction according to the deviation value and the trend characteristic of the current value when the welding gun swings to two ends, and corrects the movement track of the welding gun according to the path correction data in the horizontal direction and the path correction data in the vertical direction.
The current collection method provided by the above embodiment is further described in a supplementary manner in another embodiment of the present invention.
Optionally, the method further comprises:
modifying configuration parameters of the welding gun, wherein the configuration parameters at least comprise one or more of a path correction maximum offset, a tracking type (center line tracking and height tracking), a sensitivity of path correction in the left-right direction and a sensitivity of path correction in the height direction, and the tracking type comprises center line tracking and height tracking.
Optionally, the controller calculates path correction data in a horizontal direction and path correction data in a vertical direction according to the deviation value and the trend characteristic of the current value when the welding gun swings to the two ends, and corrects the welding gun motion trajectory according to the path correction data in the horizontal direction and the path correction data in the vertical direction, including:
the controller calculates by adopting a Kalman filtering model according to the current value when the welding gun swings to two ends, and obtains a current deviation value and a trend characteristic;
respectively calculating path correction data in the horizontal direction and path correction data in the vertical direction according to the current deviation value and the trend characteristic;
and correcting the motion track of the welding gun according to the path correction data in the horizontal direction and the path correction data in the vertical direction.
Specifically, fig. 5 is a flowchart of steps of another embodiment of the current collection method according to the present invention, where an actually collected current is input into a kalman filter model to obtain a predicted current, a calculation is performed according to the actually collected current and the predicted current to obtain a current error value, and path correction data in a horizontal direction and path correction data in a vertical direction are calculated through continuous calculation.
Optionally, the calculating the path correction data in the horizontal direction and the path correction data in the vertical direction according to the current deviation value and the trend characteristic respectively includes:
performing PID adjustment according to the difference value of the left predicted current and the right predicted current to obtain path correction data in the horizontal direction;
and carrying out PID adjustment according to the difference value of the predicted current and the average current to obtain path correction data in the vertical direction.
A PID controller (proportional-integral-derivative controller) is a common feedback loop component in industrial control applications, consisting of a proportional unit P, an integral unit I and a derivative unit D. The basis of PID control is proportional control; integral control may eliminate steady state errors, but may increase overshoot; differential control can accelerate the response speed of the large inertia system and weaken the overshoot tendency.
Specifically, fig. 6 is a flowchart of steps of another embodiment of the current collection method of the present invention, specifically, the controller performs PID adjustment according to a difference between the left predicted current and the right predicted current to obtain path correction data in the horizontal direction for adjusting the left and right positions;
fig. 7 is a flowchart illustrating steps of another embodiment of a current collection method according to the present invention, specifically, a controller performs PID adjustment according to a difference between a predicted current and an average current to obtain path correction data in a vertical direction for adjusting an up-down position.
Fig. 8 is a schematic diagram of controlling the operation of the welding gun by using the controller according to the embodiment of the invention, the positions of the two ends can be adjusted as required, and the arc tracking can adjust the motion track in real time according to the information of the welding seam during welding to achieve better welding effect.
FIG. 9a is a schematic illustration of center point tracking of the torch of the present invention, and FIG. 9b is a schematic illustration of height tracking of the torch of the present invention, in an embodiment of the present invention arc tracking is adaptable to a variety of welding needs, supporting center point tracking and height tracking.
The embodiment of the invention adopts the arc tracking control function, and the function is characterized in that a welding gun swings at a welding seam in the welding process, a current collecting device collects current data in real time and transmits the current value to a controller, and the controller calculates path correction data in the horizontal direction and the vertical direction according to arc current deviation values and trend characteristics at two swinging ends, corrects the motion track of the welding gun in real time and ensures that stable welding requirements are met.
The welding current acquisition technology based on the bus is more real-time, faster and more stable;
the current filtering technology based on the Kalman filtering model can more truly reduce the welding current, and has small phase lag and high precision; based on the PID technology, the motion position is adjusted stably and quickly in real time, and the installation is simple, convenient and reliable.
According to the current collecting method provided by the embodiment of the invention, the current value in the cable to be detected between the controller and the electric welding gun is collected in real time through the current collecting device, wherein the current value is the current value when the electric welding gun swings to two ends; the current value is sent to the controller, so that the controller calculates the path correction data in the horizontal direction and the path correction data in the vertical direction according to the deviation value and the trend characteristic of the current value when the welding gun swings to two ends, and corrects the movement track of the welding gun according to the path correction data in the horizontal direction and the path correction data in the vertical direction.
It should be noted that, for simplicity of description, the method embodiments are described as a series of acts or combination of acts, but those skilled in the art will recognize that the present invention is not limited by the illustrated order of acts, as some steps may occur in other orders or concurrently in accordance with the embodiments of the present invention. Further, those skilled in the art will appreciate that the embodiments described in the specification are presently preferred and that no particular act is required to implement the invention.
The embodiments in the present specification are described in a progressive manner, each embodiment focuses on differences from other embodiments, and the same and similar parts among the embodiments are referred to each other.
As will be appreciated by one skilled in the art, embodiments of the present invention may be provided as a method, apparatus, or computer program product. Accordingly, embodiments of the present invention may take the form of an entirely hardware embodiment, an entirely software embodiment or an embodiment combining software and hardware aspects. Furthermore, embodiments of the present invention may take the form of a computer program product embodied on one or more computer-usable storage media (including, but not limited to, disk storage, CD-ROM, optical storage, and the like) having computer-usable program code embodied therein.
While preferred embodiments of the present invention have been described, additional variations and modifications of these embodiments may occur to those skilled in the art once they learn of the basic inventive concepts. Therefore, it is intended that the appended claims be interpreted as including preferred embodiments and all such alterations and modifications as fall within the scope of the embodiments of the invention.
Finally, it should also be noted that, herein, relational terms such as first and second, and the like may be used solely to distinguish one entity or action from another entity or action without necessarily requiring or implying any actual such relationship or order between such entities or actions. Also, the terms "comprises," "comprising," or any other variation thereof, are intended to cover a non-exclusive inclusion, such that a process, method, article, or electronic device that comprises a list of elements does not include only those elements but may include other elements not expressly listed or inherent to such process, method, article, or electronic device. Without further limitation, an element defined by the phrase "comprising an … …" does not exclude the presence of other like elements in a process, method, article, or electronic device that comprises the element.
Claims (10)
1. A current collection device, the device comprising: the device comprises a current acquisition unit, a power input unit, a metal shielding shell and a cable access port unit; wherein:
the current acquisition unit is used for acquiring the current value of the cable to be detected between the controller and the electric welding gun; the current acquisition unit is positioned in the metal shielding shell;
the power input unit is used for providing power for the current acquisition unit;
an interface of a power input unit and the cable access interface unit are arranged on the surface of the shielding shell;
the cable access interface unit is used for connecting a network cable and is connected with the controller, so that the controller is used for controlling the welding gun.
2. The device of claim 1, wherein the current collection unit comprises a hole for passing the cable to be tested and a cable locking mechanism for fixing the cable to be tested on the current collection unit.
3. The apparatus of claim 2, wherein an interference fit is employed between the cable locking mechanism and the metallic shielding shell.
4. The apparatus as claimed in claim 3, wherein the cable locker mechanism is provided at one side thereof with two fixing holes and coupled to the metal shield case through the fixing holes by bolts.
5. The device of claim 1, further comprising an analog-to-digital conversion unit and a hall sensor, wherein the analog-to-digital conversion unit and the hall sensor are located in the metal shielding shell, and the hall sensor is connected with the current acquisition unit.
6. The apparatus of claim 5, wherein the power input unit is configured to convert 220V AC power to 24V DC power.
7. A current collection method using the current collection apparatus according to any one of claims 1 to 6, the method comprising:
collecting a current value in a cable to be detected between a controller and a welding gun, wherein the current value is the current value when the welding gun swings to two ends;
and sending the current value to a controller, so that the controller calculates path correction data in the horizontal direction and path correction data in the vertical direction according to the deviation value and the trend characteristic of the current value when the welding gun swings to two ends, and corrects the motion track of the welding gun according to the path correction data in the horizontal direction and the path correction data in the vertical direction.
8. The method of claim 7, further comprising:
modifying configuration parameters of the welding gun, wherein the configuration parameters at least comprise one or more of a path correction maximum offset, a tracking type (center line tracking and height tracking), a sensitivity of path correction in the left-right direction and a sensitivity of path correction in the height direction, and the tracking type comprises center line tracking and height tracking.
9. The method of claim 7, wherein the controller calculates path correction data in a horizontal direction and path correction data in a vertical direction according to the deviation value and the trend characteristic of the current value when the welding torch swings to both ends, and corrects the welding torch movement trajectory according to the path correction data in the horizontal direction and the path correction data in the vertical direction, comprising:
the controller calculates by adopting a Kalman filtering model according to the current value when the welding gun swings to two ends, and obtains a current deviation value and a trend characteristic;
respectively calculating path correction data in the horizontal direction and path correction data in the vertical direction according to the current deviation value and the trend characteristic;
and correcting the motion track of the welding gun according to the path correction data in the horizontal direction and the path correction data in the vertical direction.
10. The method of claim 9, wherein calculating the path correction data in the horizontal direction and the path correction data in the vertical direction according to the current deviation value and the trend characteristic respectively comprises:
performing PID adjustment according to the difference value of the left predicted current and the right predicted current to obtain path correction data in the horizontal direction;
and carrying out PID adjustment according to the difference value of the predicted current and the average current to obtain path correction data in the vertical direction.
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| CN113848513A (en) * | 2021-09-23 | 2021-12-28 | 全球能源互联网研究院有限公司 | Multifunctional sensor and application method thereof |
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