CN112427774A - Corrugated plate welding method and system based on weld seam tracking - Google Patents
Corrugated plate welding method and system based on weld seam tracking Download PDFInfo
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- CN112427774A CN112427774A CN202011280399.5A CN202011280399A CN112427774A CN 112427774 A CN112427774 A CN 112427774A CN 202011280399 A CN202011280399 A CN 202011280399A CN 112427774 A CN112427774 A CN 112427774A
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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
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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
- B23K9/02—Seam welding; Backing means; Inserts
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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
- B23K9/32—Accessories
Abstract
The invention relates to the technical field of welding, and provides a corrugated plate welding method and system based on weld joint tracking. The method comprises the following steps: a laser sensor and a robot are arranged on a walking shaft, the laser sensor is arranged in front of the robot, and the laser sensor and the robot are respectively communicated with an industrial personal computer; calibrating a world coordinate system of the robot and a laser coordinate system of the laser sensor; teaching the robot based on the corrugation characteristics of corrugated plates to be welded; and in the welding process, the laser sensor scans the welding seam of the corrugated plate and transmits coordinates in real time, the industrial personal computer plans and tracks the welding track of the welding seam according to the corrugated characteristic and the acquired coordinates, and the robot welds the corrugated plate along the welding track of the welding seam according to calibration and teaching. The automatic welding line tracking device can realize automatic welding line tracking of the corrugated plate, meet the requirement of automatic welding of the corrugated plate and greatly improve the production efficiency.
Description
Technical Field
The invention relates to the technical field of welding, in particular to a corrugated plate welding method and a corrugated plate welding system based on weld joint tracking.
Background
The robot is an industrial automation device and has the advantages of low price, high flexibility, good accessibility and the like. With the upgrading of productivity and the reduction of labor force, and due to various reasons such as bad welding environment, the robot has gradually replaced manual welding, and becomes an automatic welding technology widely applied in the welding field.
In the container industry, corrugated plates have been widely used in containers because of their three-dimensional structural particularity, which provides good resistance to external load impacts. However, due to the three-dimensional structure of the corrugated plate, the welding line of the corrugated plate is difficult to track in the whole course of the welding process by the robot, and stable welding cannot be realized. This is because, the traditional laser locating and real-time tracking function for the welding seam generally only provides simple welding guidance for the robot for the welding workpiece with a relatively simple structure, and cannot meet the automatic welding requirement of the corrugated plate.
It is to be noted that the information disclosed in the above background section is only for enhancement of understanding of the background of the invention and therefore may include information that does not constitute prior art that is already known to a person of ordinary skill in the art.
Disclosure of Invention
In view of the above, the invention provides a corrugated plate welding method and system based on weld tracking, which can realize automatic weld tracking of corrugated plates, meet the requirements of automatic welding of corrugated plates in the container industry, and greatly improve the production efficiency.
One aspect of the present invention provides a corrugated plate welding method based on weld tracking, including: a laser sensor and a robot are arranged on a walking shaft, the laser sensor is arranged in front of the robot, and the laser sensor and the robot are respectively communicated with an industrial personal computer; calibrating a world coordinate system of the robot and a laser coordinate system of the laser sensor; teaching the robot based on the corrugation characteristics of corrugated plates to be welded; and in the welding process, the laser sensor scans the welding seam of the corrugated plate and transmits coordinates in real time, the industrial personal computer plans and tracks the welding track of the welding seam according to the corrugated characteristic and the acquired coordinates, and the robot welds the corrugated plate along the welding track of the welding seam according to calibration and teaching.
In some embodiments, said teaching said robot comprises: teaching a welding point gun posture and all idle walking point positions of one corrugation period of the corrugated plate.
In some embodiments, before the welding process, the method further comprises: the laser sensor pre-scans the welding seam of the first corrugation, generates welding seam position coordinates through laser identification and transmits the welding seam position coordinates to the industrial personal computer; the industrial personal computer synchronously acquires the welding position coordinates and the corresponding walking shaft position coordinates, and generates a first ripple track according to the ripple characteristics and the acquired coordinates, wherein the first ripple track comprises a welding starting point and coordinate information corresponding to a plurality of welding inflection points; and the robot reaches the welding starting point and automatically starts an arc to enter the welding process.
In some embodiments, the planning tracks the weld trajectory of the weld, further comprising: generating a plurality of middle corrugated tracks and a tail end corrugated track, wherein the middle corrugated track comprises coordinate information corresponding to a plurality of welding inflection points, and the tail end corrugated track comprises a plurality of welding inflection points and coordinate information corresponding to a welding end point; and sending the corresponding ripple track according to the request of the robot.
In some embodiments, the robot welds the corrugated sheet along a weld trajectory that tracks the weld according to calibration and teaching, comprising: the robot requests a next ripple track from the industrial personal computer when welding a current ripple according to the recorded number of the welded ripples and the set total number of the ripples; and converting the received corrugated track according to the calibration, and welding the corrugated plates according to the teaching along the converted corrugated track.
In some embodiments, at least one corrugation of the corrugated plates is spaced between a scan center point of the laser sensor and a tool center point of the robot; the + X direction or the + Y direction of the robot is in reverse parallel to the welding advancing direction of the walking shaft.
In some embodiments, before calibrating the world coordinate system of the robot and the laser coordinate system of the laser sensor, the method further includes: and calibrating the tool center point of the robot based on the world coordinate system of the robot.
In some embodiments, said calibrating the world coordinate system of the robot and the laser coordinate system of the laser sensor comprises: starting the laser sensor to enable a linear light spot of the laser sensor to irradiate a calibration plate; obtaining reference coordinates of the laser sensor and the robot, comprising: moving the calibration plate to enable an angle welding seam of the calibration plate to be opposite to an edge of the linear light spot; reading a first coordinate of the edge position in the laser coordinate system; enabling the tool center point to face the fillet weld position, and reading a second coordinate of the tool center point in the world coordinate system; repeating the step of obtaining the contrast coordinates until four groups of contrast coordinates corresponding to four edge positions of the linear light spots are obtained, wherein the four edge positions are formed by the upper edge position and the lower edge position of the linear light spots with different distances; and determining the conversion relation between the world coordinate system and the laser coordinate system according to the four groups of the comparison coordinates.
In some embodiments, teaching the robot further teaches a monitored area of the welding process, including: placing a welding workpiece on a welding tool, and enabling a linear light spot of the laser sensor to irradiate the center of a welding seam of the welding workpiece; setting a monitoring block to enable the monitoring block to contain the identifiable range of the linear light spot at minimum; moving the robot, reading the coordinates of the tool center points of the robot respectively facing the corner positions of the monitoring blocks, and forming the monitoring area; in the welding process, when the industrial personal computer monitors that the robot exceeds the monitoring area, the welding is stopped, and meanwhile, an error is reported for warning.
In accordance with another aspect of the present invention, there is provided a corrugated plate welding system, which is based on the corrugated plate welding method according to any of the above embodiments, and includes: a corrugated plate to be welded; the walking shaft is arranged opposite to the corrugated plate; the laser sensor and the robot are respectively arranged on the walking shaft and are arranged in front of the robot along the welding advancing direction; the industrial personal computer is respectively communicated with the laser sensor and the robot; following the walking shaft advances, the leading scanning of laser sensor the welding seam of buckled plate, the industrial computer planning is tracked the welding orbit of welding seam, the robot is followed the welding orbit welding buckled plate.
Compared with the prior art, the invention has the beneficial effects that:
the laser sensor is arranged in front of the robot along the welding advancing direction, so that the laser sensor is arranged in front for scanning in the welding process, and the robot is arranged behind for welding; the laser sensor and the robot are respectively communicated with the industrial personal computer, and the industrial personal computer can plan and guide the robot to track the welding track of the welding seam according to the ripple characteristics and the coordinate information acquired by the laser sensor, so that the robot can automatically weld the corrugated plate along the welding seam; therefore, the automatic welding line tracking device can realize automatic welding line tracking of the corrugated plate, meet the requirement of automatic welding of the corrugated plate in the container industry and greatly improve the production efficiency.
It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory only and are not restrictive of the invention, as claimed.
Drawings
The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate embodiments consistent with the invention and together with the description, serve to explain the principles of the invention. It is obvious that the drawings described below are only some embodiments of the invention, and that for a person skilled in the art, other drawings can be derived from them without inventive effort.
FIG. 1 is a schematic diagram illustrating the steps of a method for welding corrugated plates according to an embodiment of the present invention;
FIG. 2 illustrates a schematic top view of a corrugated sheet welding system in an embodiment of the present invention;
FIG. 3 shows a schematic cross-sectional structural view of a corrugated plate welding system in an embodiment of the present invention;
FIG. 4 is a schematic diagram illustrating the communication principle among the laser sensor, the industrial personal computer and the robot in the embodiment of the invention;
FIG. 5 shows a schematic view of a welding process of a robot in an embodiment of the invention;
fig. 6 shows a schematic control process diagram of an industrial personal computer in the embodiment of the invention.
Detailed Description
Example embodiments will now be described more fully with reference to the accompanying drawings. Example embodiments may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein. Rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the concept of example embodiments to those skilled in the art.
Furthermore, the drawings are merely schematic illustrations of the invention and are not necessarily drawn to scale. The same reference numerals in the drawings denote the same or similar parts, and thus their repetitive description will be omitted. Some of the block diagrams shown in the figures are functional entities and do not necessarily correspond to physically or logically separate entities. These functional entities may be implemented in the form of software, or in one or more hardware modules or integrated circuits, or in different networks and/or processor devices and/or microcontroller devices.
The step numbers in the following embodiments are merely used to indicate different execution contents, and the execution order between the steps is not strictly limited. The use of "first," "second," and similar terms in the detailed description is not intended to imply any order, quantity, or importance, but rather is used to distinguish one element from another. It should be noted that features of the embodiments of the invention and of the different embodiments may be combined with each other without conflict.
Fig. 1 shows the main steps of a corrugated plate welding method based on seam tracking in the embodiment, and referring to fig. 1, the corrugated plate welding method based on seam tracking in the embodiment comprises: in step S110, a laser sensor and a robot are arranged on a walking shaft, the laser sensor is arranged in front of the robot, and the laser sensor and the robot are respectively communicated with an industrial personal computer; in step S120, calibrating a world coordinate system of the robot and a laser coordinate system of the laser sensor; in step S130, teaching the robot based on the corrugation characteristics of the corrugated plates to be welded; in the step S140, in the welding process, the laser sensor scans the welding line of the corrugated plate and transmits coordinates in real time, the industrial personal computer plans and tracks the welding track of the welding line according to the corrugated characteristics and the acquired coordinates, and the robot welds the corrugated plate along the welding track of the tracking welding line according to calibration and teaching.
According to the corrugated plate welding method, the laser sensor is arranged in front of the robot along the welding advancing direction, so that the laser sensor is arranged in front for scanning in the welding process, and the robot is arranged behind for welding; the laser sensor and the robot are respectively communicated with the industrial personal computer, and the industrial personal computer can plan and guide the robot to track the welding track of the welding seam according to the ripple characteristics and the coordinate information acquired by the laser sensor, so that the robot can automatically weld the corrugated plate along the welding seam; therefore, the automatic welding line tracking device can realize automatic welding line tracking of the corrugated plate, meet the requirement of automatic welding of the corrugated plate in the container industry and greatly improve the production efficiency.
Fig. 2 shows a top view structure of a corrugated plate welding system in an embodiment, referring to fig. 2, a laser sensor 11 and a robot 12 are both installed on a walking shaft 20, and at least one corrugation 300 of a corrugated plate 30 is spaced between a scanning center point of the laser sensor 11 and a tool center point of the robot 12, so as to ensure that the laser sensor 11 scans at least one corrugation in front for an industrial personal computer to plan a welding track.
The laser sensor 11 and the robot 12 may be mounted on the traveling shaft 20 via a slide table 21. When the robot 12 is mounted, the + X direction or the + Y direction of the robot 12 is made antiparallel to the welding traveling direction X of the traveling shaft 20. The robot 12 used in the present embodiment is specifically a six-joint industrial robot, and the + X direction and the + Y direction thereof are set at the time of shipment.
Fig. 3 shows a cross-sectional structure of a corrugated plate welding system in an embodiment, wherein the working principle of the laser sensor 11 is mainly shown, and the irradiation area of the laser sensor 11 is concentrated at the weld position of the corrugated plate 30, i.e. the interface between the corrugated plate 30 and the bottom frame 31.
Fig. 4 shows the communication principle between the laser sensor, the industrial personal computer and the robot in the embodiment. Referring to fig. 4, an industrial personal computer 40 is a master station of communication processing, and the laser sensor 11 and the robot 12 are slave stations of communication processing. The laser sensor 11 and the robot 12 are communicated through the industrial personal computer 40, and the laser sensor, the robot and the industrial personal computer form a local area network. The laser sensor 11 and the industrial personal computer 40 can communicate through Ethernet, and the industrial personal computer 40 and the robot 12 can communicate through a Modbus TCP protocol.
In the welding process, the laser sensor 11 is used for processing images, scanning a welding seam, recognizing the position coordinate of the welding seam by laser, and sending the position coordinate to the industrial personal computer 40; the industrial personal computer 40 plans the welding track of the robot based on the drawing information of the corrugated plate and the acquired coordinate information, and sends the teaching point information scanned by the laser sensor to the robot 12; the robot 12 receives the teaching point information, performs coordinate conversion on the welding trajectory, and executes the welding program.
The working principle of the laser sensor, the industrial personal computer and the robot during welding will be described in detail with reference to specific examples.
The process of teaching the robot specifically includes: and (3) teaching the positions of a welding point gun posture and all idle walking points in one ripple period of the corrugated plate, and storing the positions in corresponding teaching points of a welding program of the robot. The gesture of the teaching point can be directly stored in the robot, and the position of the teaching point can be scanned through the laser sensor and sent to the robot through the industrial personal computer.
Before welding starts, the laser sensor can pre-scan the welding seam of the first corrugation, and position coordinates of the welding seam are generated through laser identification and transmitted to the industrial personal computer.
The industrial personal computer synchronously acquires the welding position coordinates and the corresponding walking shaft position coordinates, and generates a first ripple track according to the ripple characteristics and the acquired coordinates, wherein the first ripple track comprises a welding starting point of the first ripple and coordinate information corresponding to a plurality of welding inflection points. The ripple characteristics specifically comprise information of wave distance of the corrugated plate, circular arc radius and included angle at the inflection point, and the like, and are recorded into a system before teaching, and the inflection point position of each ripple can be calculated according to the ripple characteristics. In the embodiment shown in fig. 2, the inflection points of one corrugation comprise four, i.e. four vertices of the corrugated trapezoidal structure.
The position coordinates of the walking shaft can be obtained by the robot or the related control device of the walking shaft. The industrial personal computer can guide the robot to weld a certain welding seam position at a certain walking axis position according to the corresponding relation between the welding seam position coordinate and the walking axis position coordinate.
And the robot reaches the welding starting point and automatically starts arc to enter the welding process.
And after the welding process is started, the laser sensor formally starts scanning, and transmits the acquired coordinates to the industrial personal computer in real time. The industrial computer calculates the inflection point coordinate of each ripple according to the welding seam position coordinate and the walking shaft position coordinate that obtain in step, specifically includes: and generating a plurality of middle ripple tracks and end ripple tracks, wherein one middle ripple track comprises coordinate information corresponding to a plurality of welding inflection points of one middle ripple, and the end ripple track comprises a plurality of welding inflection points of the end ripple and coordinate information corresponding to a welding end point. And when the welding track is planned, the industrial control machine sends the corresponding ripple track to the robot according to the request of the robot.
When the robot is used for welding, a next ripple track is requested from the industrial personal computer when a current ripple is welded according to the recorded number of the welded ripples and the set total ripple, then the received ripple track is converted according to calibration, and the corrugated plate is welded according to teaching along the converted ripple track.
Fig. 5 shows a welding process of the robot in the embodiment, and referring to fig. 5, a welding program of the robot specifically includes: after the initialization of the signal is completed, S510-11, the wave number and product number of the corrugated board to be welded are set. S510-22, moving the robot to a standby position, S510-33, moving the robot to a welding approach point, executing S520-11 at the moment, starting moving the walking shaft, starting scanning by the laser sensor, scanning the first corrugation by the laser sensor, and calculating a welding starting point and a welding inflection point of the first corrugation by the industrial personal computer. S520-22, the robot requests the first ripple track, and specifically, the request can be sent through the upper computer; and the industrial control unit downloads the coordinate information corresponding to the welding starting point and the welding inflection point of the first corrugation to the robot. And S520-33, the upper computer responds whether to send the laser successfully or not, if so, the laser is fed back to the robot, and if not, a laser error is displayed. S520-44, executing a coordinate conversion subprogram; s520-55, the robot starts to operate, arc striking operation is carried out when the welding start point is reached, arc striking successfully and automatically enters the main welding program S520-66, welding teaching points of the first corrugation are executed, and the welding teaching points can comprise all welding points of the first corrugation or only inflection points of the first corrugation according to teaching conditions.
The process of executing the coordinate conversion subroutine specifically includes: the system is completed by an industrial personal computer and a robot together, the robot only transmits integer variables in the embodiment, the industrial personal computer expands the position information of the laser coordinate converted into the world coordinate by 100 times or 10 times and transmits the position information to the robot, and the robot divides the position information by the corresponding multiple to obtain the real world coordinate. The process of coordinate transformation is not limited thereto. Different ways of coordinate transformation can be implemented based on different robots, for example, some robots can independently perform transformation from laser coordinates to world coordinates, and therefore the above list should not be construed as limiting the present invention.
S520-77, the robot records the welded wave number, namely the current wave number is added by one. S530-11, judging whether the current wave number is smaller than the total welding wave number by the robot, if so, continuing to S530-22, and judging whether the current wave number is equal to the total welding wave number minus one; if no indicates that all the wave soldering is completed, S570 is directly performed. In the judgment of S530-22, if yes, executing S540 to request to send the tail end ripple track and close the laser; if not, S530-33 is executed to request the transmission of the middle ripple track. And after the request is sent, whether the sending is successful or not is fed back through the upper computer S550, if so, the execution is continued, and if not, a laser error is fed back. Then, when the middle ripple track/the end ripple track is received, the process proceeds to S560, the coordinate conversion subroutine is executed, and the process returns to S520 to S66, four welding teaching points in one ripple are executed, and welding is performed on the current ripple. After the current wave soldering is completed, the wave number self-increment and subsequent steps as described above are continued. When all the wave welding is finished, the process goes to S570, the welding end point is executed, and S580, the gun is retreated to the original position, and the whole welding procedure of the current product number is finished.
Fig. 6 shows a control process of an industrial personal computer in an embodiment, and referring to fig. 6, during the whole welding process, the industrial personal computer mainly plans a welding track based on laser scanning and sends a ripple track based on a robot request. The method specifically comprises the following steps: after the laser sensor starts scanning, the industrial personal computer executes S610 to plan a welding track, which may refer to the description of the above embodiments, and the description is not repeated here. S620, responding to the request of the robot, and when the request instruction is 1, indicating that the robot requests the first ripple track, executing S630, and sending the first ripple track, which specifically includes coordinate information corresponding to the welding start point and the welding inflection point of the first ripple. When the request instruction is 2, the robot is instructed to request the middle ripple track, S640 is executed, and the middle ripple track is sent, specifically including coordinate information corresponding to the welding inflection point of the middle ripple. When the request command is 3, the robot is instructed to request the end corrugation track, that is, the last corrugation track, S650 is executed, and the end corrugation track is sent, specifically, coordinate information corresponding to a welding inflection point and a welding end point of the end corrugation is included. After the ripple trace is sent, a send success instruction is returned. In special cases, when the request command has other values, the feedback command is wrong.
Through the description of the embodiments, the laser sensor is pre-scanned, and the robot tracks the welding track of the welding seam based on the planning of the industrial personal computer and executes automatic welding.
In the above embodiments, before calibrating the world coordinate system and the laser coordinate system, the method further includes: based on a world coordinate system, the tool center point of the robot is calibrated, and a gun calibration ruler or a gun calibration block can be used for calibration. And calibrating the world coordinate system and the laser coordinate system, namely determining the conversion relation of the world coordinate system and the laser coordinate system. The method specifically comprises the following steps: starting the laser sensor to enable a linear light spot of the laser sensor to irradiate a calibration plate; obtaining reference coordinates of the laser sensor and the robot, comprising: moving the calibration plate to enable an angle welding seam position of the calibration plate to be opposite to an edge position of the linear light spot, wherein the edge position is a relative edge position of the linear light spot at a near position or a far position; reading a first coordinate of the edge position in a laser coordinate system; enabling the center point of the tool to be opposite to the position of the fillet weld, and reading a second coordinate of the center point of the tool in a world coordinate system; repeating the step of obtaining the contrast coordinates until four groups of contrast coordinates corresponding to four edge positions of the linear light spot are obtained, wherein the four edge positions are formed by the upper edge position and the lower edge position of the linear light spot with different distances, namely the upper edge position and the lower edge position corresponding to the far and near two positions of the linear light spot, namely the four angular positions on the interface; and finally, determining the conversion relation between the world coordinate system and the laser coordinate system according to the four groups of comparison coordinates.
During specific calibration operation, the positions of the gun attitude and the walking axis of the robot need to be kept unchanged, and a four-point method is adopted for calibration. Firstly, starting welding seam tracking system software and laser operation display software of an industrial personal computer; then, installing a special calibration plate, enabling the position of the fillet weld to be positioned at the edge position of the laser visual field by adjusting the front, back, upper and lower installation positions of the calibration plate, and reading the current laser position coordinate; then, enabling a robot TCP (Tool Center Point) to Point to the position of the fillet weld, and reading the coordinates of the robot; circularly operating the steps, selecting edge positions of four corners of a laser visual field, and sequentially recording laser position coordinates and robot coordinates under four groups of corner weld positions; and finally, calibrating by using a calibration function in the welding seam tracking system software of the industrial personal computer, and additionally selecting a point to test a calibration result.
The specific mathematical derivation of the four-point calibration is as follows:
the coordinate of the point C under the robot coordinate system and the laser coordinate system is known as CaAnd CbAccording to X of the robot coordinate systema、Ya、ZaRespectively rotateThe rotation gamma, beta and alpha are known from the relation of the rotation matrix:
wherein the content of the first and second substances,
in order to be a matrix of rotations,
is a translation matrix.
Order to
Then there is
Each equation in the equation set has 4 unknowns, and all unknowns in the equation can be solved by 4 sets of coordinates, so that a calibration matrix can be solved by calibration through a four-point method.
Further, in each of the above embodiments, teaching a monitoring region during welding also when teaching a robot includes: placing a welding workpiece on the welding tool, and enabling the linear light spot of the laser sensor to irradiate the center of a welding seam of the welding workpiece; setting a monitoring block to enable the monitoring block to contain the recognizable range of the linear light spot at minimum; the mobile robot reads the coordinates of the tool center points of the robot respectively facing the corner positions of the monitoring blocks to form a monitoring area; and in the welding process, when the industrial personal computer monitors that the robot exceeds the monitoring area, stopping welding and simultaneously reporting errors for warning.
In one specific example, the following steps are performed to achieve the seam tracking and automatic welding of corrugated board.
In the first step, a laser sensor and a robot are mounted on a traveling axis, and the robot can be mounted in a direction opposite to the traveling direction of the traveling axis in the + X direction or the + Y direction.
And secondly, the laser sensor, the industrial personal computer and the robot form a local area network for communication, and the industrial personal computer can establish bidirectional communication connection with the robot and the laser sensor respectively through the POE switch to form the local area network.
And thirdly, calibrating the robot TCP by using a gun calibration block and other modes, and judging whether the offset of the robot TCP is in a normal range or not by rotating a welding gun around the coordinates of the robot tool, wherein the normal range is determined according to each robot brand.
And fourthly, calibrating a world coordinate system and a laser sensor coordinate system of the robot, and specifically referring to the description of the above embodiment.
And fifthly, writing in parameters such as wave distance, circular arc and included angle of a product drawing and creating a product number, wherein related product information can be stored in an industrial personal computer, and calling is performed through an interface of the industrial personal computer or a main program of a robot running different products for identifying the position of a welding line and calculating an inflection point coordinate.
And sixthly, teaching welding points, welding gun postures, welding approach point postures and teaching point postures of the scanning first wave are respectively stored in corresponding teaching points in a main program of the robot.
And seventhly, teaching a safety monitoring area in the welding process. An actual workpiece can be placed on the tool, a laser line is shot to the middle position of a welding line, and the mobile robot checks coordinates and sets two point coordinates of a diagonal line of the monitoring block respectively. Two points should be ensured to contain the coordinate position recognized by the laser at the minimum.
And eighthly, starting a welding main program of the robot, leading the laser sensor to scan, uploading scanning data to the industrial personal computer in real time, automatically planning a track of the robot by system software on the industrial personal computer, and then downloading the track to guide the robot to carry out motion welding. Specifically, in the whole operation process, the laser sensor is used for scanning in a front-mounted mode, and scanning data are uploaded to a first queue set of the industrial personal computer in real time. And system software in the industrial personal computer automatically plans a welding track according to data containing the position coordinates of the welding seam and the corresponding position coordinates of the travelling shaft in the first queue set, and stores the welding track comprising information of a welding starting point, a welding inflection point, a welding ending point and the like into the second queue set. And the industrial personal computer takes out related data from the second queue set according to the robot request instruction and downloads the related data to the robot so as to guide the robot to carry out motion welding. After the specified wave number is welded, the robot can automatically calculate the coordinates of the welding end point according to the arc closing distance to perform arc closing, and the welding is finished and returns to the standby position. If the laser sensor identifies that the welding seam is abnormal or the robot exceeds a monitoring area in the scanning welding process, the robot stops moving, and the industrial personal computer reports errors to warn. In addition, when a relatively stable error value exists or position errors caused by different gun postures due to low precision of the robot TCP are identified, the position coordinates of the same characteristic point or the integral deviation of the welding line can be adjusted by an upper computer interface to compensate.
In the above specific examples, steps that are not developed in detail may refer to the description of the above embodiments, and the description is not repeated.
The embodiment of the present invention further provides a corrugated plate welding system, where the corrugated plate welding system is based on the corrugated plate welding method described in any of the above embodiments, and the corrugated plate welding system specifically includes: a corrugated plate to be welded; the walking shaft is arranged opposite to the corrugated plate; the laser sensor and the robot are respectively arranged on the walking shaft and are arranged in front of the robot along the welding advancing direction; the industrial personal computer is respectively communicated with the laser sensor and the robot; the laser sensor is arranged in front of the walking shaft and scans the welding seam of the corrugated plate, the industrial personal computer plans and tracks the welding track of the welding seam, and the robot welds the corrugated plate along the welding track.
For example, in one specific example, a corrugated plate welding system may be as described with reference to FIG. 2 and will not be repeated here.
In summary, according to the corrugated plate welding method and system based on seam tracking, the laser sensor is arranged in front of the robot along the welding advancing direction, so that the front scanning of the laser sensor in the welding process is realized, and the robot is used for welding in the rear position; the laser sensor and the robot are respectively communicated with the industrial personal computer, and the industrial personal computer can plan and guide the robot to track the welding track of the welding seam according to the ripple characteristics and the coordinate information acquired by the laser sensor, so that the robot can automatically weld the corrugated plate along the welding seam; therefore, the automatic welding line tracking device can realize automatic welding line tracking of the corrugated plate, meet the requirement of automatic welding of the corrugated plate in the container industry and greatly improve the production efficiency.
The foregoing is a more detailed description of the invention in connection with specific preferred embodiments and it is not intended that the invention be limited to these specific details. For those skilled in the art to which the invention pertains, several simple deductions or substitutions can be made without departing from the spirit of the invention, and all shall be considered as belonging to the protection scope of the invention.
Claims (10)
1. A corrugated plate welding method based on weld seam tracking is characterized by comprising the following steps:
a laser sensor and a robot are arranged on a walking shaft, the laser sensor is arranged in front of the robot, and the laser sensor and the robot are respectively communicated with an industrial personal computer;
calibrating a world coordinate system of the robot and a laser coordinate system of the laser sensor;
teaching the robot based on the corrugation characteristics of corrugated plates to be welded; and
in the welding process, the laser sensor scans the welding seam of the corrugated plate and transmits coordinates in real time, the industrial personal computer plans and tracks the welding track of the welding seam according to the corrugated characteristic and the acquired coordinates, and the robot welds the corrugated plate along the welding track of the welding seam according to calibration and teaching.
2. The corrugated plate welding method of claim 1, wherein teaching said robot comprises:
teaching a welding point gun posture and all idle walking point positions of one corrugation period of the corrugated plate.
3. A method of welding corrugated board according to claim 2, characterized in that before the welding process, it further comprises:
the laser sensor pre-scans the welding seam of the first corrugation, generates welding seam position coordinates through laser identification and transmits the welding seam position coordinates to the industrial personal computer;
the industrial personal computer synchronously acquires the welding position coordinates and the corresponding walking shaft position coordinates, and generates a first ripple track according to the ripple characteristics and the acquired coordinates, wherein the first ripple track comprises a welding starting point and coordinate information corresponding to a plurality of welding inflection points;
and the robot reaches the welding starting point and automatically starts an arc to enter the welding process.
4. The corrugated sheet welding method of claim 3, wherein said planning tracks a weld trajectory of said weld, further comprising:
generating a plurality of middle corrugated tracks and a tail end corrugated track, wherein the middle corrugated track comprises coordinate information corresponding to a plurality of welding inflection points, and the tail end corrugated track comprises a plurality of welding inflection points and coordinate information corresponding to a welding end point; and
and sending the corresponding ripple track according to the request of the robot.
5. The corrugated sheet welding method of claim 4, wherein said robot welds said corrugated sheet along a weld path following said weld according to calibration and teaching, comprising:
the robot requests a next ripple track from the industrial personal computer when welding a current ripple according to the recorded number of the welded ripples and the set total number of the ripples; and
and converting the received corrugated track according to the calibration, and welding the corrugated plates according to the teaching along the converted corrugated track.
6. A corrugated board welding method according to claim 1, characterized in that at least one corrugation of the corrugated board is spaced between the scanning center point of the laser sensor and the tool center point of the robot;
the + X direction or the + Y direction of the robot is in reverse parallel to the welding advancing direction of the walking shaft.
7. The corrugated board welding method of claim 1, wherein prior to calibrating the world coordinate system of the robot and the laser coordinate system of the laser sensor, further comprising:
and calibrating the tool center point of the robot based on the world coordinate system of the robot.
8. The corrugated board welding method of claim 7, wherein said calibrating the world coordinate system of the robot and the laser coordinate system of the laser sensor comprises:
starting the laser sensor to enable a linear light spot of the laser sensor to irradiate a calibration plate;
obtaining reference coordinates of the laser sensor and the robot, comprising:
moving the calibration plate to enable an angle welding seam of the calibration plate to be opposite to an edge of the linear light spot;
reading a first coordinate of the edge position in the laser coordinate system;
enabling the tool center point to face the fillet weld position, and reading a second coordinate of the tool center point in the world coordinate system;
repeating the step of obtaining the contrast coordinates until four groups of contrast coordinates corresponding to four edge positions of the linear light spots are obtained, wherein the four edge positions are formed by the upper edge position and the lower edge position of the linear light spots with different distances; and
and determining the conversion relation between the world coordinate system and the laser coordinate system according to the four groups of the contrast coordinates.
9. A method of welding corrugated board according to claim 1, wherein teaching said robot further teaches a monitoring area during welding, comprising:
placing a welding workpiece on a welding tool, and enabling a linear light spot of the laser sensor to irradiate the center of a welding seam of the welding workpiece;
setting a monitoring block to enable the monitoring block to contain the identifiable range of the linear light spot at minimum;
moving the robot, reading the coordinates of the tool center points of the robot respectively facing the corner positions of the monitoring blocks, and forming the monitoring area;
in the welding process, when the industrial personal computer monitors that the robot exceeds the monitoring area, the welding is stopped, and meanwhile, an error is reported for warning.
10. Corrugated board welding system based on the method of welding corrugated boards according to any of the claims 1-9, characterized in that the corrugated board welding system comprises:
a corrugated plate to be welded;
the walking shaft is arranged opposite to the corrugated plate;
the laser sensor and the robot are respectively arranged on the walking shaft and are arranged in front of the robot along the welding advancing direction; and
the industrial personal computer is respectively communicated with the laser sensor and the robot;
following the walking shaft advances, the leading scanning of laser sensor the welding seam of buckled plate, the industrial computer planning is tracked the welding orbit of welding seam, the robot is followed the welding orbit welding buckled plate.
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| CN114434001A (en) * | 2021-03-24 | 2022-05-06 | 西华大学 | Weld joint track autonomous tracking algorithm |
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