CN113245668B

CN113245668B - Method and apparatus for controlling welding robot, and computer-readable storage medium

Info

Publication number: CN113245668B
Application number: CN202110730101.4A
Authority: CN
Inventors: 冯消冰; 潘际銮; 安兵; 潘百蛙; 赵星
Original assignee: Beijing Bo Tsing Technology Co Ltd
Current assignee: Beijing Bo Tsing Technology Co Ltd
Priority date: 2021-06-29
Filing date: 2021-06-29
Publication date: 2023-03-24
Anticipated expiration: 2041-06-29
Also published as: CN113245668A

Abstract

The application provides a control method, a device and a computer readable storage medium of a welding robot, wherein the control method comprises the following steps: determining the initial position and the stop position of welding, controlling the laser sensor to be at the initial position, and when the laser sensor is at the initial position, the laser line of the laser sensor is superposed with the initial position; acquiring a first distance detected by a laser sensor, wherein the first distance is the distance between the laser sensor and a welding gun when the laser sensor is at an initial position; determining the target number of pulse signals required by the motor driver according to the first distance; controlling a motor driver to send out a pulse signal, and acquiring the number of rotation turns of the motor detected by an encoder in real time until the target number is reached; the distance deviation is determined at least according to the first distance and the actual distance corresponding to the number of rotation turns, the absolute value of the distance deviation is smaller than or equal to the preset difference value, and the problem that the crimping connector is poor due to inaccurate detection and control is solved.

Description

Method and apparatus for controlling welding robot, and computer-readable storage medium

Technical Field

The present application relates to the field of welding, and in particular, to a method and an apparatus for controlling a welding robot, a computer-readable storage medium, a processor, and a welding apparatus.

Background

At present, the automatic specific process that opens and stops the arc of pipeline welding robot includes: firstly, solving the angle value of the current pipeline robot through attitude calculation; and then, controlling the pipeline welding robot to start and stop the arc according to the angle value.

The above method has the following disadvantages: the interference is easy to happen, and the precision is not enough; the inherent drift characteristic of the sensor is easily influenced by temperature, humidity and the outside, namely the accuracy is easily influenced by the outside; in the method, the pipeline and the corresponding gesture can be obtained only through the gesture sensor, the sensor is single, and emergency risk avoidance is not carried out for standby after the sensor fails; in the common welding process, the detection precision is not enough, the control is not accurate, the crimping joint is poor, and the welding workpiece has defects.

The above information disclosed in this background section is only for enhancement of understanding of the background of the technology described herein and, therefore, it may contain information that does not form the prior art that is already known in this country to a person of ordinary skill in the art.

Disclosure of Invention

The application mainly aims to provide a control method and device of a welding robot, a computer readable storage medium, a processor and a welding device, so as to solve the problems that in the prior art, due to insufficient detection precision and inaccurate control, a pressure welding joint is poor and a welding workpiece has defects.

According to an aspect of an embodiment of the present invention, there is provided a control method of a welding robot including a body structure, a laser sensor, a motor driver, an encoder, and a welding torch, the laser sensor, the motor driver, the encoder, and the welding torch being located on the body structure, the control method including: determining a starting position and a stopping position of welding, controlling the laser sensor to be at the starting position, and when the laser sensor is at the starting position, a laser line of the laser sensor is overlapped with the starting position; acquiring a first distance detected by the laser sensor, wherein the first distance is the distance between the laser sensor and the welding gun when the laser sensor is positioned at the initial position; determining the target number of pulse signals required by the motor driver according to the first distance; controlling the motor driver to send out the pulse signal, and acquiring the number of rotation turns of the motor detected by the encoder in real time until the target number is reached; determining a distance deviation according to at least the first distance and an actual distance corresponding to the number of turns, wherein the absolute value of the distance deviation is smaller than or equal to a preset difference value, and the preset difference value is the absolute value of the difference value between the first distance and the actual distance; and updating the stop position according to the distance deviation to obtain an updated stop position.

Optionally, determining the target number of pulse signals required by the motor driver according to the first distance includes: acquiring a corresponding travel distance of one circle of rotation of the motor to obtain a unit distance; acquiring the number of the pulses required by one rotation of the motor to obtain unit number; and calculating the target number according to the unit distance, the unit number and the first distance.

Optionally, determining a distance deviation according to at least the first distance and an actual distance corresponding to the number of turns comprises: determining an average distance at least according to the first distance and the actual distance corresponding to the number of turns; and calculating the difference value between the average distance and the first distance to obtain the distance deviation.

Optionally, the welding robot further includes an attitude sensor located on the body structure, and before determining a distance deviation according to at least the actual distance corresponding to the number of turns and the first distance, the control method further includes: acquiring a target position of the laser sensor detected by the attitude sensor, wherein the target position is the position of the laser sensor when the pulse signals sent by the motor driver reach the target number; calculating the arc length between the target position and the initial position to obtain a second distance, and determining an average distance at least according to the first distance and the actual distance corresponding to the number of turns, wherein the step of determining the average distance comprises the following steps: and calculating the average value of the actual distance, the first distance and the second distance to obtain the average distance.

Optionally, after the stopping position is updated according to the distance deviation to obtain an updated stopping position, the control method further includes: controlling the welding robot to start welding from an actual starting position until welding to the updated stopping position; acquiring height data of the weld between the actual starting position and the updated stopping position; determining an altitude abnormal area according to the altitude data; determining a supplementary welding amount according to the target height, the height data of the height abnormal region and the area; and controlling the welding robot to perform supplementary welding on the height abnormal area according to supplementary welding amount until the height abnormal area is corrected to be a height normal area.

Optionally, after the stopping position is updated according to the distance deviation to obtain an updated stopping position, before determining a supplementary welding amount according to a target height, the height data of the height abnormal region, and an area, the control method further includes: determining a second predetermined area, wherein the second predetermined area is an area of which the minimum distance between the second predetermined area and the actual starting position and the minimum distance between the second predetermined area and the updating stopping position are both larger than a predetermined distance; and calculating the average value of the height data in the second preset area to obtain the target height.

Optionally, controlling the welding robot to perform supplementary welding on the height abnormal region until the height abnormal region is corrected to a height normal region according to a supplementary welding amount includes: determining corresponding welding control parameters according to the supplementary welding quantity; and controlling the welding robot to perform the supplementary welding according to the welding control parameter until the height abnormal area is corrected to a height normal area.

According to another aspect of the embodiments of the present invention, there is also provided a control apparatus of a welding robot, including: welding robot includes body structure, laser sensor, motor driver, encoder and welder, laser sensor the motor driver the encoder and welder all is located the body is structural, controlling means includes: the first determining unit is used for determining the starting position and the stopping position of welding and controlling the laser sensor to be positioned at the starting position, and when the laser sensor is positioned at the starting position, the laser line of the laser sensor is superposed with the starting position; the first acquisition unit is used for acquiring a first distance detected by the laser sensor, wherein the first distance is the distance between the laser sensor and the welding gun when the laser sensor is positioned at the initial position; a second determination unit configured to determine a target number of pulse signals required by the motor driver according to the first distance; the first control unit is used for controlling the motor driver to send out the pulse signal and acquiring the number of turns of the motor detected by the encoder in real time until the target number is reached; a third determining unit, configured to determine a distance deviation according to at least the first distance and an actual distance corresponding to the number of turns, where an absolute value of the distance deviation is smaller than or equal to a predetermined difference, and the predetermined difference is an absolute value of a difference between the first distance and the actual distance; and the updating unit is used for updating the stopping position according to the distance deviation to obtain an updated stopping position.

According to still another aspect of embodiments of the present invention, there is also provided a computer-readable storage medium including a stored program, wherein the program executes any one of the methods.

According to still another aspect of the embodiments of the present invention, there is further provided a processor, configured to execute a program, where the program executes any one of the methods.

According to an aspect of an embodiment of the present invention, there is also provided a welding apparatus including: a welding robot, one or more processors, memory, and one or more programs, wherein the one or more programs are stored in the memory and configured to be executed by the one or more processors, the one or more programs comprising instructions for performing any of the methods.

In the embodiment of the invention, in the control method of the welding robot, firstly, a starting position and a stopping position of welding are determined, the laser sensor is controlled to be located at the starting position, when the laser sensor is located at the starting position, a laser line of the laser sensor is overlapped with the starting position, then, a first distance detected by the laser sensor is obtained, and the first distance is a distance between the laser sensor and the welding gun when the laser sensor is located at the starting position; secondly, determining the target number of pulse signals required by the motor driver according to the first distance, controlling the motor driver to send out the pulse signals, and acquiring the number of rotation turns of the motor detected by the encoder in real time until the target number is reached; and finally, updating the stop position according to the distance deviation to obtain an updated stop position. In the control method of the welding robot, the distance deviation is determined according to the first distance and the actual distance corresponding to the number of turns of rotation, and the stop position is updated according to the distance deviation. Therefore, the problems that in the process that the welding gun moves from the point C to the initial position, the welding gun cannot accurately reach the initial position due to inaccurate control, welding leakage or welding multiple occurs in the subsequent welding process, the quality of the crimping connector is better, and the problems that the crimping connector is poor and the welding workpiece has defects due to insufficient detection precision and inaccurate control in the prior art are solved.

Drawings

The accompanying drawings, which are incorporated in and constitute a part of this application, are included to provide a further understanding of the application, and the description of the exemplary embodiments and illustrations of the application are intended to explain the application and are not intended to limit the application. In the drawings:

FIG. 1 shows a schematic diagram of a welding robot control method according to an embodiment of the present application;

FIG. 2 shows a schematic view of a start position and a stop position according to an embodiment of the present application;

FIG. 3 shows a schematic diagram of a distance deviation according to an embodiment of the present application;

FIG. 4 shows a schematic diagram of a welding robot roll-back according to an embodiment of the present application;

FIG. 5 illustrates a weld bead joint schematic view according to an embodiment of the present application;

fig. 6 illustrates a weld bead joint schematic view according to yet another embodiment of the present application;

FIG. 7 illustrates a weld bead joint schematic view according to yet another embodiment of the present application;

FIG. 8 illustrates a supplemental weld schematic according to an embodiment of the present application;

fig. 9 shows a structural diagram of a bead robot control device according to an embodiment of the present application.

Detailed Description

It should be noted that the embodiments and features of the embodiments in the present application may be combined with each other without conflict. The present application will be described in detail below with reference to the embodiments with reference to the attached drawings.

In order to make the technical solutions better understood by those skilled in the art, the technical solutions in the embodiments of the present application will be clearly and completely described below with reference to the drawings in the embodiments of the present application, and it is obvious that the described embodiments are only partial embodiments of the present application, but not all 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 application.

It should be noted that the terms "first," "second," and the like in the description and claims of this application and in the drawings described above are used for distinguishing between similar elements and not necessarily for describing a particular sequential or chronological order. It should be understood that the data so used may be interchanged under appropriate circumstances such that embodiments of the application described herein may be used. Furthermore, the terms "comprises," "comprising," and "having," and any variations thereof, are intended to cover a non-exclusive inclusion, such that a process, method, system, article, or apparatus that comprises a list of steps or elements is not necessarily limited to those steps or elements expressly listed, but may include other steps or elements not expressly listed or inherent to such process, method, article, or apparatus.

It will be understood that when an element such as a layer, film, region, or substrate is referred to as being "on" another element, it can be directly on the other element or intervening elements may also be present. Also, in the specification and claims, when an element is described as being "connected" to another element, the element may be "directly connected" to the other element or "connected" to the other element through a third element.

As described in the background art, in order to solve the above problems, in the prior art, the pressure welding joint is poor and the welding workpiece has defects due to insufficient detection accuracy and inaccurate control, in an exemplary embodiment of the present application, a control method and apparatus for a welding robot, a computer-readable storage medium, a processor, and a welding apparatus are provided.

According to an embodiment of the present application, there is provided a control method of a welding robot.

Fig. 1 is a flowchart of a control method of a welding robot according to an embodiment of the present application. As shown in fig. 1, the welding robot includes a body structure, a laser sensor, a motor driver, an encoder, and a welding gun, the laser sensor, the motor driver, the encoder, and the welding gun are all located on the body structure, and the control method includes the steps of:

step S101, determining a starting position and a stopping position of welding, and controlling the laser sensor to be at the starting position, wherein when the laser sensor is at the starting position, a laser line of the laser sensor is superposed with the starting position;

step S102, acquiring a first distance detected by the laser sensor, wherein the first distance is a distance between the laser sensor and the welding gun when the laser sensor is at the initial position;

step S103, determining the target number of the pulse signals required by the motor driver according to the first distance;

step S104, controlling the motor driver to send out the pulse signal, and acquiring the number of rotation turns of the motor detected by the encoder in real time until the target number is reached;

step S105, determining a distance deviation at least according to the first distance and the actual distance corresponding to the number of turns, wherein the absolute value of the distance deviation is smaller than or equal to a preset difference value, and the preset difference value is the absolute value of the difference value between the first distance and the actual distance;

and step S106, updating the stop position according to the distance deviation to obtain an updated stop position.

In the method for controlling the welding robot, first, a start position and a stop position of welding are determined, and the laser sensor is controlled to be located at the start position, when the laser sensor is located at the start position, a laser line of the laser sensor coincides with the start position, and then a first distance detected by the laser sensor is acquired, wherein the first distance is a distance between the laser sensor and the welding gun when the laser sensor is located at the start position; secondly, determining the target number of pulse signals required by the motor driver according to the first distance, controlling the motor driver to send out the pulse signals, and acquiring the number of rotation turns of the motor detected by the encoder in real time until the target number is reached; and finally, updating the stop position according to the distance deviation to obtain an updated stop position. In the control method of the welding robot, the distance deviation is determined according to the first distance and the actual distance corresponding to the number of turns of rotation, and the stop position is updated according to the distance deviation. Therefore, the problems that in the process that the welding gun moves from the point C to the initial position, the welding gun cannot accurately reach the initial position due to inaccurate control, welding leakage or welding multiple occurs in the subsequent welding process, the quality of the crimping connector is better, and the problems that the crimping connector is poor and the welding workpiece has defects due to insufficient detection precision and inaccurate control in the prior art are solved.

In practical applications, the laser sensor may be located in an integrated sensor module at the front end of the machine, but is not limited to an integrated sensor module at the front end of the machine, and the laser sensor may also be located elsewhere in the machine and other sensor modules.

In an embodiment of the present application, as shown in fig. 2, after the welding gun performs welding from the starting position O, and then determines the coordinates of the starting position O, the stopping position D of the welding gun can be determined according to the radius of the pipe and the radius-perimeter formula.

In a specific embodiment of the present application, as shown in fig. 2, a laser line of the laser sensor coincides with an O point, the laser sensor recognizes from a welding position, the positions of the laser sensor and the welding gun are measured, a position of a C point, that is, a welding gun coordinate, is obtained, and the welding gun coordinate and the laser coordinate are unified, so as to obtain the first distance OC.

It should be noted that the steps illustrated in the flowcharts of the figures may be performed in a computer system such as a set of computer-executable instructions and that, although a logical order is illustrated in the flowcharts, in some cases, the steps illustrated or described may be performed in an order different than presented herein.

In an embodiment of the present application, determining the target number of pulse signals required by the motor driver according to the first distance includes: acquiring a corresponding travel distance of the motor rotating for one circle to obtain a unit distance; acquiring the number of the pulses required by one rotation of the motor to obtain unit number; and calculating the target number according to the unit distance, the unit number and the first distance, so that the target number can be accurately determined, the number of pulses initiated by the motor driver can be controlled according to the target number subsequently, the rotation of the motor can be controlled more accurately, and the actual stop position of the welding gun is closer to the stop position.

Specifically, a travel distance corresponding to one rotation of the motor is obtained to obtain a unit distance S, a unit number M is obtained according to the number of pulses required for one rotation of the motor, and a target number Z can be calculated according to the first distance OC, the unit distance S, and the unit number M by using a formula that is

Z＝OC/S*M

In another embodiment of the present application, as shown in fig. 3, determining the distance deviation OE based on at least the actual distance corresponding to the first distance and the number of turns comprises: determining an average distance at least according to the first distance and the actual distance corresponding to the number of turns; the difference between the average distance and the first distance is calculated to obtain the distance deviation OE. In the embodiment, firstly, an average distance is determined at least according to the first distance and the actual distance corresponding to the number of turns of rotation, and then, a distance deviation OE is determined according to the difference between the average distance and the first distance, so that the determined distance deviation OE is relatively accurate, and then, the stopping position of the welding gun can be relatively accurately updated according to the determined distance deviation OE.

Of course, the method of determining the distance deviation is not limited to the above method, and the difference between the actual distance and the first distance may be directly determined as the distance deviation.

In another embodiment of the present application, the welding robot further includes an attitude sensor, the attitude sensor is located on the body structure, and before determining a distance deviation according to at least an actual distance corresponding to the number of turns and the first distance, the control method further includes: acquiring a target position of the laser sensor detected by the attitude sensor, the target position being a position of the laser sensor when the pulse signal emitted by the motor driver reaches the target number; calculating an arc length between the target position and the initial position to obtain a second distance, and determining an average distance at least according to the first distance and an actual distance corresponding to the number of turns, including: and calculating an average value of the actual distance, the first distance and the second distance to obtain the average distance. In the embodiment, the second distance is determined according to the arc length between the target position and the initial position of the laser sensor detected by the attitude sensor, so that the determined second distance is relatively accurate, the average distance is determined according to the actual distance, the first distance and the second distance, and the distance deviation can be more accurately determined according to the average distance subsequently, so that the stop position can be relatively accurately updated, and the welding effect is further ensured to be relatively good. According to the scheme, the distance deviation is obtained through the three sensors, so that the determined distance deviation is more accurate.

In a specific embodiment of the application, the position of the laser sensor is obtained through the attitude sensor, the arc length from the laser sensor to the point O can be calculated through an arc length formula, the calculated arc length and the first distance OC are weighted and averaged to obtain an average value, the obtained average value is subtracted from the OC to obtain a distance deviation OE, and a new stop position D can be obtained through the distance deviation OE to form a new stop position.

In yet another specific embodiment of the present application, the crawler starts arcing, welds the weld, and stops arcing when it reaches the new stop position E point by calculating the number of pulses to the new stop position E point.

In another embodiment of the present application, after the stop position is updated according to the distance deviation to obtain an updated stop position, the control method further includes: controlling the welding robot to start welding from an actual initial position until the welding is carried out to the updated stop position; acquiring height data of the weld between the actual starting position and the update stopping position; determining a height abnormal area according to the height data; determining a supplementary welding amount according to the target height, the height data and the area of the height abnormal area; and controlling the welding robot to perform supplementary welding on the height abnormal area according to the supplementary welding amount until the height abnormal area is corrected to be a height normal area. In the embodiment, the supplementary welding amount is determined according to the target height and the height data and the area of the height abnormal area, and the welding robot is controlled according to the supplementary welding amount to carry out supplementary welding on the height abnormal area, so that the welded welding seam surface is further ensured to be relatively flat, particularly, the problem of poor surface flatness of a pressure welding joint can be avoided, the welding effect is further ensured to be good, and the problem of defects in a welding workpiece is further avoided.

In a specific embodiment of this application, after welding, the welding robot is automatic to roll back, laser sensor carries out high discernment to the welded joint, can obtain high unusual regional Q, when the welding robot rolls back to initial position O point, the high change of the welded joint to initial position O point is discerned, after general welding, the welded joint is the slope form, through laser sensor to the welded joint discernment, can obtain high unusual regional Q, the welding robot is from the shaping of bottom striking semicircle, it is circular finally to form complete closed loop.

In one embodiment of the present application, after the stop position is updated based on the distance deviation to obtain an updated stop position, the control method further includes, before the supplementary welding amount is determined based on the target height, the height data of the height abnormal region, and the area: determining a second predetermined area, wherein the second predetermined area is an area in which the minimum distance between the second predetermined area and the actual starting position and the minimum distance between the second predetermined area and the updating stopping position are both greater than a predetermined distance, namely the area is an area with better surface flatness and is also an area with more stable welding; and calculating the average value of the height data in the second preset area to obtain the target height, and determining the target height according to the height data corresponding to the second preset area, so that the determined target height is more accurate, the supplementary welding amount can be determined more accurately according to the target height subsequently, and the better welding effect is further ensured.

Of course, the target height is not limited to be determined by the height data of the second predetermined region, and may be determined by the height data of the region corresponding to the entire weld.

In a specific embodiment of the present application, as shown in fig. 5, 6 and 7, the weld joint may be, but is not limited to, a ramp shape after welding and before additional welding, and may be in other welded shapes.

In another specific embodiment of the present application, as shown in fig. 4, 5, 6, 7 and 8, in the retraction process, the laser sensor first retracts to the actual starting point E, and starts to record the height information, and when the height deviation value is small, the recording is stopped, and the recorded height change is the height change of the joint, and similarly, the information of the starting position O at the bottom of the pipeline can be obtained. In the process of supplementary welding, filling is started at the point P and stopped to the initial position, and the parameters of the supplementary welding machine are changed according to the size of supplementary welding quantity to achieve crimping due to different volumes needing to be filled.

In another embodiment of the present invention, the controlling the welding robot to perform supplementary welding on the height abnormal region until the height abnormal region is corrected to a height normal region according to a supplementary welding amount includes: determining corresponding welding control parameters according to the supplementary welding quantity; and controlling the welding robot to perform the supplementary welding until the height abnormal region is corrected to a height normal region according to the welding control parameter. In the embodiment, the corresponding welding control parameters are determined according to the supplementary welding quantity, and the welding robot is controlled to carry out supplementary welding, so that the better welding effect is further ensured, and full-automatic welding in the whole process is further realized.

In a specific embodiment of the present application, the corresponding welding control parameters are determined according to the supplementary welding amount, wherein the welding control parameters may be current, voltage, required swing size of the welding robot during the welding process, and speed of the vehicle body, but the welding control parameters are not limited to these parameters, and may also be other control parameters required by the welding robot during other welding processes.

The embodiment of the present application further provides a control device of a welding robot, and it should be noted that the control device of a welding robot of the embodiment of the present application can be used to execute the control method for a welding robot provided by the embodiment of the present application. The following describes a control device for a welding robot according to an embodiment of the present invention.

Fig. 9 is a schematic diagram of a control device of a welding robot according to an embodiment of the present application. As shown in fig. 9, the welding robot includes a body structure, a laser sensor, a motor driver, an encoder, and a welding gun, the laser sensor, the motor driver, the encoder, and the welding gun are all located on the body structure, and the control device includes:

a first determining unit 10, configured to determine a start position and a stop position of welding, and control the laser sensor to be in the start position, where a laser line of the laser sensor coincides with the start position when the laser sensor is in the start position;

a first acquiring unit 20 configured to acquire a first distance detected by the laser sensor, where the first distance is a distance between the laser sensor and the welding torch when the laser sensor is at the home position;

a second determining unit 30 for determining a target number of pulse signals required for the motor driver based on the first distance;

a first control unit 40, configured to control the motor driver to send the pulse signal, and obtain the number of turns of the motor detected by the encoder in real time until the target number is reached;

a third determining unit 50, configured to determine a distance deviation at least according to the actual distance corresponding to the first distance and the number of turns, wherein an absolute value of the distance deviation is smaller than or equal to a predetermined difference, and the predetermined difference is an absolute value of a difference between the first distance and the actual distance;

and an updating unit 60 for updating the stop position based on the distance deviation to obtain an updated stop position.

In the control device of the welding robot, a first determining unit is used for determining a starting position and a stopping position of welding and controlling the laser sensor to be positioned at the starting position, and when the laser sensor is positioned at the starting position, a laser line of the laser sensor is superposed with the starting position; the first acquisition unit is used for acquiring a first distance detected by the laser sensor, wherein the first distance is the distance between the laser sensor and the welding gun when the laser sensor is positioned at the initial position; a second determining unit for determining a target number of pulse signals required by the motor driver according to the first distance; the first control unit is used for controlling the motor driver to send out the pulse signal and acquiring the number of turns of the motor detected by the encoder in real time until the target number is reached; a third determining unit, configured to determine a distance deviation at least according to the first distance and an actual distance corresponding to the number of turns, where an absolute value of the distance deviation is smaller than or equal to a predetermined difference, and the predetermined difference is an absolute value of a difference between the first distance and the actual distance; the updating unit is used for updating the stopping position according to the distance deviation to obtain an updated stopping position. In the control device for the welding robot, the third determining unit determines the distance deviation according to the first distance and the actual distance corresponding to the number of turns of the rotation, and the updating unit updates the stop position according to the distance deviation. Therefore, the problems that in the process that the welding gun moves from the point C to the initial position, the welding gun cannot accurately reach the initial position due to inaccurate control, welding leakage or welding multiple occurs in the subsequent welding process, the quality of the crimping connector is better, and the problems that the crimping connector is poor and the welding workpiece has defects due to insufficient detection precision and inaccurate control in the prior art are solved.

In a specific embodiment of the present application, as shown in fig. 2, a laser line of the laser sensor coincides with an O point, the laser sensor recognizes from a welding position, measures positions of the laser sensor and the welding gun, and obtains a position of a point C, i.e., a welding gun coordinate, and unifies the welding gun coordinate and the laser coordinate to obtain the first distance OC.

In an embodiment of the application, the second determining unit further includes a first obtaining module, a second obtaining module, and a first calculating module, where the first obtaining module is configured to obtain a travel distance corresponding to one rotation of the motor to obtain a unit distance; the second acquisition module is used for acquiring the number of the pulses required by one rotation of the motor to obtain unit number; the first calculating module is used for calculating the target number according to the unit distance, the unit number and the first distance, so that the target number can be accurately determined, the number of pulses initiated by the motor driver can be subsequently controlled according to the target number, the rotation of the motor can be more accurately controlled, and the actual stop position of the welding gun is closer to the stop position.

Specifically, a travel distance corresponding to one rotation of the motor is obtained to obtain a unit distance S, a unit number M is obtained according to the number of pulses required for one rotation of the motor, and a target number Z can be calculated according to the first distance OC, the unit distance S and the unit number M by the following formula, that is, the target number Z is calculated

Z＝OC/S*M

In another embodiment of the present application, as shown in fig. 3, the third determining unit further includes a first determining module and a second calculating module, wherein the first determining module is configured to determine an average distance according to at least the first distance and an actual distance corresponding to the number of turns; the second calculation module is configured to calculate a difference between the average distance and the first distance, so as to obtain the distance deviation OE. In the embodiment, the first determining module determines the average distance at least according to the first distance and the actual distance corresponding to the number of turns of rotation, and the second calculation model determines the distance deviation OE according to the difference between the average distance and the first distance, so that the determined distance deviation OE is relatively accurate, and the stopping position of the welding gun can be relatively accurately updated subsequently according to the determined distance deviation OE.

Of course, in practice, the method of determining the distance deviation is not limited to the above method, and the difference between the actual distance and the first distance may be directly determined as the distance deviation.

In another embodiment of the present application, the welding robot further includes an attitude sensor, the attitude sensor is located on the body structure, and before determining a distance deviation according to at least an actual distance corresponding to the number of turns and the first distance, the control device further includes a second acquiring unit and a first calculating unit, wherein the second acquiring unit is configured to acquire a target position of the laser sensor detected by the attitude sensor, the target position being a position of the laser sensor when the pulse signal sent by the motor driver reaches the target number; the first calculation unit is configured to calculate an arc length between the target position and the start position to obtain a second distance, and the first determination module further includes a first calculation submodule configured to calculate an average value of the actual distance, the first distance, and the second distance to obtain the average distance. In this embodiment, the second obtaining unit determines the second distance according to the arc length between the target position and the start position of the laser sensor detected by the attitude sensor, so that the determined second distance is relatively accurate, the average distance is determined according to the actual distance, the first distance and the second distance, and the distance deviation can be more accurately determined according to the average distance subsequently, so that the stop position can be relatively accurately updated, and the welding effect is further ensured to be relatively good. According to the scheme, the distance deviation is obtained through the three sensors, so that the determined distance deviation is more accurate.

In yet another embodiment of the present application, after the updated stop position is obtained by updating the stop position according to the distance deviation, the control apparatus further includes a second first control unit, a third obtaining unit, a fourth determining unit, a fifth determining unit, and a third controlling unit, wherein the second control unit is configured to control the welding robot to start welding from an actual start position until welding to the updated stop position; a third acquiring unit for acquiring height data of the weld between the actual start position and the update stop position; the fourth determining unit is used for determining a height abnormal area according to the height data; a fifth determination unit configured to determine a supplementary welding amount based on the target height, the height data of the height abnormal region, and the area; and a third control unit for controlling the welding robot to perform supplementary welding on the height abnormal region according to the supplementary welding amount until the height abnormal region is corrected to a height normal region. In the embodiment, the fifth determining unit determines the supplementary welding amount according to the target height, the height data and the area of the height abnormal area, and the third controlling unit controls the welding robot to perform supplementary welding on the height abnormal area according to the supplementary welding amount, so that the welded welding seam surface is further ensured to be relatively flat, particularly the problem of poor surface flatness of a pressure welding joint is avoided, the welding effect is further ensured to be good, and the problem of defects in a welding workpiece is further avoided.

In an embodiment of the present application, after the updated stop position is obtained by updating the stop position according to the distance deviation, and before the supplementary welding amount is determined according to the target height, the height data of the height abnormal region, and the area, the control device further includes a sixth determining unit and a second calculating unit, wherein the sixth determining unit is configured to determine a second predetermined region, and the second predetermined region is a region in which both the minimum distance from the actual start position and the minimum distance from the updated stop position are greater than predetermined distances, that is, a region with good surface flatness and a region with stable welding; the second calculating unit is used for calculating the average value of the height data in the second preset area to obtain the target height, and the target height is determined according to the height data corresponding to the second preset area, so that the determined target height is more accurate, the supplementary welding amount can be determined more accurately according to the target height, and the better welding effect is further ensured.

In another specific embodiment of the present application, as shown in fig. 4, 5, 6, 7, and 8, during the retraction process, the laser sensor first retracts to the actual starting point E, and starts to record the height information, and when the height deviation value is very small, the recording is stopped, and the recorded height change is the height change of the joint, and similarly, the information of the starting position O at the bottom of the pipeline can be obtained. In the process of supplementary welding, filling is started at the point P and stopped to the initial position, and the parameters of the supplementary welding machine are changed according to the size of supplementary welding quantity to achieve crimping due to different volumes needing to be filled.

In another embodiment of the present application, the third control unit further includes a second determination module and a control module, wherein the second determination module is configured to determine a corresponding welding control parameter according to the supplementary welding quantity; the control module controls the welding robot to perform the supplementary welding according to the welding control parameter until the height abnormal area is corrected to a height normal area. In the embodiment, the second determining module determines the corresponding welding control parameter according to the supplementary welding amount, and controls the welding robot to perform supplementary welding, so that the better welding effect is further ensured, and full-automatic welding is further realized.

The control device for the welding robot includes a processor and a memory, the first determining unit, the first acquiring unit, the second determining unit, the first control unit, the third determining unit, the updating unit, and the like are stored in the memory as program units, and the processor executes the program units stored in the memory to realize corresponding functions.

The processor comprises a kernel, and the kernel calls the corresponding program unit from the memory. The kernel can set up one or more, solves among the prior art because detection precision is not enough and control is not accurate to lead to crimping to connect relatively poor and welding workpiece to appear the problem of defect through adjusting kernel parameter.

The memory may include volatile memory in a computer readable medium, random Access Memory (RAM) and/or non-volatile memory, such as Read Only Memory (ROM) or flash memory (flash RAM), including at least one memory chip.

An embodiment of the present invention provides a storage medium having a program stored thereon, the program implementing the above-described control method of a welding robot when executed by a processor.

The embodiment of the invention provides a processor, which is used for running a program, wherein the program executes the control method of the welding robot when running.

An embodiment of the present invention provides an apparatus, where the apparatus includes a processor, a memory, and a program that is stored in the memory and is executable on the processor, and when the processor executes the program, at least the following steps are implemented:

step S105, determining a distance deviation at least according to the first distance and an actual distance corresponding to the number of turns, wherein the absolute value of the distance deviation is smaller than or equal to a preset difference value, and the preset difference value is the absolute value of the difference value between the first distance and the actual distance;

The device herein may be a server, a PC, a PAD, a mobile phone, etc.

The present application further provides a computer program product adapted to perform a program of initializing at least the following method steps when executed on a data processing device:

In still another embodiment of the present invention, there is also provided a welding apparatus including: a welding robot, one or more processors, memory, and one or more programs, wherein the one or more programs are stored in the memory and configured to be executed by the one or more processors, the one or more programs comprising instructions for performing any of the above-described methods.

The welding device comprises a welding robot, the welding robot can execute a control method of the welding robot, the control method of the welding robot determines a distance deviation according to the first distance and an actual distance corresponding to the number of turns of rotation, and updates the stop position according to the distance deviation. Therefore, the problems that in the process that the welding gun moves from the point C to the initial position, the welding gun cannot accurately reach the initial position due to inaccurate control, welding leakage or welding multiple occurs in the subsequent welding process, the quality of the crimping connector is better, and the problems that the crimping connector is poor and the welding workpiece has defects due to insufficient detection precision and inaccurate control in the prior art are solved.

In the above embodiments of the present invention, the descriptions of the respective embodiments have respective emphasis, and for parts that are not described in detail in a certain embodiment, reference may be made to related descriptions of other embodiments.

In the embodiments provided in the present application, it should be understood that the disclosed technology can be implemented in other ways. The above-described embodiments of the apparatus are merely illustrative, and for example, the above-described division of the units may be a logical division, and in actual implementation, there may be another division, for example, multiple units or components may be combined or may be integrated into another system, or some features may be omitted, or not executed. In addition, the shown or discussed mutual coupling or direct coupling or communication connection may be an indirect coupling or communication connection through some interfaces, units or modules, and may be in an electrical or other form.

The units described as separate parts may or may not be physically separate, and parts displayed as units may or may not be physical units, may be located in one place, or may be distributed on a plurality of units. Some or all of the units can be selected according to actual needs to achieve the purpose of the solution of the embodiment.

In addition, functional units in the embodiments of the present invention may be integrated into one processing unit, or each unit may exist alone physically, or two or more units are integrated into one unit. The integrated unit can be realized in a form of hardware, and can also be realized in a form of a software functional unit.

The integrated unit may be stored in a computer-readable storage medium if it is implemented in the form of a software functional unit and sold or used as a separate product. Based on such understanding, the technical solution of the present invention may be embodied in the form of a software product, which is stored in a storage medium and includes instructions for causing a computer device (which may be a personal computer, a server, or a network device) to execute all or part of the steps of the above methods according to the embodiments of the present invention. And the aforementioned storage medium includes: a U-disk, a Read-Only Memory (ROM), a Random Access Memory (RAM), a removable hard disk, a magnetic or optical disk, and other various media capable of storing program codes.

From the above description, it can be seen that the above-described embodiments of the present application achieve the following technical effects:

1) Determining a starting position and a stopping position of welding, controlling the laser sensor to be at the starting position, wherein when the laser sensor is at the starting position, a laser line of the laser sensor coincides with the starting position, and then acquiring a first distance detected by the laser sensor, wherein the first distance is a distance between the laser sensor and the welding gun when the laser sensor is at the starting position; secondly, determining the target number of pulse signals required by the motor driver according to the first distance, controlling the motor driver to send out the pulse signals, and acquiring the number of rotation turns of the motor detected by the encoder in real time until the target number is reached; and finally, updating the stopping position according to the distance deviation to obtain an updated stopping position. In the control method of the welding robot, the distance deviation is determined according to the first distance and the actual distance corresponding to the number of turns, and the stop position is updated according to the distance deviation. Therefore, the problems that in the process that the welding gun moves from the point C to the initial position, the welding gun cannot accurately reach the initial position due to inaccurate control, welding leakage or welding multiple occurs in the subsequent welding process, the quality of the crimping connector is better, and the problems that the crimping connector is poor and the welding workpiece has defects due to insufficient detection precision and inaccurate control in the prior art are solved.

2) In the control device of the welding robot, the first determining unit is used for determining the starting position and the stopping position of welding and controlling the laser sensor to be positioned at the starting position, and when the laser sensor is positioned at the starting position, the laser line of the laser sensor is superposed with the starting position; the first acquisition unit is used for acquiring a first distance detected by the laser sensor, wherein the first distance is the distance between the laser sensor and the welding gun when the laser sensor is positioned at the initial position; a second determining unit for determining a target number of pulse signals required by the motor driver according to the first distance; the first control unit is used for controlling the motor driver to send out the pulse signal and acquiring the number of turns of the motor detected by the encoder in real time until the target number is reached; a third determining unit, configured to determine a distance deviation according to at least the first distance and an actual distance corresponding to the number of turns, where an absolute value of the distance deviation is smaller than or equal to a predetermined difference, and the predetermined difference is an absolute value of a difference between the first distance and the actual distance; the updating unit is used for updating the stopping position according to the distance deviation to obtain an updated stopping position. In the control device for the welding robot, the third determining unit determines the distance deviation according to the first distance and the actual distance corresponding to the number of turns of the rotation, and the updating unit updates the stop position according to the distance deviation. Therefore, the problems that in the process that the welding gun moves from the point C to the initial position, the welding gun cannot accurately reach the initial position due to inaccurate control, welding missing or welding more occurs in the subsequent welding process, the quality of a pressure welding connector is good, and the defects of the pressure welding connector and the welding workpiece caused by insufficient detection precision and inaccurate control in the prior art are solved.

3) The welding device comprises a welding robot, the welding robot can execute a control method of the welding robot, the control method of the welding robot determines a distance deviation according to a first distance and an actual distance corresponding to the number of turns, and updates a stop position according to the distance deviation. Therefore, the problems that in the process that the welding gun moves from the point C to the initial position, the welding gun cannot accurately reach the initial position due to inaccurate control, welding leakage or welding multiple occurs in the subsequent welding process, the quality of the crimping connector is better, and the problems that the crimping connector is poor and the welding workpiece has defects due to insufficient detection precision and inaccurate control in the prior art are solved.

The above description is only a preferred embodiment of the present application and is not intended to limit the present application, and various modifications and changes may be made by those skilled in the art. Any modification, equivalent replacement, improvement and the like made within the spirit and principle of the present application shall be included in the protection scope of the present application.

Claims

1. A control method of a welding robot, the welding robot comprising a body structure, a laser sensor, a motor driver, an encoder, and a welding gun, the laser sensor, the motor driver, the encoder, and the welding gun all being located on the body structure, the control method comprising:

determining a starting position and a stopping position of welding, controlling the laser sensor to be at the starting position, and when the laser sensor is at the starting position, a laser line of the laser sensor is overlapped with the starting position;

acquiring a first distance detected by the laser sensor, wherein the first distance is the distance between the laser sensor and the welding gun when the laser sensor is positioned at the initial position;

determining the target number of pulse signals required by the motor driver according to the first distance;

controlling the motor driver to send out the pulse signal, and acquiring the number of rotation turns of the motor detected by the encoder in real time until the target number is reached;

determining a distance deviation according to at least the first distance and an actual distance corresponding to the number of turns, wherein the absolute value of the distance deviation is smaller than or equal to a preset difference value, and the preset difference value is the absolute value of the difference value between the first distance and the actual distance;

updating the stop position according to the distance deviation to obtain an updated stop position,

determining a target number of pulse signals required by the motor driver according to the first distance, comprising:

acquiring a corresponding travel distance of one circle of rotation of the motor to obtain a unit distance;

acquiring the number of the pulses required by one rotation of the motor to obtain unit number;

and calculating the target number according to the unit distance, the unit number and the first distance.

2. The method of claim 1, wherein determining a distance deviation based on at least the first distance and an actual distance corresponding to the number of rotations comprises:

determining an average distance at least according to the first distance and the actual distance corresponding to the number of turns;

and calculating the difference value between the average distance and the first distance to obtain the distance deviation.

3. The method of claim 2, wherein the welding robot further comprises a pose sensor, the pose sensor being located on the body structure,

before determining a distance deviation at least according to the actual distance corresponding to the number of turns and the first distance, the control method further comprises:

acquiring a target position of the laser sensor detected by the attitude sensor, wherein the target position is the position of the laser sensor when the pulse signals sent by the motor driver reach the target number;

calculating an arc length between the target position and the start position to obtain a second distance,

determining an average distance at least according to the first distance and the actual distance corresponding to the number of turns, comprising:

and calculating the average value of the actual distance, the first distance and the second distance to obtain the average distance.

4. The method according to any one of claims 1 to 3, characterized in that after updating the stop position according to the distance deviation, resulting in an updated stop position, the control method further comprises:

controlling the welding robot to start welding from an actual starting position until welding to the update stopping position;

acquiring height data of the weld between the actual starting position and the updated stopping position;

determining a height abnormal area according to the height data;

determining a supplementary welding amount according to the target height, the height data of the height abnormal region and the area;

and controlling the welding robot to perform supplementary welding on the height abnormal area according to supplementary welding amount until the height abnormal area is corrected to be a height normal area.

5. The method according to claim 4, wherein after updating the stop position according to the distance deviation to obtain an updated stop position, before determining a supplementary welding amount according to a target height, the height data of the height abnormal region, and an area, the control method further comprises:

determining a second predetermined area, wherein the second predetermined area is an area of which the minimum distance between the second predetermined area and the actual starting position and the minimum distance between the second predetermined area and the updating stopping position are both larger than a predetermined distance;

and calculating the average value of the height data in the second preset area to obtain the target height.

6. The method according to claim 4, wherein controlling the welding robot to perform supplementary welding on the height abnormal region until the height abnormal region is corrected to a height normal region according to a supplementary welding amount comprises:

determining corresponding welding control parameters according to the supplementary welding quantity;

and controlling the welding robot to perform the supplementary welding according to the welding control parameter until the height abnormal area is corrected to a height normal area.

7. The utility model provides a controlling means of welding robot, its characterized in that, welding robot includes body structure, laser sensor, motor driver, encoder and welder, laser sensor the motor driver the encoder and welder all is located the body is structural, controlling means includes:

the first determining unit is used for determining the starting position and the stopping position of welding and controlling the laser sensor to be positioned at the starting position, and when the laser sensor is positioned at the starting position, the laser line of the laser sensor is superposed with the starting position;

the first acquisition unit is used for acquiring a first distance detected by the laser sensor, wherein the first distance is the distance between the laser sensor and the welding gun when the laser sensor is positioned at the initial position;

a second determination unit configured to determine a target number of pulse signals required by the motor driver according to the first distance;

the first control unit is used for controlling the motor driver to send out the pulse signal and acquiring the number of turns of the motor detected by the encoder in real time until the target number is reached;

a third determining unit, configured to determine a distance deviation according to at least the first distance and an actual distance corresponding to the number of turns, where an absolute value of the distance deviation is smaller than or equal to a predetermined difference, and the predetermined difference is an absolute value of a difference between the first distance and the actual distance;

an updating unit for updating the stopping position according to the distance deviation to obtain an updated stopping position,

the second determining unit further comprises a first obtaining module, a second obtaining module and a first calculating module, wherein the first obtaining module is used for obtaining a travel distance corresponding to one rotation of the motor to obtain a unit distance; the second acquisition module is used for acquiring the number of the pulses required by one rotation of the motor to obtain unit number; the first calculating module is configured to calculate the target number according to the unit distance, the unit number, and the first distance.

8. A computer-readable storage medium, characterized in that the computer-readable storage medium comprises a stored program, wherein the program performs the method of any one of claims 1 to 6.

9. A processor, characterized in that the processor is configured to run a program, wherein the program when running performs the method of any of claims 1 to 6.

10. A welding device, comprising: a welding robot, one or more processors, memory, and one or more programs, wherein the one or more programs are stored in the memory and configured to be executed by the one or more processors, the one or more programs comprising instructions for performing the method of any of claims 1-6.