CN113848811A - Plasma arc welding process and method of motion centralized control system - Google Patents
Plasma arc welding process and method of motion centralized control system Download PDFInfo
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- CN113848811A CN113848811A CN202110992737.6A CN202110992737A CN113848811A CN 113848811 A CN113848811 A CN 113848811A CN 202110992737 A CN202110992737 A CN 202110992737A CN 113848811 A CN113848811 A CN 113848811A
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- 238000004886 process control Methods 0.000 claims abstract description 17
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- G—PHYSICS
- G05—CONTROLLING; REGULATING
- G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
- G05B19/00—Programme-control systems
- G05B19/02—Programme-control systems electric
- G05B19/18—Numerical control [NC], i.e. automatically operating machines, in particular machine tools, e.g. in a manufacturing environment, so as to execute positioning, movement or co-ordinated operations by means of programme data in numerical form
- G05B19/414—Structure of the control system, e.g. common controller or multiprocessor systems, interface to servo, programmable interface controller
- G05B19/4142—Structure of the control system, e.g. common controller or multiprocessor systems, interface to servo, programmable interface controller characterised by the use of a microprocessor
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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
- B23K10/00—Welding or cutting by means of a plasma
- B23K10/02—Plasma welding
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- G—PHYSICS
- G05—CONTROLLING; REGULATING
- G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
- G05B2219/00—Program-control systems
- G05B2219/30—Nc systems
- G05B2219/34—Director, elements to supervisory
- G05B2219/34013—Servocontroller
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- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P90/00—Enabling technologies with a potential contribution to greenhouse gas [GHG] emissions mitigation
- Y02P90/02—Total factory control, e.g. smart factories, flexible manufacturing systems [FMS] or integrated manufacturing systems [IMS]
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Abstract
The invention discloses a plasma arc welding process and a method of a motion centralized control system, which utilize a GUC-EtherCAT multi-axis motion controller as a control system core, a servo motor and a stepping motor are respectively control units of welding motion and process, and the control units are controlled by a matched servo motor driver and an Ethercat stepping motor driver, so that the plasma arc welding process and the motion centralized control system are designed for a special welding machine. The system uses a plasma arc welding special machine and a rectangular coordinate system robot as carriers, and integrates the process control of the welding special machine and the motion control of the welding rectangular coordinate system robot into a GUC-EtherCAT multi-axis controller for unified control, so as to integrate into a whole set of plasma arc welding control system. Compared with the prior art, the method overcomes the defect that the welding process control and the motion control are independent, enables the welding process control and the motion control to work cooperatively, and can effectively reduce the complicated field wiring when the PLC control box is used for controlling.
Description
Technical Field
The invention belongs to the field of welding control systems, and relates to a plasma arc welding process and a method of a motion centralized control system.
Background
In recent years, automatic welding is in ChinaThe field of welding technology has been greatly developed and automatic welding technology has been widely used in various industries. For production type enterprises, the automatic welding technology greatly reduces the number of workers and has great advantages in reducing the enterprise cost. Meanwhile, the application of the automatic welding technology overcomes a plurality of adverse factors in the production, and is suitable for the production of large-scale industrial products[1]。
The technical level of the welding automation equipment is an important embodiment of the national technology level and directly determines the technical level of national important core equipment. At present, various special welding automation equipment can be designed, manufactured and integrated by China welding automation equipment manufacturing enterprises according to different requirements of customers, and a large amount of computer control technology is adopted. Part of the welding automation equipment is also provided with an automatic welding seam tracking system and an image monitoring system, so that the welding quality in the welding process is ensured[2]。
Especially after the innovation, along with the improvement of the quality of life of people, the positive sight on the health of workers and the request for improving the production efficiency, in the modern industrial production, the special welding machine is used at the head in the more and more welding production processes[3]. In most production, the technological process of the special welding machine is generally independently controlled, and the defects are obvious. The field wiring is very cumbersome and cannot be operated in conjunction with the welding robot motion to work in tandem.
In the field of traditional welding, most of automatic (robot, machine tool direct-connection welding gun) welding has low efficiency and low precision. If the special welding machine is applied to the welding work of machinery (robots and machine tools), the operation quality can be greatly improved, and the problems of insufficient welding precision, pose adjustment and the like are solved. The method is suitable for some engineering welding projects with extremely high welding precision and strict pose requirements. The welding can not meet the requirements only by controlling the welding gun by the robot, and the problems of welding precision, pose accuracy and the like can be solved by connecting the special welding machine frame on the coordinate system robot.
The control modes of the special welding machine are various, and are generally divided into open-loop control type, self-adaptive control type and intelligent type[4]. The open-loop control mode generally adopts open-loop control, namely preset parameters of a control system are controlled, and an execution mechanism executes according to a control program sequence. The equipment has simple structure and relatively low technical requirement and cost, so the application field is wider[5]。
Therefore, in order to make the welding requirement higher in precision and the welding control unit more compact. The plasma arc welding control system can carry a special plasma arc welding machine on the existing welding robot (machine tool), and a multi-axis motion controller is used for integrating the control of the special welding machine and the control of the welding robot to form a whole set of plasma arc welding control system. The complicated wiring difficulty can be greatly reduced, the traditional special welding machine is generally independent in control, a PLC control box is generally adopted in a control strategy, a large number of circuit layouts are required in the control method, and a set of control cabinet needs to be independently and independently used for special control. The control cabinet is used for independently controlling the welding special machine (process control), and is not integrated with a robot (machine tool) control system (motion control). Namely, the two parts are independently controlled, and two control units need to be adjusted, so that the invention aims to integrate process control and motion control into a whole and facilitate control.
[1] Leda Wei, research on the control system of the special pipe welding machine [ J/OL ] thermal processing technology, 2021(19), 140-144[2021-07-06].
[2] Yu nationality, contactor coil automatic welding special plane control system design and development [ D ]. Lanzhou university of science and technology, 2019.
[3] Research on motion control system of special machine for welding blade of mixing drum in lei repairing, university of Nanchang aviation, 2012.
[4] Design of a control system of a special welding machine for fin heating pipe plates, wherein the control system is Wangkai, Zhang Yi, Zhang Shijust, 2016,45(04) and 56-59.
[5] An ultrasonic automatic detection control system for welding quality of Li Xiang and ultra-long thin-wall pressure pipe fittings is developed to be used in university of North and Central, 2018.
Disclosure of Invention
The invention provides a centralized control method based on a plasma arc (VPPA) welding special machine and a rectangular coordinate system robot, aiming at the problems of a plasma arc welding process and centralized control of motion. The invention can be applied to the occasions with strict requirements on welding environment and higher precision, can effectively reduce complex field wiring, and can realize centralized control of welding process and motion and cooperative work.
The technical scheme is as follows:
the invention utilizes a GUC-EtherCAT multi-axis motion controller as a control system core, a servo motor and a stepping motor are respectively control units of welding motion and process, and the control units are controlled by a matched servo motor driver and an Ethercat stepping motor driver, so that a plasma arc welding process and motion centralized control system is designed for a special welding machine. The system uses a plasma arc (VPPA) welding special machine and a rectangular coordinate system robot as carriers, and integrates the process control of the welding special machine and the motion control of the welding rectangular coordinate system robot into a GUC-EtherCAT multi-axis controller for unified control to form a whole set of plasma arc welding control system. Compared with the prior art, the method overcomes the defect that the welding process control and the motion control are independent, enables the welding process control and the motion control to work cooperatively, and can effectively reduce the complicated field wiring when the PLC control box is used for controlling.
Drawings
FIG. 1 is a diagram of a GUC-EtherCAT multi-axis motion controller.
FIG. 2 is a diagram of a plasma arc welding machine and a welding coordinate system robot.
FIG. 3 is a circuit diagram of the plasma arc welding machine.
FIG. 4 is a diagram of a handpiece navigation definition.
FIG. 5 is a diagram of a process control stepper motor and a motion control servo motor.
Fig. 6 is a block diagram of the overall system structure.
FIG. 7 is a functional block diagram of a teach pendant.
Detailed Description
The equipment adopted by the embodiment comprises: 1. the robot comprises a welding rectangular coordinate system robot, a 2. plasma arc welding special machine body, a 3.GUC-EtherCAT multi-axis motion controller, a 4.Otostudio open software platform, a 5.Ethercat stepper motor driver and servo motor driver and a 6. demonstrator.
In order to make the technical scheme of the invention clearer, the invention is further explained below by combining the attached drawings. The invention is realized by the following steps:
(1) integrated welding special machine process control and welding robot motion control
The special plasma arc welding machine frame is connected to a 4+ 2-axis rectangular coordinate system robot, namely X, Y, Z-axis and Z-axis rotating shafts and rotating and overturning shafts of a workbench. The plasma arc welding special machine has 6 shafts, namely, the forward extension, the backward extension and the rotation adjustment of a welding gun, the forward extension and the backward extension of wire feeding and the wire feeding motor.
(2) The GUC-EtherCAT multi-axis motion controller is adopted as a control core
The scheme of a control system of the conventional special welding machine is searched by turning over, and the conclusion is drawn that the PLC control box has complicated circuits for independent control and cannot enable the special welding machine (process control) and the welding robot (motion control) to work cooperatively. Therefore, a GUC-EtherCAT multi-axis motion controller of Gangjia company is adopted as a control system core.
1. And (3) configuring 6 axes including a rotating shaft (A) of an axis of the welding robot X, Y, Z, Z and two axes (T, R) of the workbench, generating an XML configuration file, importing the XML configuration file into a GUC-EtherCAT multi-axis motion controller, and electrically connecting the axes by an Ethercat servo motor driver. The motion controller is integrated, and the servo motor is controlled by the servo motor driving controller. The corresponding power is 200w, 400w, 750w, 950w and 950w in sequence, the communication protocol is Ethercat, all Ethercat servo motor drivers are connected in series with one another through network cables to communicate with a GUC-Ethercat multi-axis motion controller, namely, the field bus system based on the Ethernet. The 6 axes adopt a more effective three-point positioning method to determine the installation pose description matrix of the motor shafts, including a turning axis of the positioner, a rotating axis and a deflection axis of the rectangular coordinate type robot.
2. Configuring 6 shafts of a plasma arc welding special machine, namely 6 shafts of the forward extension, the backward extension and the rotation adjustment of a welding gun and 6 shafts of the forward extension and the backward adjustment of wire feeding, generating an XML configuration file and importing the XML configuration file into a GUC-EtherCAT multi-shaft motion controller. The connection mode is network cable series connection (Ethercat communication protocol), and the control is realized by sending an instruction to an Ethercat stepper motor driver through a GUC-EtherCAT multi-axis motion controller to control the forward rotation and the reverse rotation of the stepper motor. Because the stepping motor is adopted, and no encoder exists, the control mode is controlled in an open loop mode. Starting and stopping, and returning to the coordinate position through the probe function of the Ethercat stepper motor driver. The GUC-EtherCAT motion controller controls the wire feeding motor by sending an enabling signal, a direction signal and a pulse signal to the wire feeding machine driver.
(3) And selecting a proper demonstrator, selecting Qt software with cross-platform characteristics to design a cooperative control interface of the welding process and the welding motion, and starting a wire feeding function by using 11 shafts and one wire feeder, wherein the wire feeding function comprises 4+2 shafts of a welding robot, 5 shafts of a special welding machine and a wire feeding function of the wire feeder. Six axes of the welding robot have a motion interpolation function, and a self interpolation motion mode can complete multi-axis combined coordinated motion, so that a complex motion track is realized. The interpolation motion mode provided by the motion control library can complete circular interpolation and linear interpolation, the process control of the special welding machine realizes a jog mode, the start and stop limit returns, and the motion control library can be cooperatively controlled and integrated in the same demonstrator.
Compared with the prior art, the method overcomes the defect that the welding process control and the motion control are independent, enables the welding process control and the motion control to work cooperatively, and can effectively reduce the complicated field wiring when the PLC control box is used for controlling.
While the invention has been described in detail with reference to specific embodiments thereof, it will be understood by those skilled in the art that the present invention is not limited to the specific embodiments described above, and that various changes and modifications may be made therein without departing from the spirit of the invention.
Claims (4)
1. A plasma arc welding process and a method of a motion centralized control system are characterized in that: the GUC-EtherCAT multi-axis motion controller is used as a control system core, the servo motor and the stepping motor are respectively control units of welding motion and process, and the control units are controlled by a matched servo motor driver and an Ethercat stepping motor driver, so that a plasma arc welding process and motion centralized control system is designed for a special welding machine; the plasma arc VPPA welding special machine and the rectangular coordinate system robot are used as carriers, and process control of the welding special machine and motion control of the welding rectangular coordinate system robot are integrated into a GUC-EtherCAT multi-axis controller for unified control, so that a whole set of plasma arc welding control system is integrated.
2. The plasma arc welding process and centralized motion control system method of claim 1, wherein: the method is specifically realized according to the following steps:
(1) integrated welding special machine process control and welding robot motion control
The special plasma arc welding machine frame is connected to a 4+ 2-axis rectangular coordinate system robot, namely an X, Y, Z axis, a Z-axis rotating shaft and a rotating and overturning shaft of a workbench; the control of the welding process is matched with the motion control, and the special plasma arc welding machine has 6 shafts, namely the forward extension, the backward extension and the rotation adjustment of a welding gun, the forward extension and the backward adjustment of wire feeding and a wire feeding motor;
(2) the GUC-EtherCAT multi-axis motion controller is adopted as a control core
The control system scheme of the conventional special welding machine is searched through turning over, and the conclusion is drawn, the PLC control box is independently controlled, so that the circuit is complicated, and the special welding machine and the welding robot cannot work cooperatively; a fixed GUC-EtherCAT multi-axis motion controller is adopted as a control system core;
(3) selecting a proper demonstrator, selecting Qt software with cross-platform characteristics to design a cooperative control interface of a welding process and motion, and starting a wire feeding function by a wire feeder with 11 shafts, wherein the wire feeding function comprises 4+2 shafts of a welding robot, 5 shafts of a special welding machine and a wire feeding function of the wire feeder; six axes of the welding robot have a motion interpolation function, and an interpolation motion mode of the welding robot can complete multi-axis combined coordinated motion, so that a complex motion track is realized; the interpolation motion mode provided by the motion control library completes circular interpolation and linear interpolation, the welding special machine process control realizes a inching mode, the start and stop limit returns, and the combination of the start and stop limit and the stop limit can be cooperatively controlled and integrated in the same demonstrator.
3. The method of claim 2 wherein the plasma arc welding process and the centralized motion control system further comprise: configuring 6 shafts of a rotating shaft of an X, Y, Z, Z shaft of the welding robot and two shafts of a workbench, generating an XML configuration file, importing the XML configuration file into a GUC-EtherCAT multi-shaft motion controller, and electrically connecting the axes by an Ethercat servo motor driver; a motion controller is integrated, and the servo motor is controlled by the servo motor driving controller; the corresponding power is 200w, 400w, 750w, 950w and 950w in sequence, the communication protocol is Ethercat, all Ethercat servo motor drivers are connected in series with one another through network cables to communicate with a GUC-Ethercat multi-axis motion controller, namely an Ethernet-based field bus system; and the 6-axis adopts a three-point positioning method to determine the installation pose description matrix of the motor shafts, and comprises a turnover shaft of the positioner, a rotating shaft and a rectangular coordinate type robot deflection shaft.
4. The method of claim 2 wherein the plasma arc welding process and the centralized motion control system further comprise: configuring 6 shafts of a plasma arc welding special machine, namely 6 shafts of the forward extension, the backward extension and the rotation adjustment of a welding gun and 6 shafts of the forward extension and the backward adjustment of wire feeding, generating an XML configuration file and importing the XML configuration file into a GUC-EtherCAT multi-shaft motion controller; the connection mode is network cable series connection, and the control is realized by sending an instruction to an Ethercat stepping motor driver through a GUC-EtherCAT multi-axis motion controller to control the forward rotation and the reverse rotation of the stepping motor; because the stepping motor is adopted, and no encoder exists, the control mode is controlled in an open loop mode; starting and stopping, and returning to the coordinate position through the probe function of an Ethercat stepper motor driver; the GUC-EtherCAT motion controller controls the wire feeding motor by sending an enabling signal, a direction signal and a pulse signal to the wire feeding machine driver.
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Citations (5)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JP2010269336A (en) * | 2009-05-20 | 2010-12-02 | Kobe Steel Ltd | Welding setting device, welding robot system, and welding setting program |
| CN108942932A (en) * | 2018-07-19 | 2018-12-07 | 深圳市智能机器人研究院 | Industrial robot control system and method based on EtherCAT bus |
| CN208304122U (en) * | 2018-05-23 | 2019-01-01 | 山东省科学院自动化研究所 | A kind of welding robot control system based on bus |
| CN112276348A (en) * | 2020-11-06 | 2021-01-29 | 优尔金属制品(苏州)有限公司 | Five-axis linkage welding mechanical arm |
| CN112894102A (en) * | 2021-01-18 | 2021-06-04 | 温州大学 | Three-wire plasma arc additive manufacturing device and method |
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- 2021-08-27 CN CN202110992737.6A patent/CN113848811B/en active Active
Patent Citations (5)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JP2010269336A (en) * | 2009-05-20 | 2010-12-02 | Kobe Steel Ltd | Welding setting device, welding robot system, and welding setting program |
| CN208304122U (en) * | 2018-05-23 | 2019-01-01 | 山东省科学院自动化研究所 | A kind of welding robot control system based on bus |
| CN108942932A (en) * | 2018-07-19 | 2018-12-07 | 深圳市智能机器人研究院 | Industrial robot control system and method based on EtherCAT bus |
| CN112276348A (en) * | 2020-11-06 | 2021-01-29 | 优尔金属制品(苏州)有限公司 | Five-axis linkage welding mechanical arm |
| CN112894102A (en) * | 2021-01-18 | 2021-06-04 | 温州大学 | Three-wire plasma arc additive manufacturing device and method |
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