CN113909765B - Guiding welding system - Google Patents
Guiding welding system Download PDFInfo
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- CN113909765B CN113909765B CN202111295973.9A CN202111295973A CN113909765B CN 113909765 B CN113909765 B CN 113909765B CN 202111295973 A CN202111295973 A CN 202111295973A CN 113909765 B CN113909765 B CN 113909765B
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K37/00—Auxiliary devices or processes, not specially adapted to a procedure covered by only one of the preceding main groups
- B23K37/02—Carriages for supporting the welding or cutting element
- B23K37/0252—Steering means
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B25—HAND TOOLS; PORTABLE POWER-DRIVEN TOOLS; MANIPULATORS
- B25J—MANIPULATORS; CHAMBERS PROVIDED WITH MANIPULATION DEVICES
- B25J9/00—Programme-controlled manipulators
- B25J9/16—Programme controls
- B25J9/1656—Programme controls characterised by programming, planning systems for manipulators
- B25J9/1664—Programme controls characterised by programming, planning systems for manipulators characterised by motion, path, trajectory planning
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- Optics & Photonics (AREA)
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- Butt Welding And Welding Of Specific Article (AREA)
Abstract
The invention discloses a guiding welding system which is used for welding corrugated plates. The welding robot comprises a welding robot body, a scanning device and a control device connected with the welding robot body and the scanning device in a signal mode. The welding robot is provided with a welding gun at its tip and is configured to be movable in the extending direction of the slit to be welded. The scanning device is arranged at the tail end. The control device is configured to perform a scanning step, a planning step, and a welding step. The scanning step comprises the steps of obtaining contour data of a gap, and obtaining three-dimensional coordinate data of contour points of the gap at intervals of preset distances by taking a starting point of the gap as an origin. The planning step comprises the steps of planning a movement track of the welding gun according to the profile data, determining a starting point and an ending point of a corrugated corner, and planning a posture changing action for the welding gun between the starting point and the ending point. The welding step comprises the step of controlling a welding gun to weld the gap along the movement track. According to the guiding welding system, the influence caused by steep slopes can be effectively avoided, and the welding precision is high.
Description
Technical Field
The invention relates to the technical field of containers, in particular to a guiding welding system.
Background
With the continuous development of industrial technology, industrial manufacturing is increasingly tending to be automated, and industrial welding robots have been introduced in the field of container manufacturing. At present, most welding robots in container manufacturing workshops still adopt a teaching fixed track method for welding.
On one hand, as containers are more in variety, the workload of workers can be greatly increased by adopting a method for teaching fixed tracks for welding; on the other hand, due to positioning errors of the fixture, positioning errors of manual spot welding and the like, when the robot performs welding work according to the taught fixed track, the problems of welding missing, welding off and the like can occur, the welding quality of products is greatly affected, and the labor cost and the time cost of follow-up maintenance reworking are greatly increased.
In particular, when welding workpieces having steep slopes, such as corrugated plates, the presence of the steep slopes greatly affects the positioning of the robot, resulting in poor welding accuracy and quality.
Accordingly, there is a need for a guided welding system that at least partially addresses the above issues.
Disclosure of Invention
In the summary, a series of concepts in a simplified form are introduced, which will be further described in detail in the detailed description. The summary of the invention is not intended to define the key features and essential features of the claimed subject matter, nor is it intended to be used as an aid in determining the scope of the claimed subject matter.
To at least partially solve the above problems, the present invention provides a guided welding system for welding of corrugated plates, the guided welding system comprising:
a welding robot having a tip configured to be movable in an extending direction of a slit to be welded, the tip being provided with a welding gun;
the scanning device is arranged at the tail end of the welding robot;
a control device in signal connection with the scanning device and the welding robot, the control device configured to perform the steps of:
a scanning step of obtaining contour data of the gap to be welded, wherein the length direction of the corrugated plate is defined as an x axis, the width direction of the corrugated plate is defined as a z axis, the corrugated depth direction of the corrugated plate is defined as a y axis, a starting point of the gap is used as an origin point, three-dimensional space coordinate data of the x axis, the y axis and the z axis of the contour point of the gap are obtained at intervals of preset distances,
a planning step of planning a movement track of the welding gun according to the contour data, determining a corner starting point and a corner ending point of a corrugated corner of the contour of the gap, planning a posture changing action for the welding gun between the corner starting point and the corner ending point,
and a welding step, controlling the welding gun to weld the gap along the motion trail.
Further, in the step of scanning,
fitting by using the data of the x axis and the y axis of the contour points, and calculating the homodromous variation value of the slope of a fitting straight line between two continuous points;
wherein when the value of the change in the same direction of at least two consecutive points exceeds a first threshold, determining a first point of the at least two consecutive points as the corner starting point of the corner;
and after the corner starting point, when the value of the change in the same direction of at least two groups of continuous points is smaller than a second threshold value, determining that a first point in the at least two groups of continuous points is the corner ending point of the corner.
According to the guiding welding system, when workpieces with steep slopes such as corrugated plates and the like are guided and welded, the gesture can be changed in the process of scanning the profile, the influence caused by a steep slope blind area can be effectively avoided, complete welding seam characteristic data can be acquired, and welding precision and quality are improved.
Further, the slope of the fit line is fitted by using more than 5 continuous points on the contour, including the points to be fitted. Thereby, the accuracy of the contour can be improved.
Further, the gesture changing action includes a rotation action, and an angular velocity of rotation is positively correlated with a change in the slope of the fitted straight line. According to the scheme, the welding precision can be further improved.
Further, the posture changing operation is configured to make the welding gun perpendicular to the slit. Thus, the optimum welding state can be maintained at all times.
Further, the scanning step further includes:
when the absolute value of the difference of the y-axis data between two consecutive points is greater than a third threshold value and/or when the absolute value of the difference of the z-axis data between two consecutive points is greater than a fourth threshold value, the latter point is confirmed as an invalid point and the invalid point is excluded. According to the scheme, errors can be removed and reduced, and the accuracy of gap characteristics is improved.
Further, the scanning step further includes:
and performing space fitting according to three continuous points before the invalid point to obtain theoretical data at the invalid point, and replacing the invalid data with the theoretical data. Thereby, the accuracy of the slit feature can be further improved.
Further, the preset distance is 0.1-2 mm. According to the scheme, the accuracy of the contour data can be further improved.
Further, the scanning device comprises a line laser sensor.
Further, the control device controls the scanning step, the planning step and the welding step to be performed synchronously; or alternatively
And after the scanning step and the planning step are controlled by the control device, controlling the welding robot to execute the welding step. According to the above arrangement, the production efficiency can be improved.
Drawings
The following drawings are included to provide an understanding of the invention and are incorporated in and constitute a part of this specification. The drawings illustrate embodiments of the invention and their description to explain the principles of the invention.
In the accompanying drawings:
FIG. 1 is a block diagram of a guided welding system according to a preferred embodiment of the present invention;
FIG. 2 is a partial schematic view of a pilot welding system according to a preferred embodiment of the present invention;
FIG. 3 is a schematic view of a workpiece to be welded;
FIG. 4 is a schematic cross-sectional view along the Y-direction of the workpiece to be welded of FIG. 3 at the seam to be welded; and
fig. 5 is a flow chart illustrating the steps performed by a control device of a lead welding system according to a preferred embodiment of the present invention.
Reference numerals illustrate:
10: the workpiece 11 to be welded: gap to be welded
12: corner 13: corner origin
14: corner endpoint 100: guidance welding system
110: welding robot 111: welding gun
120: scanning device 130: control device
140: welding machine
Detailed Description
In the following description, numerous specific details are set forth in order to provide a more thorough understanding of the present invention. It will be apparent, however, to one skilled in the art that the invention may be practiced without one or more of these details. In other instances, well-known features have not been described in detail in order to avoid obscuring the invention.
In the following description, a detailed description will be given for the purpose of thoroughly understanding the present invention. It should be appreciated that these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the concept of these exemplary embodiments to those skilled in the art. It will be apparent that embodiments of the invention may be practiced without limitation to the specific details that are familiar to those skilled in the art. Preferred embodiments of the present invention are described in detail below, however, the present invention may have other embodiments in addition to these detailed descriptions.
It is noted that the terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of exemplary embodiments according to the present invention. As used herein, the singular is intended to include the plural unless the context clearly indicates otherwise. Furthermore, it will be further understood that the terms "comprises" and/or "comprising," when used in this specification, specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof.
Ordinal numbers such as "first" and "second" cited in the present invention are merely identifiers and do not have any other meaning, such as a particular order or the like. Also, for example, the term "first component" does not itself connote the presence of "second component" and the term "second component" does not itself connote the presence of "first component". It should be noted that the terms "upper", "lower", "front", "rear", "left", "right", "inner", "outer", and the like are used herein for illustrative purposes only and are not limiting.
Exemplary embodiments according to the present invention will now be described in more detail with reference to the accompanying drawings.
The lead welding system 100 of the preferred embodiment of the present invention is used for welding of containers. In particular, it is suitable for carrying out corrugated sheets, which are suitable for welding corrugated sheets with deep waves.
Referring to fig. 1 and 2, the guided welding system 100 includes a scanning device 120, a control device 130, a welding robot 110, and a welder 140.
The welding robot 110 is provided with a welding gun 111 for performing welding operation on the slit 11 to be welded. The scanning device 120 is used for scanning the shape of the gap 11 to be welded of the workpiece 10 to be welded and obtaining position data, and the scanning device 120 is also provided on the welding robot 110. The workpiece 10 to be welded may be a corrugated plate.
Specifically, a flange (not shown) is provided at the end of the welding robot 110, and a welding gun 111 is provided on the flange. The scanner 120 is also disposed on the flange. Preferably, the scanning device 120 is configured as a line laser sensor.
The welding robot 110 is configured such that its tip can move along the slit 11 to be welded, and thus the welding gun 111 and the scanning device 120 can also move in synchronization with the tip of the welding robot 110. The welder 140 is coupled to the welding gun 111, which provides the welding gun 111 with a source of solder and energy (e.g., electrical energy, etc.).
The control device 130 is in signal connection with the welder 140, the welding robot 110, and the scanning device 120. Which is configured to control a motion trajectory of the welding robot 110 according to data acquired by the scanning device 120. Or, it is configured to guide the welding robot 110 to weld the slit 11 to be welded according to the data scanned by the scanning device 120. And the control device 130 is further configured to control the welder 140 to provide material and energy to the welding gun 111 according to the progress of the welding.
Specifically, as shown in fig. 3, 4 and 5, the length direction of the corrugated plate is defined as the x-axis, the corrugation depth direction of the corrugated plate is defined as the y-axis, and the width direction of the corrugated plate is defined as the z-axis. And the control device 130 is configured to perform a scanning step S1, a planning step S2 and a welding step S3.
In the scanning step S1, the control device 130 controls the scanning device 120 to acquire profile data of the slit 11 to be welded. Specifically, three-dimensional space coordinate data of an x axis, a y axis and a z axis of a contour point of a slit are obtained at intervals of a preset distance by taking a starting point of the slit as an origin. Namely P 0 (x 0 ，y 0 ，z 0 )，P 0 (x 1 ，y 1 ，z 1 )，P 0 (x 2 ，y 2 ，z 2 )，P 0 (x 3 ，y 3 ，z 3 )…P n (x n ，y n ，z n ). The preset distance is preferably 0.1-2 mm, more preferably 1mm, so as to obtain more point location data, and further improve the accuracy of the contour data.
In this case, the point data acquired should also be graded, since the contour of the slot 11 of the corrugated plate to be welded varies gradually. If a certain point data suddenly changes, in order to reduce errors and improve the accuracy of the slit characteristics, the coordinate data of the point needs to be excluded.
Specifically, when the absolute value of the difference in y-axis data between two consecutive points is greater than the third threshold value and/or when the absolute value of the difference in z-axis data between two consecutive points is greater than the fourth threshold value, the latter point is confirmed as an invalid point, and the invalid point is excluded.
The data is illustratively processed in a limiting filter method. Setting the third threshold value to be theta y The third threshold value is theta z . When y is n -y n-1 ＞θ y When and/or when z n -z n-1 ＞θ z Point P is considered to be n (x n ，y n ，z n ) Is an invalid point, and is excluded.
And then, in order to further improve the accuracy of the slit characteristics, carrying out space fitting by using three continuous points before the invalid point, obtaining theoretical coordinate data at the invalid point, and replacing the invalid data with the theoretical data.
Specifically, according to the space fitting equation
Wherein a, b, x m ，y m Are all the preset coefficients, and the preset coefficients are all the same,
p n-1 ，P n-2 ，P n-3 Fitting the three-point data, and writing into a matrix
Calculating the theoretical value P of coordinates at invalid point n ’(x n ’，y n ’，z n ') to replace the null point.
In the planning step S2, the control device 130 plans the movement trace of the welding gun 111 based on the contour data that has been processed as described above. Further, since the corrugated board has the corner 12 at the corrugation, it is necessary to determine the corner start point 13 and the corner end point 14 of the corner 12 and plan the posture changing action for the welding gun 111 between the corner start point 13 and the corner end point 14. For example, the end rotation of welding robot 110 may be controlled between corner start point 13 and corner end point 14, thereby rotating welding gun 111 to maintain an optimal welding pose to improve consistency of welding quality. More preferably, the welding gun 111 is kept perpendicular to the slit between the corner start point 13 and the corner end point 14 to improve welding accuracy.
Specifically, the x-axis and y-axis data of the contour points are fitted, the change value in the same direction of the slope of the fitted straight line between two consecutive points is calculated, and the start point and the end point of the corner 12 are determined from the change value.
Since the slope of the fitted straight line changes little at the time of the straight line stage of the round, the whole is stable, so when the slope changes largely in the same direction for 2 times or more continuously, it can be judged that the corner 12 has been reached, that is, the first point of the first large change can be regarded as the corner starting point 13. Alternatively, when the value of the change in the same direction of at least two consecutive points exceeds the first threshold value, it is determined that the first point of the at least two consecutive points is the corner start point 13 of the corner 12.
When the slope change again tends to smooth, the corner 12 can be considered to have ended. The first point at which the slope change is determined to be smooth is the corner endpoint 14. Alternatively, after the corner start point 13, when the value of the change in the same direction of at least two consecutive points is smaller than the second threshold value, it is determined that the first point of the at least two consecutive points is the corner end point 14 of the corner 12.
Preferably, the fitting is performed using more than 5 consecutive points on the contour, including the point to be fitted. Illustratively, a system of fitting equations is written from the linear equations and matrix calculations are performed to find P n The slope k of the fitted straight line at n 。
Illustratively, let the first threshold be θ 1 The second threshold value is theta 2 . When k is n+1 -k n ＞θ 1 And k is n+2 -k n+1 ＞θ 1 At the time, judge P n At the corner starting point 13. Thereafter, when k n+5 -k n+4 ＜θ 2 And k is n+6 -k n+5 ＜θ 2 At the time, it is considered that the slope change has been smoothed and P is determined n+4 At the corner end point 14.
In the welding step S3, the welding gun 111 is controlled to weld the slit along the movement locus. In an alternative embodiment, the control device 130 may control the welding robot 110 and the scanning device 120 to move along the length direction of the corrugated board, so as to complete the scanning step S1. Immediately thereafter, a planning step S2 is performed. The welding robot 110 is controlled to return to the gap starting point to start the welding step S3.
Preferably, in the case where the scanning device 120 is configured as a line laser sensor, the control device 130 can also control the scanning step S1, the planning step S2 and the welding step S3 to be performed simultaneously. For example, the control device 130 performs the processing calculation of the data while the scanning device 120 scans the profile data, and at the same time, controls the welding gun 111 to perform welding while planning the movement locus of the welding gun 111. Since the signal of the line laser has a certain length dimension, the slit profile can be captured at the same time as welding.
According to the guiding welding system 100 disclosed by the invention, when workpieces with steep slopes such as corrugated plates and the like are guided and welded, the gesture can be changed in the process of scanning the profile, the influence caused by a steep slope blind area can be effectively avoided, and further, complete welding seam characteristic data can be acquired, so that the welding precision and quality are improved.
The processes, steps described in all the preferred embodiments described above are examples only. Unless adverse effects occur, various processing operations may be performed in an order different from that of the above-described flow. The step sequence of the above-mentioned flow can also be added, combined or deleted according to the actual requirement.
Unless defined otherwise, technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention pertains. The terminology used herein is for the purpose of describing particular implementations only and is not intended to be limiting of the invention. Features described herein in one embodiment may be applied to another embodiment alone or in combination with other features unless the features are not applicable or otherwise indicated in the other embodiment.
The present invention has been illustrated by the above-described embodiments, but it should be understood that the above-described embodiments are for purposes of illustration and description only and are not intended to limit the invention to the embodiments described. In addition, it will be understood by those skilled in the art that the present invention is not limited to the embodiments described above, and that many variations and modifications are possible in light of the teachings of the invention, which variations and modifications are within the scope of the invention as claimed. The scope of the invention is defined by the appended claims and equivalents thereof.
Claims (9)
1. A pilot welding system for welding corrugated board, comprising:
a welding robot having a tip configured to be movable in an extending direction of a slit to be welded, the tip being provided with a welding gun;
the scanning device is arranged at the tail end of the welding robot;
a control device in signal connection with the scanning device and the welding robot, the control device configured to perform the steps of:
scanning, namely acquiring profile data of a gap to be welded, wherein the length direction of a corrugated plate is defined as an x axis, the width direction of the corrugated plate is defined as a z axis, the corrugated depth direction of the corrugated plate is defined as a y axis, starting points of the gap are used as origins, three-dimensional space coordinate data of the x axis, the y axis and the z axis of a profile point of the gap are acquired every preset distance, fitting is carried out by the data of the x axis and the y axis of the profile point, the homodromous change value of a fitting straight line slope between two continuous points is calculated,
a planning step of planning a movement track of the welding gun according to the contour data, determining a corner starting point and a corner ending point of a corrugated corner of the contour of the gap, planning a posture changing action for the welding gun between the corner starting point and the corner ending point,
wherein when the value of the change in the same direction of at least two consecutive points exceeds a first threshold, determining that a first point of the at least two consecutive points is the corner starting point of the corner,
after the corner start point, determining that a first point of the consecutive at least two sets of the two consecutive points is the corner end point of the corner when the value of the change in the same direction of the consecutive at least two sets of the two consecutive points is less than a second threshold value,
and a welding step, controlling the welding gun to weld the gap along the motion trail.
2. The guidance welding system of claim 1, wherein the fit line slope is fit using more than 5 consecutive points on the profile including points to be fit.
3. The guidance welding system of claim 1, wherein the gesture altering action comprises a rotational action, an angular velocity of rotation being positively correlated with a change in slope of the fitted line.
4. The guided welding system of claim 1, wherein the act of altering the pose is configured to cause the welding gun to be perpendicular to the gap.
5. The guided welding system of claim 1, wherein the scanning step further comprises:
when the absolute value of the difference in y-axis data between two consecutive points is greater than the third threshold, and/or when the absolute value of the difference in z-axis data between two consecutive points is greater than the fourth threshold,
confirming the latter point as an invalid point and excluding the invalid point.
6. The guided welding system of claim 5, wherein the scanning step further comprises:
and performing space fitting according to three continuous points before the invalid point to obtain theoretical data at the invalid point, and replacing the invalid data with the theoretical data.
7. The guidance welding system of any of claims 1-6, wherein the predetermined distance is 0.1-2 mm.
8. The guided welding system of any of claims 1-6, wherein the scanning device comprises a line laser sensor.
9. The guidance welding system of any of claims 1-6,
the control device controls the scanning step, the planning step and the welding step to be synchronously performed; or alternatively
And after the scanning step and the planning step are controlled by the control device, controlling the welding robot to execute the welding step.
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| CN202111295973.9A CN113909765B (en) | 2021-11-03 | 2021-11-03 | Guiding welding system |
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| CN202111295973.9A CN113909765B (en) | 2021-11-03 | 2021-11-03 | Guiding welding system |
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| CN114669831B (en) * | 2022-05-11 | 2024-04-26 | 法孚低温设备(苏州)有限公司 | Automatic welding system and method applied to plate-fin heat exchanger |
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