CN114309930B - Symmetrical double-station spray pipe laser welding equipment - Google Patents
Symmetrical double-station spray pipe laser welding equipment Download PDFInfo
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Abstract
The invention discloses symmetrical double-station spray pipe laser welding equipment, which belongs to the technical field of non-standard equipment and process equipment development, and comprises the following steps: the device comprises a first six-axis industrial robot, a second six-axis industrial robot, a first lifting assembly, a second lifting assembly, a first sliding assembly, a second sliding assembly, a turntable, a switching disc, a spray pipe welding mould, a spray pipe, a first laser welding head, a second laser welding head, a robot control system, a first laser, a second laser, a first water chiller, a second water chiller and a PLC main control system. The invention improves the welding quality and the production efficiency.
Description
Technical Field
The invention belongs to the technical field of non-standard equipment and process equipment development, and particularly relates to symmetrical double-station spray pipe laser welding equipment.
Background
The jet pipe extension section of the space engine is an important component of a thrust chamber, adopts a spiral tube bundle structure, is formed by welding hundreds of space spiral curve square tubes, and has an overall appearance of bell-shaped outlines with two unequal diameters. After the tube bundle spray tube is tightly assembled on the die, the penetration depth and the consistency of the kilometer-level welding seam are required to be ensured, and the welding quality is required to be stable and reliable.
In the past, automatic argon arc welding of the spray pipe has only one station, and the welding efficiency of the spray pipe is lower due to the limitation of the welding speed.
Disclosure of Invention
The invention solves the technical problems that: overcomes the defects of the prior art, provides symmetrical double-station spray pipe laser welding equipment, and improves welding quality and production efficiency.
The invention aims at realizing the following technical scheme: a symmetrical double-station nozzle laser welding apparatus, comprising: the device comprises a first six-axis industrial robot, a second six-axis industrial robot, a first lifting assembly, a second lifting assembly, a first sliding assembly, a second sliding assembly, a turntable, a transfer disc, a spray pipe welding mould, a spray pipe, a first laser welding head, a second laser welding head, a robot control system, a first laser, a second laser, a first water chiller, a second water chiller and a PLC main control system; one end of the first six-axis industrial robot is connected with the first laser welding head, the other end of the first six-axis industrial robot is connected with the first lifting assembly, and the first lifting assembly is arranged on the first sliding assembly; one end of a second six-axis industrial robot is connected with the second laser welding head, the other end of the second six-axis industrial robot is connected with a second lifting assembly, and the second lifting assembly is arranged on the second sliding assembly; the spray pipe is sleeved on the outer surface of the spray pipe welding mould, the spray pipe welding mould is connected with the upper end of the switching disc, and the lower end of the switching disc is connected with the rotary table; the first laser is connected with the first laser welding head through an optical fiber, and the second laser is connected with the second laser welding head through an optical fiber; the first water chiller is connected with the first laser, and the second water chiller is connected with the second laser; the robot control system is connected with the PLC main control system; the PLC main control system is communicated with the robot control system, and the PLC main control system sends welding start instructions to the first laser and the second laser through the IO bus.
Among the above-mentioned symmetry duplex position spray tube laser welding equipment, the structure of first laser welding head and second laser welding head is the same, all includes: the device comprises a laser welding head main body, a tracking sensor, a multi-degree-of-freedom adjusting and installing tool, a video monitoring head, a tracking sensor cooling port and a shielding plate; the laser welding head main body is connected with the six-axis industrial robot; the video monitoring head is arranged on one side of the laser welding head main body; the tracking sensor is connected with the laser welding head main body through a multi-degree-of-freedom adjusting and installing tool; the tracking sensor cooling port is arranged on the tracking sensor; the shielding plate is arranged at the lower part of the light outlet of the laser welding head main body.
In the symmetrical double-station spray pipe laser welding equipment, a laser welding track planning method is designed according to the tracking sensor and the laser welding head main body.
In the symmetrical double-station spray pipe laser welding equipment, the laser welding track planning method designed according to the tracking sensor and the laser welding head main body comprises the following steps: step one: connecting the tracking sensor with the laser welding head main body through a connecting tool; step two: a ten-point calibration method is adopted to establish the relative position relation between the tracking sensor and the laser welding head main body; step three: performing plane calibration of the focal distance of the laser welding head main body; step four: adjusting the posture of the laser welding head main body by adopting a two-to-one vertical alignment method; step five: completing the alignment of the focal distance of the laser head aiming at the space curve according to the plane calibration result of the focal distance of the laser welding head main body in the third step; step six: adjusting a tracking field of view of the tracking sensor; step seven: four teaching points of the space curve track of the welding line of the spray pipe are found out, the four teaching points are input into a robot control system, and the robot control system controls the six-axis industrial robot to move according to the four teaching points.
In the symmetrical double-station spray pipe laser welding equipment, in the first step, the height of the tracking sensor is adjusted so that the position of the tracking scanning line is positioned at the position of the maximum resolution of the tracking sensor;
the distance between the bottom of the tracking sensor and the surface of the spray pipe workpiece is 100-110 mm; the angle between the tracking sensor and the laser welding head main body is 12-15 degrees; the forward looking distance of the tracking sensor is 12-15 mm.
In the symmetrical double-station spray pipe laser welding equipment, in the second step, the method for establishing the relative position relationship between the tracking sensor and the laser welding head main body by using a ten-point calibration method comprises the following steps: preparing two upper plates and lower plates with the thickness of 2mm, overlapping the upper plates and the lower plates together to form an overlap joint, irradiating a tracking scanning line on the overlap joint, and making two marking points A and B on the overlap joint, wherein the distance between the two marking points is more than 300mm; calibrating one point and two points of the main body of the laser welding head: adjusting the posture of the laser welding head main body, enabling a tracking scanning line to vertically irradiate on the lap joint, keeping the posture, and enabling a robot to point to align a TCP point and an A point of the laser welding head main body to obtain one point of the laser welding head main body, and enabling a TCP point and a B point of the laser welding head main body to align to obtain two points of the laser welding head main body; performing three-point and four-point calibration of the laser welding head main body: respectively aligning the middle part of the tracking scanning line with the reference point A, B in the direction of moving X, Y, Z under the robot world coordinate system to obtain three points and four points of the laser welding head main body; performing five-point and six-point calibration of the laser welding head main body: rotating 15 degrees along the Z direction under a robot world coordinate system, and moving X, Y, Z to align the middle part of a tracking scanning line with a reference point A to obtain five points of a laser welding head main body; the rotation of the laser welding head body in the Z direction is kept unchanged by 15 degrees, the laser welding head body is moved, and the middle part of the tracking scanning line is aligned with the reference point B to obtain six points of the laser welding head body; performing seven-point and eight-point calibration of the laser welding head main body: forward rotating 15 degrees along the Y direction under a robot world coordinate system, and moving X, Y, Z to align the middle part of a tracking scanning line with the reference point A to obtain seven points of the laser welding head main body; the forward rotation of the laser welding head body along the Y direction is kept unchanged by 15 degrees, the laser welding head body is moved, and the middle part of the tracking scanning line is aligned with the reference point B to obtain eight points of the laser welding head body; calibrating nine points and ten points of the main body of the laser welding head: reversely rotating by 15 degrees along the Y direction under a robot world coordinate system, and moving X, Y, Z to align the middle part of a tracking scanning line with a reference point A to obtain nine points of a laser welding head main body; and (3) reversely rotating for 15 degrees along the Y direction, moving the laser welding head main body, and aligning the middle part of the tracking scanning line with the reference point B to obtain ten points of the laser welding head main body.
In the above-mentioned symmetrical duplex position spray tube laser welding equipment, in step three, carry out the plane calibration of the focal distance of laser welding head main part and include the following step: a paraxial light projection device is arranged on one side of a laser welding head main body, the heights of a collecting mirror of the laser welding head main body and the surface of a spray pipe workpiece are adjusted to be the focal distance h of positive defocus required by tube bundle welding, a switch of the paraxial light projection device is turned on to project paraxial light, the projection angle beta of the paraxial light projection device is adjusted, and the superposition of the paraxial light falling on the workpiece and a laser indication light red point is the plane calibration of the focal distance of the laser welding head main body.
In the above symmetrical double-station nozzle laser welding equipment, in the fourth step, the method of adjusting the posture of the laser welding head main body by adopting a two-to-one vertical alignment method comprises the following steps: under the coordinate system of the robot tool, the laser welding head main body rotates around the X axis, and then the laser welding head main body rotates around the Y axis, so that the central axis of the laser welding head main body is perpendicular to the normal line of the current welding profile of the spray pipe product; the main body of the laser welding head rotates around the Z axis, so that a tracking scanning line emitted by the tracking sensor is in vertical relation with a tube bundle curve of the current spray tube; the X-axis of the robot tool coordinate system is adjusted, the laser indication red spot of the laser welding head main body falls on the welding line position to be welded and tracked currently, and the laser indication red spot is aligned at half position of the tracking scanning line.
In the above-mentioned symmetrical duplex position spray pipe laser welding equipment, in step five, according to the plane calibration result of the focal distance of the laser welding head main body of step three, finish the laser head focal distance alignment to the space curve, include the following steps: on the premise of ensuring that the relative position and projection angle beta of the paraxial light projection device and the laser welding head main body are unchanged, a switch of the paraxial light projection device is turned on to project paraxial light, and the Z axis of a robot tool coordinate system is adjusted to adjust the paraxial light falling on the curved surface of the spray pipe to be overlapped with laser indication red light so as to obtain the accurate focal distance of the laser head.
In the symmetrical double-station nozzle laser welding device, in the sixth step, adjusting the tracking view field of the tracking sensor comprises the following steps:
based on the width of 4mm of the single tube bundle, the transverse effective tracking view field range of the tracking sensor is adjusted to be-2-4 mm, and the effective tracking view field range of the tracking sensor in the height direction is adjusted to be 15.5-21.5 mm.
In the symmetrical double-station spray pipe laser welding equipment, in the seventh step, four teaching points are a P1 point, a P2 point, a P3 point and a P4 point respectively; the distance between the point P1 and the tail end of the front welding seam is 6-8 mm, the point P2 is at the tail end of the front welding seam, the point P3 is the laser starting light receiving point, and the point P4 is the point at which the laser power is attenuated to zero.
Compared with the prior art, the invention has the following beneficial effects:
(1) The invention provides tube bundle type spray pipe double-station laser welding equipment which has the advantages of high welding efficiency, good welding seam quality, high automation degree and strong practicability, and has wide application prospect;
(2) The invention realizes the motion execution function of seventeen shafts of the double-station laser welding equipment. The two six-axis industrial robots with lifting and sliding functions are respectively a group 1, a group 2 and a turntable which are respectively a group 3, and are called in programming, so that the coordinated movement of the double-station robots is completed, the synchronous operation is started, and the synchronous welding function under the respective tracking state can be realized. The double-station laser welding equipment can obviously improve the welding efficiency;
(3) The invention realizes the precise laser welding of the close-packed tube bundle type spray pipes under the condition of seam tracking and video monitoring. The spray pipe meets the requirements of the grade I welding seam, and the welding seam has smooth, centered and continuous appearance. And passed kerosene test, channel inspection, X-ray inspection, pressing test, etc.
(4) The invention can meet the precision butt welding of other large-size and complex structures, and the equipped weld tracking system can identify and track the weld, thereby improving the welding quality and the welding automation level and reducing the programming workload of operators.
Drawings
Various other advantages and benefits will become apparent to those of ordinary skill in the art upon reading the following detailed description of the preferred embodiments. The drawings are only for purposes of illustrating the preferred embodiments and are not to be construed as limiting the invention. Also, like reference numerals are used to designate like parts throughout the figures. In the drawings:
FIG. 1 is a schematic diagram of a dual station nozzle laser welding apparatus provided by an embodiment of the present invention;
FIG. 2 is a schematic view of a laser welding head according to an embodiment of the present invention;
fig. 3 is a diagram of connection and control circuits of each component of the dual-station laser welding apparatus according to the embodiment of the present invention.
FIG. 4 is a flow chart of a method for planning a laser welding track according to the design of the tracking sensor and the laser welding head main body according to the embodiment of the invention;
FIG. 5 is a schematic illustration of the installation of a tracking sensor with a laser welding head provided by an embodiment of the present invention;
FIG. 6 (a) is a schematic diagram of ten-point calibration of a tracking sensor provided by an embodiment of the present invention;
FIG. 6 (b) is another schematic diagram of ten-point calibration of a tracking sensor provided by an embodiment of the present invention;
FIG. 6 (c) is yet another schematic diagram of ten-point calibration of a tracking sensor provided by an embodiment of the present invention;
FIG. 6 (d) is yet another schematic diagram of ten-point calibration of a tracking sensor provided by an embodiment of the present invention;
FIG. 6 (e) is yet another schematic diagram of ten-point calibration of a tracking sensor provided by an embodiment of the present invention;
FIG. 7 (a) is a schematic diagram of a planar calibration of focal distance provided by an embodiment of the present invention;
FIG. 7 (b) is another schematic illustration of a planar calibration of focal distance provided by an embodiment of the present invention;
FIG. 7 (c) is a further schematic illustration of planar calibration of focal distance provided by an embodiment of the present invention;
fig. 8 is a schematic diagram of posture adjustment of a laser head according to an embodiment of the present invention;
FIG. 9 is a schematic diagram of laser head focal length alignment of a nozzle space curve provided by an embodiment of the present invention;
FIG. 10 is a schematic diagram of adjustment of tracking field of view provided by an embodiment of the present invention;
FIG. 11 is a schematic diagram of four-point programming of a space curve trace provided by an embodiment of the present invention.
Detailed Description
Exemplary embodiments of the present disclosure will be described in more detail below with reference to the accompanying drawings. While exemplary embodiments of the present disclosure are shown in the drawings, it should be understood that the present disclosure may be embodied in various forms and should not be limited to the embodiments set forth herein. Rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the disclosure to those skilled in the art. It should be noted that, without conflict, the embodiments of the present invention and features of the embodiments may be combined with each other. The invention will be described in detail below with reference to the drawings in connection with embodiments.
With the development of laser welding technology, laser welding is increasingly widely used. The laser focusing light spot is small, the heating speed is high, the acting time is short, the heat affected zone and the thermal deformation are small, and the welding method is particularly suitable for welding thin-wall spray pipe structural members with high requirements on deformation control. The welding quality of the product is improved, and meanwhile, the assembly adjustment time increased by shrinkage deformation in the welding production process can be reduced. The laser welding speed is high, and compared with the current argon arc welding speed of 3-4 mm/s, the laser welding speed can reach 10-15 mm/s, thereby being beneficial to improving the welding efficiency. The laser welding method is that the laser beam directly bombards the metal surface to generate heat effect, and has no welding defects of tungsten clamping, air holes and the like caused by the gun and arc breaking of argon arc welding. In view of the fact that the accumulated length of the close-packed weld joints of the tube bundle type spray tubes reaches the kilometer level, the double-station synchronous laser welding mode is adopted, and therefore the welding efficiency can be effectively improved.
The spray pipe adopts a vertical and vertical arrangement mode, and is convenient for realizing symmetrical double-station welding in space. In order to meet the requirement of spray pipe laser welding, double-station laser welding equipment suitable for closely-arranged tube bundle spray pipe precision welding needs to be developed.
Fig. 1 is a schematic diagram of a dual-station nozzle laser welding apparatus according to an embodiment of the present invention. As shown in fig. 1, the double-station nozzle laser welding apparatus includes: the first six-axis industrial robot 1, the second six-axis industrial robot 2, the first lifting assembly 3, the second lifting assembly 4, the first sliding assembly 5, the second sliding assembly 6, the turntable 7, the adapter plate 8, the nozzle welding jig 9, the nozzle 10, the first laser welding head 11, the second laser welding head 12, the robot control system 13, the first laser 14, the second laser 15, the first water chiller 16, the second water chiller 17 and the PLC main control system 18. Wherein,
One end of the first six-axis industrial robot 1 is connected with a first laser welding head 11, the other end of the first six-axis industrial robot 1 is connected with a first lifting assembly 3, and the first lifting assembly 3 is arranged on a first sliding assembly 5; one end of the second six-axis industrial robot 2 is connected with the second laser welding head 12, the other end of the second six-axis industrial robot 2 is connected with the second lifting assembly 4, and the second lifting assembly 4 is arranged on the second sliding assembly 6; the spray pipe 10 is sleeved on the outer surface of the spray pipe welding mould 9, the spray pipe welding mould 9 is connected with the upper end of the adapter plate 8, and the lower end of the adapter plate 8 is connected with the turntable 7; the first laser 14 is connected with the first laser welding head 11 through an optical fiber, and the second laser 15 is connected with the second laser welding head 12 through an optical fiber; the first water chiller 16 is connected with the first laser 14, and the second water chiller 17 is connected with the second laser 15; the robot control system 13 is connected with the PLC main control system 18; the PLC main control system 18 communicates with the robot control system 13, and the PLC main control system 18 issues a welding start instruction to the first laser 14 and the second laser 15 through the IO bus.
Fig. 2 is a schematic structural diagram of a laser welding head according to an embodiment of the present invention. As shown in fig. 2, the first laser welding head 11 and the second laser welding head 12 have the same structure, and each includes: the laser welding head comprises a laser welding head main body 11-1, a tracking sensor 11-2, a multi-degree-of-freedom adjusting and installing tool 11-3, a video monitoring head 11-4, a tracking sensor cooling port 11-5 and a shielding plate 11-6. Wherein,
The laser welding head main body 11-1 is connected with a six-axis industrial robot; the video monitoring head 11-4 is arranged on one side of the laser welding head main body 11-1; the tracking sensor 11-2 is connected with the laser welding head main body 11-1 through the multi-degree-of-freedom adjusting and installing tool 11-3; the tracking sensor cooling port 11-5 is arranged on the tracking sensor 11-2; the shielding plate 11-6 is provided at the lower part of the light outlet port of the laser welding head main body 11-1.
The double robot configuration is to adopt two six-axis industrial robots with 50 kg load, and the bases of the two robots are respectively arranged on lifting components at two sides.
The rotary table performs rotary motion, the spray pipe welding mould and the switching disc are arranged on the rotary table, and the rotary table drives the welding mould to perform rotary motion. The turntable comprises a servo motor and a speed reducer. In the spray pipe laser welding process, each time a sectional welding line is welded, the turntable rotates according to the indexing angle to the initial position of the next welding line, and the robot executes a track program to continue the welding of the next welding line.
The robot sliding component is a screw rod sliding rail, and the lifting component is arranged on the screw rod sliding rail. The effective lifting height of the robot lifting assembly is 2.5m, and the effective distance of the sliding rail of the horizontal sliding assembly is 3.0m. The screw slide rails are arranged in two groups, are symmetrically placed at left and right, are arranged in a superposition mode, and pass through the rotating center shaft of the turntable.
The six-axis industrial robot, the turntable, the lifting assembly and the sliding assembly are collectively referred to as a motion actuator.
The welder includes a laser and a laser welding head. The power of the laser is 1KW. The laser welding head is a modularized welding combination head, the collimation focal length is 125mm, the focusing focal length is 300mm, and the spot diameter is 0.48mm. The laser welding heads are respectively arranged at the execution ends of the six-axis industrial robot.
The weld joint tracking system is adapted to the FANUC robot double-machine system, the depth of field range is 16mm, the field range is +/-3 mm when the welding joint tracking system is at the nominal installation height, the horizontal measurement precision of weld joint identification is +/-0.05 mm, the vertical measurement precision of weld joint identification is +/-0.05 mm, and the weld joint tracking precision is 0.1mm. The weld joint tracking system comprises a laser scanning tracking sensor and a tracking interface box. The tracking sensor is connected with the laser welding head, and the tracking interface box is connected with the robot control cabinet.
The CCD video monitoring system is arranged on the laser welding head for observing the molten pool and the weld joint formation.
The motion executing mechanism comprises two groups of six-axis industrial robots, a lifting assembly and a sliding assembly which are symmetrically arranged. The sliding component comprises two groups of sliding rails. The lifting component is arranged on the sliding rail and slides on the sliding rail, and can lift up and down. The six-axis industrial robot is fixed at a proper position of the lifting assembly, can move up and down along with the lifting assembly, and can move on the sliding rail along with the lifting assembly. The six-axis industrial robot has higher degree of freedom and can realize movement in a larger range and various postures.
The lifting component adopts a lifting structure commonly used in the field, and the effective lifting height of the lifting component is 0.5-2.5m. The horizontal sliding component adopts two groups of screw rod sliding rail structures, is placed at bilateral symmetry positions, is arranged at the central line position in a superposition mode, and the central line of the sliding rail passes through the rotating central shaft of the turntable. The sliding rail with high bearing model is selected, so that no shaking can be ensured in moving and working, the stability of a laser welding head during welding is ensured, and the maximum effective distance of the sliding rail moving forwards and backwards is particularly preferably 0.5-3m.
The loading platform comprises a servo motor and a speed reducer, the servo motor drives the speed reducer, and the turntable is driven to rotate through a gapless gear transmission technology. The turntable can perform infinite rotation movement without limiting the number of revolution. The maximum bearing load is 5 tons, and the rotation positioning precision is +/-0.03 degrees.
The spray pipe (product) is assembled on the spray pipe welding mould, and a turntable is adopted to connect the welding mould base with the turntable. The turntable is connected with the adapter plate, the adapter plate is connected with the welding mould base, a clearance fit mode of a central shaft and a central hole H7/g6 is adopted, and screws uniformly distributed in the circumferential direction are screwed after the central positioning.
As shown in the enlarged view of fig. 2, a laser welding head integrated with a tracking sensor, a video monitoring head, and the like is mounted at the execution end of the six-axis industrial robot. The multi-degree-of-freedom adjusting and installing tool is adopted to connect the tracking sensor with the laser welding head, and the tracking sensor is subjected to multi-dimensional adjustment in the vertical direction, the front-back direction and the inclination angle relative to the laser welding head through tool adjustment so as to determine the optimal installing position and meet the requirements of the weld joint on tracking the front viewing distance and the tracking view field. The tracking sensor is externally connected with gas cooling and is connected with a gas circuit through a cooling port. The video monitoring head is arranged on one side of the laser welding head, the interface is an HDMI high-definition multimedia interface, and the molten pool and the welding seam can be observed in real time through the video display to form. The shielding plate is arranged on the side surface of the tracking sensor, which is close to the laser welding head, shields the laser reflected light 11-7, prevents the reflected light of the laser from entering the window of the tracking sensor, and avoids the interference on the weld tracking.
As shown in the connection and control circuit diagram of the components of the double-station laser welding equipment in fig. 3, a laser communication line is adopted to connect the weld tracking sensor with the tracking interface box. The industrial network exchanger is respectively connected with the tracking interface box, the robot control cabinet of the double-machine system, the tracking state display computer and the like by adopting network cables, so that the communication between the weld tracking and the robot is realized. The network cable connected to the robot control cabinet needs to be connected to a designated interface and port. The tracking interface box needs to be powered by a 24V power supply using a cable connector.
The PLC main control system is communicated with the robot control system through an IO input/output bus, the CCD video monitoring system is connected with the PLC main control system through a video monitoring line, the main control cabinet is provided with an operation table top, and the video display is arranged on the operation table top and can perform key operations such as laser light emission, scram and the like and weld pool and weld joint forming observation during welding. The PLC main control system is communicated with the robot control system, a Weldstart welding start instruction is issued to the laser through the IO bus, and the laser outputs laser to the laser welding head by adopting an optical fiber with the length of 15 m. The laser welding head is externally connected with high-pressure air and welding protective gas except for being connected with a tracking sensor and a video monitoring head. The water supply of the chiller system is divided into two paths, so that the water cooling of an external light path of the fiber laser welding system and the laser is realized respectively.
The working principle of the symmetrical double-station spray pipe laser welding equipment provided by the invention is as follows:
the PLC main control system is communicated with the robot control system, after a Weldstart welding start instruction is given to the robot and the laser, the symmetrically distributed robots on two sides drive the laser welding heads to synchronously start welding under advancing according to a track program, and the posture of the laser welding heads is always kept perpendicular to the normal direction of the track path of the current space curved surface. The weld joint tracking sensor detects track deviation values in two directions of horizontal displacement and vertical displacement in real time, and transmits the track deviation values to the robot control system, and the track deviation correction is completed by the robot motion executing mechanism. The staff carries out molten pool and weld forming observation through a CCD video monitoring display before the operation platform of the main control cabinet. In the spray pipe laser welding process, after each welding of symmetrical double stations completes one section welding seam, the laser welding head is lifted, the rotary table rotates according to the indexing angle to the starting position of the next welding seam, and the double station robot executes a track program to continue to weld the next welding seam synchronously. The spray pipe welding is carried out from the large end to the small end, after each circle of sectional welding, when the welding position is close to the limit of the preferred path range of the robot, the sliding component moves towards the direction close to the turntable, the lifting component moves upwards, the motion path range of the robot reaches the preferred state again, and the welding is continued after the re-track programming.
FIG. 4 is a flow chart of a method for planning a laser welding track according to the design of the tracking sensor and the laser welding head main body according to the embodiment of the invention; as shown in fig. 4, the method comprises the steps of:
step one: connecting the tracking sensor with a laser welding head through a connecting tool;
step two: a ten-point calibration method is adopted to establish the relative position relation between the tracking sensor and the laser welding head;
step three: performing plane calibration of the focal distance of the laser welding head;
step four: adjusting the posture of the laser welding head by adopting a two-to-one vertical alignment method;
step five: completing the alignment of the focal distance of the laser head aiming at the space curve according to the plane calibration result of the focal distance of the laser welding head in the third step;
step six: adjusting a tracking field of view of the tracking sensor;
step seven: four teaching points of the space curve track of the welding line of the spray pipe are found out, the four teaching points are input into a robot control system, and the robot control system controls the six-axis industrial robot to move according to the four teaching points.
1. Tracking sensor and laser welding head installation
As shown in fig. 5, the tracking sensor is installed beside the laser welding head through a connection tool, and the connection tool has functions of height direction adjustment, front-rear direction adjustment, angle adjustment and the like.
The tracking scanning line is a laser stripe projected on the workpiece by the tracking sensor, and the position of the scanning line determines the current area for carrying out welding track identification and track accuracy inspection on the workpiece.
First, the height of the tracking sensor is adjusted, and the position of the tracking scanning line is located near the maximum resolution position of the tracking sensor by adjusting the mounting height of the sensor. The distance between the bottom of the tracking sensor and the surface of the workpiece is 100-110 mm after the installation of the optimal focusing position of the laser welding head during welding of the thin-wall tube bundle.
The installation angle of the tracking sensor needs to be adjusted according to the reflection condition of the surface of the workpiece, and the more serious the reflection condition of the surface of the workpiece is, the larger the installation angle is, and if the workpiece is not reflected, the installation angle of the tracking sensor can be zero degrees. The surface of the tube bundle material has brighter metallic luster and serious light reflection, the angle between the tracking sensor and the laser welding head is adjusted through the connecting tool, and the tube bundle material has the best use effect within the range of 12-15 degrees.
The distance between the tracking scanning line projected by the tracking sensor and the indicating light red point projected by the laser head is the forward looking distance, and the distance represents the advance of the tracking scanning position earlier than the current welding position. On the premise of meeting the requirement of no interference in installation, the front view distance should be shortened as much as possible. The front-rear direction is adjusted through the connecting tool, and the front viewing distance can meet the tracking and welding requirements within the range of 12-15 mm.
2. Ten-point calibration of tracking sensor
And a ten-point calibration method is adopted to establish the relative position relation between the tracking sensor and the laser welding head.
Calibrating:
before the ten-point method is adopted for calibration, two upper plate and lower plate flat workpieces with the thickness of about 2mm are prepared, the upper plate and the lower plate are lapped together to form a lap joint, and a tracking scanning line is irradiated on the lap joint, so that the effective identification can be realized. Two marking points A and B are made on the lap joint, and the distance between the marking points is more than 300 mm.
As shown in fig. 6 (a), the laser welding head was calibrated at one or two points. And adjusting the posture of the laser welding head, enabling the tracking scanning line to vertically irradiate on the lap joint, keeping the posture, pointing the robot, enabling the TCP point and the A, B point of the laser welding head to be aligned to obtain one point and two points of the laser welding head, and recording the two points in the robot control box. The TCP point is the origin of coordinates of the robot in the tool coordinate system, and is generally at the center of the flange plane of the sixth axis of the robot.
As shown in fig. 6 (b), three-point calibration and four-point calibration are performed. And respectively aligning the middle part of the tracking scanning line with the reference point A, B in the direction of movement X, Y, Z under the robot world coordinate system to obtain three points and four points of the laser welding head, and recording the two points.
As shown in FIG. 6 (c), five and six calibration points were performed. And rotating 15 degrees along the Z direction under the 'world' coordinate system of the robot, moving X, Y, Z to align the middle part of the tracking scanning line with the reference point A to obtain five points of the laser welding head, and recording the positions. And (3) keeping the rotation of the laser welding head along the Z direction for 15 degrees unchanged, moving the laser welding head, aligning the middle part of the tracking scanning line with the reference point B to obtain six points of the laser welding head, and recording the positions.
As shown in FIG. 6 (d), calibration was performed at seven or eight points. The laser welding head was rotated forward 15 ° in the Y direction under the robot "world" coordinate system (with the laser welding head TCP pointing toward the upper plate) and moved X, Y, Z to align the middle of the tracking scan line to reference point a to obtain seven points of the laser welding head, which were recorded. And (3) keeping forward rotation by 15 degrees along the Y direction, moving the laser welding head, aligning the middle part of the tracking scanning line with the reference point B to obtain eight points of the laser welding head, and recording the positions.
As shown in fig. 6 (e), calibration at nine and ten points is performed. The laser welding head was rotated 15 ° in the reverse direction in the Y direction (with the laser welding head TCP pointing towards the lower plate) under the robot "world" coordinate system and the nine points of the laser welding head were obtained by aligning the middle of the tracking scan line to reference point a in the direction of movement X, Y, Z, and the positions were recorded. And (3) reversely rotating the laser welding head by 15 degrees along the Y direction, moving the laser welding head, aligning the middle part of the tracking scanning line with the reference point B to obtain ten points of the laser welding head, and recording the positions.
3. Plane calibration of focal distance of laser welding head
A paraxial light projection device is installed on one side of the laser welding head. As shown in fig. 7 (a), the height of the focusing mirror of the laser welding head and the surface of the workpiece of the nozzle are adjusted to a focal distance h of positive defocus required by tube bundle welding, and on the premise of accurate focal distance, a switch of the paraxial light projection device is turned on to project paraxial light, and the projection angle β of the paraxial light projection device is adjusted to overlap the paraxial light falling on the workpiece with the laser indication light red point. Namely, the plane calibration of the focal distance of the laser welding head.
Keeping the projection angle β unchanged, as the value of h becomes smaller (the focal distance becomes smaller), as shown in fig. 7 (b); or becomes larger (the focal distance is larger), as in fig. 7 (c), it is found that the paraxial ray falling on the workpiece and the laser pointer red point cannot coincide. By observing the coincidence, it is verified whether the focal distance h is accurate.
4. Laser welding head attitude adjustment for space curves
And the posture of the laser head is adjusted by adopting a method of 'two-vertical one-alignment'. As shown in fig. 8, under the robot "tool" coordinate system, the laser welding head rotates around the X axis, and then the laser welding head rotates around the Y axis, and in the process, the right angle ruler and the angle measuring tool are used for checking, so that the central axis of the laser welding head is perpendicular to the normal line of the current welding profile of the spray pipe product, and the angle alpha of the laser head in fig. 6 is consistent with the tangential angle alpha of the current profile of the spray pipe.
The laser welding head rotates around the Z axis, so that the tracking scanning line emitted by the tracking sensor is in vertical relation with the tube bundle curve of the current spray tube.
The X-axis of the robot 'tool' coordinate system is adjusted, the laser indication red spot of the laser welding head falls on the welding seam position to be welded and tracked currently, and the laser indication red spot is aligned at half position of the tracking scanning line (the full length L of the tracking scanning line and L/2 at half position).
5. Completing laser head focal distance alignment aiming at space curve according to plane calibration result of focal distance of laser welding head
In order to obtain a stable and reliable welding process, it is necessary to ensure that the laser welding head focal distance (i.e., the Z value shown in fig. 9) is accurate. Because the current welding surface of the spray pipe is a curved surface, the Z value shown in fig. 9 is inconvenient and has errors by directly measuring the Z value on the curved surface, and the laser head focal distance alignment is performed by adopting a projection overlapping method under a constant height.
On the premise of ensuring that the relative positions and projection angles beta of the paraxial light projection device and the laser welding head are unchanged, a switch of the paraxial light projection device is turned on to project paraxial light, and the Z axis of a robot 'tool' coordinate system is adjusted to adjust the paraxial light falling on the curved surface of the spray pipe to be overlapped with laser indication red light so as to obtain the accurate focal distance of the laser head.
The focal distance of the laser welding head at this time is adjusted to be identical to the h value in fig. 6 (a), that is, the exact focal distance of the laser head.
6. Tracking field of view adjustment of tracking sensor
The target weld joint is moved to the center of the tracking view field through track teaching, a left boundary and a right boundary are determined according to the position coordinates of the characteristic points of the weld joint of the spray pipe, and an effective view field range is reasonably regulated, so that a laser only processes the characteristic points in the range, even if the adjacent weld joint enters the view field due to the influence of a certain factor, the adjacent weld joint is not in the effective view field range, the adjacent weld joint is not processed, interference is not eliminated, and the processing speed is improved. As shown in fig. 10, the effective tracking field of view range of the tracking sensor in the transverse direction is adjusted to-2 to 4mm based on the width of the single tube bundle of 4mm, and the effective tracking field of view range of the tracking sensor in the height direction is adjusted to 15.5 to 21.5mm.
7. Four-point programming of space curve trajectories
Four teaching points of the space curve track of the welding line of the spray pipe are found out, the four teaching points are input into a robot control system, and the robot control system controls the six-axis industrial robot to move according to the four teaching points.
The distance between the point P1 and the tail end of the front welding line is 6-8 mm (approximately the laser light-emitting point position), the point P2 is at the tail end of the front welding line, the point P3 is the point where the laser starts to receive light, and the point P4 is the point where the laser power is attenuated to zero.
Aiming at the space curved surface subsection welding seam of the tube bundle, a four-point programming scheme is adopted. By means of the weld joint tracking system, teaching programming of the total 4-point positions of the P1 point and the P4 point can be simplified. As shown in fig. 11, the distance from the point P1 to the end of the preceding weld is about 6 to 8mm (approximately the laser spot-emitting position), the point P2 is approximately at the end of the preceding weld, the point P3 is the point where the laser starts to receive light, and the point P4 is the point where the laser power decays to zero. Taking P1 as an example, the specific method is to adjust the tail end gesture of the robot and advance, so that the tracking scanning line is positioned near the P1 point and is perpendicular to the curved surface track, observe the tracking display screen, adjust the height and the transverse directions, and respectively position the identified current joint at the middle position of the height range of the tracking view field and the middle position of the transverse range of the tracking view field, thus the P1 point obtained by programming. Compared with the teaching programming of the strictly visual centering seam, the track programming based on the seam tracking can shorten the track programming workload and fully utilize the tracking function.
8. Lap welding zone programming process
After traveling to P1 and P2 teaching points, the weld joint identification tracking function plays a role, the current tracking point PR3 is accurately identified, in order to ensure that a certain overlap welding area exists between the current segmented weld joint and the tail end of the previous circle of weld joint, the offset of the Y-direction (opposite to the advancing direction of the weld joint) is set for the PR3 point by about 10mm, then a laser emergent command is given, and the starting position of the laser emergent welding is ensured to be in the overlap welding area.
The invention realizes the connection of the sensing head of the tracking sensor and the laser welding head under the multidimensional adjustment, ensures that the tracking scanning line is near the position of maximum resolution and the distance between laser indicating light spots projected on the workpiece is proper, and establishes the relative position relationship between the tracking sensor and the laser welding head TCP by adopting a ten-point calibration method. The welding seam tracking view field is accurately set, and the risk of 'channeling' welding caused by tracking an adjacent welding seam as a target welding seam in the welding process is avoided.
The invention adopts a four-point programming method aiming at a space curve track, and realizes the welding process with stable laser head posture transition, constant laser focus position and identifiable and trackable track by adjusting the laser head posture and aligning the laser head focus distance and combining a weld joint tracking system.
The invention adopts the method of setting the forward offset, thereby conveniently and rapidly realizing that the current sectional welding line and the previous circle of welding line have a certain lap welding area, the laser light-emitting point is at the lap joint position, the current tracking scanning line falls in the unwelded joint area, the identification and the tracking can be carried out, and the tracking effect is not influenced by the lap welding area.
The invention provides tube bundle type spray pipe double-station laser welding equipment which is high in welding efficiency, good in welding quality, high in automation degree and strong in practicability. Under the condition of weld tracking and video monitoring, the precise laser welding of the close-packed tube bundle type spray pipes is realized. The double-station laser welding equipment can meet the precision butt welding of other large-size and complex structures, and has wide application prospect.
Although the present invention has been described in terms of the preferred embodiments, it is not intended to be limited to the embodiments, and any person skilled in the art can make any possible variations and modifications to the technical solution of the present invention by using the methods and technical matters disclosed above without departing from the spirit and scope of the present invention, so any simple modifications, equivalent variations and modifications to the embodiments described above according to the technical matters of the present invention are within the scope of the technical matters of the present invention.
Claims (10)
1. A symmetrical double-station nozzle laser welding apparatus, comprising: the device comprises a first six-axis industrial robot (1), a second six-axis industrial robot (2), a first lifting assembly (3), a second lifting assembly (4), a first sliding assembly (5), a second sliding assembly (6), a turntable (7), a switching disc (8), a spray pipe welding mould (9), a spray pipe (10), a first laser welding head (11), a second laser welding head (12), a robot control system (13), a first laser (14), a second laser (15), a first water chiller (16), a second water chiller (17) and a PLC main control system (18); wherein,
one end of a first six-axis industrial robot (1) is connected with a first laser welding head (11), the other end of the first six-axis industrial robot (1) is connected with a first lifting assembly (3), and the first lifting assembly (3) is arranged on a first sliding assembly (5);
one end of the second six-axis industrial robot (2) is connected with a second laser welding head (12), the other end of the second six-axis industrial robot (2) is connected with a second lifting assembly (4), and the second lifting assembly (4) is arranged on a second sliding assembly (6);
the spray pipe (10) is sleeved on the outer surface of the spray pipe welding mould (9), the spray pipe welding mould (9) is connected with the upper end of the switching disc (8), and the lower end of the switching disc (8) is connected with the rotary table (7);
The first laser (14) is connected with the first laser welding head (11) through an optical fiber, and the second laser (15) is connected with the second laser welding head (12) through an optical fiber;
the first water chiller (16) is connected with the first laser (14), and the second water chiller (17) is connected with the second laser (15);
the robot control system (13) is connected with the PLC main control system (18);
the PLC main control system (18) is communicated with the robot control system (13), and the PLC main control system (18) sends welding start instructions to the first laser (14) and the second laser (15) through the IO bus.
2. The symmetrical duplex position nozzle laser welding apparatus of claim 1, wherein: the first laser welding head (11) and the second laser welding head (12) have the same structure and both comprise: the laser welding head comprises a laser welding head main body (11-1), a tracking sensor (11-2), a multi-degree-of-freedom adjusting and installing tool (11-3), a video monitoring head (11-4), a tracking sensor cooling port (11-5) and a shielding plate (11-6); wherein,
the laser welding head main body (11-1) is connected with the six-axis industrial robot;
the video monitoring head (11-4) is arranged at one side of the laser welding head main body (11-1);
the tracking sensor (11-2) is connected with the laser welding head main body (11-1) through the multi-degree-of-freedom adjusting and installing tool (11-3);
The tracking sensor cooling port (11-5) is arranged on the tracking sensor (11-2);
the shielding plate (11-6) is arranged at the lower part of the light outlet of the laser welding head main body (11-1).
3. The symmetrical double-station nozzle laser welding equipment according to claim 2, wherein: a laser welding track planning method is designed according to the tracking sensor (11-2) and the laser welding head main body (11-1).
4. A symmetrical duplex position nozzle laser welding apparatus according to claim 3, wherein: the laser welding track planning method designed according to the tracking sensor (11-2) and the laser welding head main body (11-1) comprises the following steps:
step one: connecting the tracking sensor with the laser welding head main body through a connecting tool;
step two: a ten-point calibration method is adopted to establish the relative position relation between the tracking sensor and the laser welding head main body;
step three: performing plane calibration of the focal distance of the laser welding head main body;
step four: adjusting the posture of the laser welding head main body by adopting a two-to-one vertical alignment method;
step five: completing the alignment of the focal distance of the laser head aiming at the space curve according to the plane calibration result of the focal distance of the laser welding head main body in the third step;
Step six: adjusting a tracking field of view of the tracking sensor;
step seven: four teaching points of the space curve track of the welding line of the spray pipe are found out, the four teaching points are input into a robot control system, and the robot control system controls the six-axis industrial robot to move according to the four teaching points.
5. The symmetrical duplex position nozzle laser welding apparatus of claim 4, wherein: in the first step, the height of the tracking sensor is adjusted so that the position of the tracking scanning line is at the position of the maximum resolution of the tracking sensor;
the distance between the bottom of the tracking sensor and the surface of the spray pipe workpiece is 100-110 mm;
the angle between the tracking sensor and the laser welding head main body is 12-15 degrees;
the forward looking distance of the tracking sensor is 12-15 mm.
6. The symmetrical duplex position nozzle laser welding apparatus of claim 4, wherein: in the second step, the ten-point calibration method is used for establishing the relative position relationship between the tracking sensor and the laser welding head main body, and the method comprises the following steps:
preparing two upper plates and lower plates with the thickness of 2mm, overlapping the upper plates and the lower plates together to form an overlap joint, irradiating a tracking scanning line on the overlap joint, and making two marking points A and B on the overlap joint, wherein the distance between the two marking points is more than 300mm;
Calibrating one point and two points of the main body of the laser welding head: adjusting the posture of the laser welding head main body, enabling a tracking scanning line to vertically irradiate on the lap joint, keeping the posture, and enabling a robot to point to align a TCP point and an A point of the laser welding head main body to obtain one point of the laser welding head main body, and enabling a TCP point and a B point of the laser welding head main body to align to obtain two points of the laser welding head main body;
performing three-point and four-point calibration of the laser welding head main body: respectively aligning the middle part of the tracking scanning line with the reference point A, B in the direction of moving X, Y, Z under the robot world coordinate system to obtain three points and four points of the laser welding head main body;
performing five-point and six-point calibration of the laser welding head main body: rotating 15 degrees along the Z direction under a robot world coordinate system, and moving X, Y, Z to align the middle part of a tracking scanning line with a reference point A to obtain five points of a laser welding head main body; the rotation of the laser welding head body in the Z direction is kept unchanged by 15 degrees, the laser welding head body is moved, and the middle part of the tracking scanning line is aligned with the reference point B to obtain six points of the laser welding head body;
performing seven-point and eight-point calibration of the laser welding head main body: forward rotating 15 degrees along the Y direction under a robot world coordinate system, and moving X, Y, Z to align the middle part of a tracking scanning line with the reference point A to obtain seven points of the laser welding head main body; the forward rotation of the laser welding head body along the Y direction is kept unchanged by 15 degrees, the laser welding head body is moved, and the middle part of the tracking scanning line is aligned with the reference point B to obtain eight points of the laser welding head body;
Calibrating nine points and ten points of the main body of the laser welding head: reversely rotating by 15 degrees along the Y direction under a robot world coordinate system, and moving X, Y, Z to align the middle part of a tracking scanning line with a reference point A to obtain nine points of a laser welding head main body; and (3) reversely rotating for 15 degrees along the Y direction, moving the laser welding head main body, and aligning the middle part of the tracking scanning line with the reference point B to obtain ten points of the laser welding head main body.
7. The symmetrical duplex position nozzle laser welding apparatus of claim 4, wherein: in the third step, performing plane calibration of the focal distance of the laser welding head main body includes the following steps:
a paraxial light projection device is arranged on one side of a laser welding head main body, the heights of a collecting mirror of the laser welding head main body and the surface of a spray pipe workpiece are adjusted to be the focal distance h of positive defocus required by tube bundle welding, a switch of the paraxial light projection device is turned on to project paraxial light, the projection angle beta of the paraxial light projection device is adjusted, and the superposition of the paraxial light falling on the workpiece and a laser indication light red point is the plane calibration of the focal distance of the laser welding head main body.
8. The symmetrical duplex position nozzle laser welding apparatus of claim 4, wherein: in the fourth step, the method of adjusting the posture of the laser welding head main body by adopting the two-vertical one-alignment method comprises the following steps:
Under the coordinate system of the robot tool, the laser welding head main body rotates around the X axis, and then the laser welding head main body rotates around the Y axis, so that the central axis of the laser welding head main body is perpendicular to the normal line of the current welding profile of the spray pipe product;
the main body of the laser welding head rotates around the Z axis, so that a tracking scanning line emitted by the tracking sensor is in vertical relation with a tube bundle curve of the current spray tube;
the X-axis of the robot tool coordinate system is adjusted, the laser indication red spot of the laser welding head main body falls on the welding line position to be welded and tracked currently, and the laser indication red spot is aligned at half position of the tracking scanning line.
9. The symmetrical duplex position nozzle laser welding apparatus of claim 4, wherein: in the fifth step, completing the alignment of the focal distance of the laser head for the space curve according to the plane calibration result of the focal distance of the laser welding head main body in the third step comprises the following steps:
on the premise of ensuring that the relative position and projection angle beta of the paraxial light projection device and the laser welding head main body are unchanged, a switch of the paraxial light projection device is turned on to project paraxial light, and the Z axis of a robot tool coordinate system is adjusted to adjust the paraxial light falling on the curved surface of the spray pipe to be overlapped with laser indication red light so as to obtain the accurate focal distance of the laser head.
10. The symmetrical duplex position nozzle laser welding apparatus of claim 4, wherein: in step six, adjusting the tracking field of view of the tracking sensor includes the steps of:
based on the width of 4mm of the single tube bundle, the transverse effective tracking view field range of the tracking sensor is adjusted to be-2-4 mm, and the effective tracking view field range of the tracking sensor in the height direction is adjusted to be 15.5-21.5 mm.
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