CN115716175A - Equipment debugging method for one-to-many off-line programming of welding robot - Google Patents
Equipment debugging method for one-to-many off-line programming of welding robot Download PDFInfo
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Abstract
The invention discloses a device debugging method for one-to-many off-line programming of a welding robot, which comprises the following steps: building an offline model according to the designed three-dimensional model; measuring the position size and the relative position of the installed equipment according to the designed three-dimensional model; calibrating a TCP (transmission control protocol) of a six-axis robot body; adjusting a robot TCP with an external shaft; carrying out zero position calibration and stroke setting on the field equipment according to design requirements; establishing off-line points for the characteristic points of the welding tool clamp and the welding positioner by using the established off-line model, and measuring the welding tool clamp and the welding positioner; and analyzing error trends of multiple groups of same equipment according to the recorded data, adjusting the off-line model according to the average deviation value, and adjusting the mounting position of the positioner when the direction deviations of the test points at the same position of the multiple groups of welding positioners are different. The invention adopts a pair of multi-mode off-line programming, a plurality of workstations with the same structure and the same layout use the same off-line model, and the debugging efficiency is higher and the debugging cost is lower.
Description
Technical Field
The invention relates to the technical field of equipment debugging of welding robots, in particular to an equipment debugging method for one-to-many off-line programming of a welding robot.
Background
The welding robot is an industrial robot that performs welding including cutting and painting. An industrial robot is a versatile, reprogrammable, automatically controlled Manipulator (Manipulator) with three or more programmable axes for use in the field of industrial automation, according to the international organization for standardization (ISO) which is a definition of standard welding robots. To accommodate different applications, the mechanical interface of the last axis of the robot, usually a connecting flange, may be used to attach different tools or end effectors. The welding robot is used for assembling a welding clamp or a welding (cutting) gun on a tail shaft flange of an industrial robot so as to carry out welding, cutting or hot spraying.
The programming of the welding robot can be divided into two modes of teaching programming and off-line programming, wherein the teaching programming means that an operator controls the robot to move by using a teaching box, so that a welding gun reaches a position required by the completion of welding operation, the position and attitude data of each teaching point is recorded, and then the robot can complete the welding of the welding line in a 'reproducing' state. The off-line programming is to utilize the results of three-dimensional graphics, establish a model of the robot and its working environment in the professional software of the computer, control and operate the graphics through the software function, and transmit the final data program to the robot control system for direct use after the simulation operation of the computer.
The teaching programming is greatly influenced by the experience of programmers, the complex robot motion track is difficult to realize, the accurate result of a teaching point is difficult to guarantee for a complex path, the operation time of the robot needs to be occupied, and when a plurality of welding robots work simultaneously in one process, the problem of repeated programming of a plurality of devices also exists. The process of off-line programming generally includes: describing the operation tasks of the robot and the equipment, establishing a transformation equation, solving an unknown matrix, programming a task program and the like. After the graphic simulation is carried out, the program is properly corrected according to the result of the dynamic simulation, and finally the robot is controlled on line to move to finish the operation, so that the time for programming on the robot is saved.
At present, the off-line programming at home and abroad is basically only used for simulating the feasibility of the process or one-to-one simple application. The main bottleneck problems arise: it is difficult to achieve a soft environment for off-line programming consistent with multiple devices in the field. For example, the size of the soft environment used by offline programming is consistent with that of a three-dimensional or two-dimensional model of an engineer, but the actual installation situation of a welding platform, a welding positioner and a tool clamp is deviated from that of the three-dimensional or two-dimensional model of the engineer or the equipment positioning allowance is large due to large equipment foundation allowance, and the like, so that the robot program generated by offline programming software is greatly different from the actual situation. Therefore, the existing equipment installation and debugging can not realize the one-to-many use of the robot off-line program. And off-line programming is only suitable for production of various small batches one by one compared with one by one, and one by many is suitable for production of various large and small batches, and one by one is relatively higher in cost than one by many.
Disclosure of Invention
The technical problem to be solved by the invention is to provide an equipment debugging method for one-to-many off-line programming of a welding robot, which can realize one-to-many off-line programming of a plurality of welding robots with consistent models.
In order to solve the technical problems, the invention adopts the following technical scheme:
designing a device debugging method for one-to-many off-line programming of a welding robot, comprising the following steps:
s1, an off-line model is built according to a designed three-dimensional model, and the following conditions are met: (1) The relative position relation of the robot, the welding tool fixture and the welding positioner is made to be consistent with the design three-dimensional model; (2) The relative sizes of the robot, the welding tool clamp and the welding positioner are consistent with the designed three-dimensional model;
s2, measuring the position size and the relative position of the installed equipment according to the designed three-dimensional model;
s3, calibrating a six-axis robot body TCP (TCP for short) by using a 4-point method, a 6-point method or special equipment;
s4, adjusting a robot TCP with an external shaft, wherein the adjusting comprises the combined debugging of a mobile ground rail and a robot, and the combined debugging of the robot and the ground rail as well as the lifting and rotating external shaft;
s5, completing the combined debugging and robot installation adjustment in the step S4, and performing zero position calibration and stroke setting on the field equipment according to design requirements;
the positioner is turned to a position to be worked in the step S1, the plane point position is recorded by a robot, then the positioner is moved repeatedly to the position to be welded, the previous point position at the same position is recorded again, the comparison with the previous position data is carried out, and the repeated positioning precision of the positioner is tested and adjusted;
s6, using the off-line model built in the step S1 to create off-line points for the characteristic points of the welding tool fixture and the welding positioner, using the generated off-line points to measure the welding tool fixture and the welding positioner, and recording error values and positive and negative directions in X, Y and Z directions between the measuring points and the off-line points;
and S7, analyzing error trends of multiple groups of same equipment according to the data recorded in the step S6, if one point Z in four points of the horizontal positions of the multiple groups of welding positioner deviates uniformly downwards by 3mm and 6mm, adjusting the off-line model according to the deviation average value under the condition of not influencing other positions and motions of the positioner, and adjusting the installation position of the positioner when the direction deviations of the test points at the same positions of the multiple groups of welding positioner are different. And the one-to-many off-line model takes a plurality of groups of deviation average value adjustment models with the same structure and the same layout of workstations.
Preferably, the data measured in step S2 includes: the relative position of the robot ground rail and the welding positioner and the relative position of the welding tool clamp and the welding positioner body.
Preferably, the method for combined debugging of the mobile ground rail and the robot in the step S4 includes:
the robot stops at the 0 position of a ground rail, the robot operates a joint coordinate system, the J1 axis moves to plus or minus 20 degrees, the A and B positions of the plus or minus 20-degree points are recorded, and the HH distance between the plus or minus 20-degree points is measured; the ground rail 0-position adjusting robot reaches a point position of 20 degrees or-20 degrees, only the ground rail runs for the distance HH, whether the positions AA and BB of the TCP of the robot conform to the positions A and B of plus and minus 20 degrees is detected, and the step of accurately adjusting the rotating speed of the rotating shaft to be longer than that of the cantilever is carried out. Otherwise, correcting the installation position of the robot body according to the measurement data; the model can be manually adjusted in the off-line model to the same scene as the field test, so that the adjustment of the field equipment is conveniently judged.
Preferably, the method for debugging the robot in combination with the ground rail, the lifting and rotating external shaft in step S4 includes:
a. all external axes and body axis values of the robot return to zero;
b. placing a lifting shaft of the robot at a proper position, operating a joint coordinate system by a robot body, moving a J1 shaft by plus or minus 20 degrees, recording the positions of the plus or minus 20 degrees, returning the J1 shaft of the robot body to zero, rotating an external shaft by plus or minus 20 degrees, and detecting whether the TCP position of the robot corresponds to the positions of the plus or minus 20 degrees of the external shaft; the step of debugging the center line of the flange plate of the robot is coincided with the center line of the rotating shaft.
c. Placing a lifting shaft of the robot at a proper position, rotating an external shaft to return to zero, operating a joint coordinate system by a robot body, moving a J1 shaft to move by plus or minus 20 degrees, recording the point position of the plus or minus 20 degrees, measuring the distance HH between the plus or minus 20 degrees, returning the J1 shaft of the robot body to zero, only operating a ground rail by the distance HH, and detecting whether the TCP position of the robot conforms to the position of the plus or minus 20 degrees; the debugging robot is parallel to the position of the positioner in the step.
Measuring the distance, such as 1000mm, smaller than the travel range of the lifting shaft of the robot in the Z direction of the positioner, and then moving the 1000mm displayed by the lifting shaft robot under a joint coordinate system at the measured position to determine whether the distance is consistent with the measured 1000 mm. The step is to debug the speed ratio of the external lifting shaft of the robot.
Similarly, the distance which is smaller than the travel range of the ground rail of the robot is measured in the Y direction of the positioner, for example, 1000mm, and then the 1000mm displayed by the ground rail robot is moved under a joint coordinate system at the measured position, and whether the distance is consistent with the measured 1000mm is judged. The step is to accurately debug the external ground rail speed ratio of the robot.
d. The method comprises the following steps of placing a robot lifting shaft at a proper position, enabling a robot body to return to zero, rotating an external shaft to move by plus or minus 20 degrees, measuring the distance KK between the plus or minus 20 degrees, enabling the robot body to return to zero, rotating the external shaft to return to zero, only enabling a ground rail to run for the distance HH, and detecting whether the TCP position of the robot conforms to the plus or minus 20 degrees; the model can be manually adjusted in the offline model to the same scene as the field test, so that the adjustment of the field equipment is conveniently judged.
Preferably, the characteristic points in the step S6 are selected from points related to relative positions of the welding workpieces and points related to movement of the welding tool fixture and the welding positioner
Preferably, because the debugging error of the step S7 is 2mm, a robot selects the right-angle position of the workpiece to establish a workpiece coordinate system in offline programming, and welding is carried out based on the actual workpiece coordinate system when the error of the workpiece position occurs. The robot establishes a workpiece coordinate system for each workpiece independently, and performs a machining program after independently positioning each part with the same batch and the same structure.
Preferably, in the related equipment, the types of the multiple robots are consistent, the types of the welding guns are consistent, and the sizes and specifications of the welding tool clamp and the welding positioner are consistent.
The invention has the beneficial effects that:
the existing off-line programming is mostly one set of off-line model corresponding to one set of field equipment, and the off-line programming can reduce the risks of long production procedure, long production period and programming debugging brought by the field programming. In a scene of large-area application of the robot, a part of workstations with the same structural layout finish one process of batch workpieces, and the other part of workstations with the same structural layout finish the other process of batch workpieces. If an offline programming one-to-one mode is adopted, the same workstation needs to be modeled and programmed according to the installation sizes of different workstations during offline programming, and the field device adopts an offline program corresponding to a model; the workstation with the same structure and the same layout needs to establish a plurality of offline models 2 due to equipment manufacturing and installation errors and the like, the programs of the same process of the same batch of parts need to be repeatedly edited in the offline models, and the field equipment needs to be produced according to the programs edited by the corresponding models. The invention adopts a pair of multimode off-line programming, a plurality of workstations with the same structure and the same layout use the same off-line model, and the processing programs of the same workpiece and the same procedure can be used in the plurality of workstations only by editing once; an off-line model does not need to be established for each workstation, so that the debugging efficiency is higher and the debugging cost is lower.
Drawings
FIG. 1 is one of the schematic diagrams of the combined commissioning of a mobile ground rail and a robot;
FIG. 2 is a second schematic view of the combined debugging of the mobile ground rail and the robot;
FIG. 3 is one of the schematic diagrams of the combined commissioning of the robot with ground rail, lift, rotating external shaft;
FIG. 4 is a second schematic view of the robot in combination with the ground rail, lifting and rotating outer shaft;
FIG. 5 is a third schematic view of the combined adjustment of the robot with the ground rail, lifting and rotating external shaft;
FIG. 6 is a schematic view of a welding fixture and a weld positioner for selecting characteristic points;
the reference numbers in the figures: 1 is a welding robot; 2 is a movable ground rail; and 3, a rotating outer shaft.
Detailed Description
The following examples are given to illustrate specific embodiments of the present invention, but are not intended to limit the scope of the present invention in any way. The elements of the apparatus referred to in the following examples are conventional elements of the apparatus unless otherwise specified.
Example 1: a device commissioning method for one-to-many off-line programming of a welding robot, comprising the steps of:
s1, building an offline model according to a designed three-dimensional model, and meeting the following conditions: (1) The relative position relation of the robot, the welding tool fixture and the welding positioner is made to be consistent with the design three-dimensional model; (2) The relative sizes of the robot, the welding tool fixture and the welding positioner are in accordance with the designed three-dimensional model; among the related equipment, the models of a plurality of robots are consistent, the models of welding guns are consistent, and the sizes and the specifications of a welding tool clamp and a welding positioner are consistent.
S2, measuring the position size and the relative position of the installed equipment according to the designed three-dimensional model; the data measured in step S2 includes: the relative position of the robot ground rail and the welding positioner and the relative position of the welding tool clamp and the welding positioner body.
And S3, calibrating the TCP of the six-axis robot body by using a 4-point method, a 6-point method or special equipment (the six-axis robot has a function).
And S4, adjusting the TCP with the external shaft robot, wherein the TCP with the external shaft robot comprises the combined debugging of a movable ground rail and the robot, and the combined debugging of the robot and the ground rail as well as the lifting and rotating external shaft.
The combined debugging method of the mobile ground rail and the robot comprises the following steps:
the robot stops at the 0 position of the ground rail, the robot runs a joint coordinate system, the J1 axis moves to plus or minus 20 degrees, the A and B positions of the plus or minus 20-degree points are recorded, and the HH (see figure 1) distance between the plus or minus 20-degree points is measured; the ground rail 0-position adjusting robot reaches a point position of 20 degrees or minus 20 degrees, only the ground rail runs the HH distance, whether the positions AA and BB of the TCP of the robot accord with the positions A and B of plus and minus 20 degrees is detected (see figure 2), and if not, the installation position of the robot body is corrected according to the measured data; the model can be manually adjusted in the offline model to the same scene as the field test, so that the adjustment of the field equipment is conveniently judged.
The combined debugging method of the robot, a ground rail, a lifting external shaft and a rotating external shaft comprises the following steps:
a. all external axes and body axis values of the robot return to zero;
b. the lifting shaft of the robot is placed at a proper position, the robot body runs a joint coordinate system, the J1 shaft moves by plus or minus 20 degrees, the position of the plus or minus 20-degree point is recorded, the J1 shaft of the robot body is reset to zero, the external shaft rotates by plus or minus 20 degrees, and whether the TCP position of the robot corresponds to the position of the plus or minus 20 degrees of the external shaft is detected (see figure 3).
c. Placing a lifting shaft of the robot at a proper position, rotating an external shaft to zero, operating a joint coordinate system by a robot body, moving a J1 shaft to positive and negative 20 degrees, recording the point position of the positive and negative 20 degrees, measuring the HH distance between the positive and negative 20 degrees, zeroing the J1 shaft of the robot body, only operating the HH distance on a ground rail, and detecting whether the TCP position of the robot is consistent with the positive and negative 20 degrees (see figure 4);
measuring the distance, such as 1000mm, smaller than the travel range of the lifting shaft of the robot in the Z direction of the positioner, and then moving the 1000mm displayed by the lifting shaft robot under a joint coordinate system at the measured position to determine whether the distance is consistent with the measured 1000 mm.
Similarly, the distance which is smaller than the travel range of the ground rail of the robot is measured in the Y direction of the positioner, for example, 1000mm, and then the ground rail robot is moved to the measured position to display 1000mm under the joint coordinate system, and whether the distance is consistent with the measured 1000mm is judged.
d. The robot lifting shaft is placed at a proper position, the robot body returns to zero, the external shaft is rotated to move plus or minus 20 degrees, the distance KK between the plus or minus 20 degrees is measured, the robot body returns to zero, the external shaft is rotated to return to zero, only the ground rail runs for the distance HH, and whether the TCP position of the robot conforms to the plus or minus 20 degrees is detected (see figure 5). The model can be manually adjusted in the off-line model to the same scene as the field test, so that the adjustment of the field equipment is conveniently judged.
And S5, completing the combined debugging and robot installation adjustment in the step S4, and performing zero position calibration and stroke setting on the field equipment according to design requirements.
And (3) the positioner is turned to a position to be worked in the step S1, the plane point position is recorded by a robot, then the positioner is moved repeatedly to the position to be welded, the previous point position at the same position is recorded again, the comparison with the previous position data is carried out, and the repeated positioning precision of the positioner is tested and adjusted.
S6, using the off-line model built in the step S1 to create off-line points for the characteristic points of the welding tool clamp and the welding positioner, if the welding tool clamp and the welding positioner have multiple positions for welding, the characteristic point editing needs to be carried out on the positions of each welding tool clamp and the welding positioner, and the characteristic points select points related to the relative position of a welding workpiece and points related to the movement of the welding tool clamp and the welding positioner. Such as points 11, 12, 13, 14, 15, 16, 21, 22, 23, 24, 25, 26 associated with the relative positions of the weld workpieces, and points 31, 32, 33, 34, 41, 42, 43, 44 associated with the movement of the welding tooling fixture and the weld positioner, see fig. 6. Measuring the welding tool clamp and the welding positioner by using the generated off-line point, recording error values and positive and negative directions in X, Y and Z directions between the measuring point and the off-line point,
and S7, analyzing error trends of multiple groups of same equipment according to the data recorded in the step S6, if one point in four points of the horizontal positions of the multiple groups of welding position changing machines uniformly deviates downwards by 3mm and minus 6mm along the Z direction, adjusting the model by the off-line model according to the deviation average value under the condition of not influencing other positions and motions of the position changing machines, and adjusting the installation positions of the position changing machines when the direction deviations of the same test points of the multiple groups of welding position changing machines are different. And S7, debugging error is 2mm, the robot selects the right-angle position of the workpiece to establish a workpiece coordinate system in offline programming, and welding is carried out by taking the actual workpiece coordinate system as the standard when the position of the workpiece has error.
While the present invention has been described in detail with reference to the embodiments, those skilled in the art will appreciate that various changes can be made in the specific parameters of the embodiments without departing from the spirit of the present invention, and that various specific embodiments can be made, which are common variations of the present invention and will not be described in detail herein.
Claims (7)
1. A device debugging method for one-to-many off-line programming of a welding robot is characterized by comprising the following steps:
s1, an off-line model is built according to a designed three-dimensional model, and the following conditions are met: (1) The relative position relation of the robot, the welding tool clamp and the welding positioner is matched with the design three-dimensional model; (2) The relative sizes of the robot, the welding tool fixture and the welding positioner are in accordance with the designed three-dimensional model;
s2, measuring the position size and the relative position of the installed equipment according to the designed three-dimensional model;
s3, calibrating the TCP of the six-axis robot body by using a 4-point method, a 6-point method or special calibration equipment;
s4, adjusting a robot TCP with an external shaft, wherein the adjusting comprises the combined debugging of a mobile ground rail and a robot, and the combined debugging of the robot and the ground rail as well as the lifting and rotating external shaft;
s5, completing the combined debugging and robot installation adjustment in the step S4, and performing zero position calibration and stroke setting on the field equipment according to design requirements;
the positioner in the step S1 is turned to a position to be worked, the plane point position is recorded by a robot, then the positioner is repeatedly moved to the position to be welded, the same position point position before the position to be welded is recorded again, the same position point position before the position to be welded is compared with the position data before the position to be welded, and the repeated positioning precision of the positioner is tested and adjusted;
s6, using the off-line model built in the step S1 to create off-line points for the characteristic points of the welding tool fixture and the welding positioner, using the generated off-line points to measure the welding tool fixture and the welding positioner, and recording error values and positive and negative directions in X, Y and Z directions between the measuring points and the off-line points;
and S7, analyzing error trends of multiple groups of same equipment according to the data recorded in the step S6, if one point Z in four points of the horizontal positions of the multiple groups of welding positioner deviates uniformly downwards by 3mm and 6mm, adjusting the off-line model according to the deviation average value under the condition of not influencing other positions and motions of the positioner, and adjusting the installation position of the positioner when the direction deviations of the test points at the same positions of the multiple groups of welding positioner are different.
2. The device commissioning method for one-to-many offline programming of welding robots of claim wherein said data measured in step S2 comprises: the relative position of the robot ground rail and the welding positioner and the relative position of the welding tool clamp and the welding positioner body.
3. The device commissioning method for one-to-many off-line programming of welding robot of claim, wherein said combined commissioning method of mobile ground rail and robot in step S4 comprises:
the robot stops at the 0 position of a ground rail, the robot operates a joint coordinate system, the J1 axis moves to plus or minus 20 degrees, the A and B positions of the plus or minus 20-degree points are recorded, and the HH distance between the plus or minus 20-degree points is measured; the ground rail 0-position adjusting robot reaches 20-degree or-20-degree point positions, only the ground rail runs the HH distance, whether the positions AA and BB of the robots conform to the positive and negative 20-degree positions A and B or not is detected, and otherwise, the installation position of the robot body is corrected according to the measured data; the model can be manually adjusted in the offline model to the same scene as the field test, so that the adjustment of the field equipment is conveniently judged.
4. The device commissioning method for one-to-many off-line programming of welding robots of claim, wherein said combined commissioning method of robots with ground rail, lifting, rotating external axes in step S4 comprises:
a. all external axes and body axis values of the robot return to zero;
b. placing a lifting shaft of the robot at a proper position, operating a joint coordinate system by a robot body, moving a J1 shaft by plus or minus 20 degrees, recording the positions of the plus or minus 20 degrees, returning the J1 shaft of the robot body to zero, rotating an external shaft by plus or minus 20 degrees, and detecting whether the TCP position of the robot corresponds to the positions of the plus or minus 20 degrees of the external shaft;
c. placing a lifting shaft of the robot at a proper position, rotating an external shaft to zero, operating a joint coordinate system by a robot body, moving a J1 shaft to plus or minus 20 degrees, recording the positions of the plus or minus 20-degree points, measuring the HH distance between the plus or minus 20-degree points, zeroing the J1 shaft of the robot body, operating the ground rail only by the HH distance, and detecting whether the TCP position of the robot is consistent with the plus or minus 20-degree position;
d. placing a lifting shaft of the robot at a proper position, enabling a robot body to return to zero, rotating an external shaft to move by plus or minus 20 degrees, measuring a distance KK between two points of plus or minus 20 degrees, enabling the robot body to return to zero, enabling the external shaft to return to zero, only enabling a ground rail to run for a distance HH, and detecting whether the TCP position of the robot conforms to the plus or minus 20 degrees; the model can be manually adjusted in the offline model to the same scene as the field test, so that the adjustment of the field equipment is conveniently judged.
5. The device debugging method for one-to-many off-line programming of a welding robot as claimed in, wherein the characteristic points in step S6 are selected from points related to relative positions of welding workpieces, and points related to movement of a welding tool holder and a welding positioner.
6. The device debugging method for one-to-many off-line programming of welding robots of claim, wherein, because the debugging error of step S7 is 2mm, the robot selects the right-angled position of the workpiece to establish the coordinate system of the workpiece in the off-line programming, and when the position of the workpiece has an error, the welding is carried out based on the actual coordinate system of the workpiece.
7. The method for debugging one-to-many off-line programming equipment for a welding robot as claimed in, wherein in the related equipment, the types of a plurality of robots are consistent, the types of welding guns are consistent, and the sizes and specifications of a welding tool clamp and a welding positioner are consistent.
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