CN117600624B - Welding robot system special for diaphragm wall and diaphragm wall welding method - Google Patents
Welding robot system special for diaphragm wall and diaphragm wall welding method Download PDFInfo
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- CN117600624B CN117600624B CN202410075107.6A CN202410075107A CN117600624B CN 117600624 B CN117600624 B CN 117600624B CN 202410075107 A CN202410075107 A CN 202410075107A CN 117600624 B CN117600624 B CN 117600624B
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- 238000003466 welding Methods 0.000 title claims abstract description 610
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Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K9/00—Arc welding or cutting
- B23K9/24—Features related to electrodes
- B23K9/28—Supporting devices for electrodes
- B23K9/287—Supporting devices for electrode holders
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K9/00—Arc welding or cutting
- B23K9/32—Accessories
Abstract
The invention belongs to the technical field of welding, and relates to a special welding robot system for a membrane wall and a membrane wall welding method. The special welding robot system for the diaphragm wall comprises a welding master robot, a welding guarantee slave robot and a control unit; the welding main robot comprises a composite crawler shank, a foot-type robot, a welding gun pose control mechanism, a welding gun fixing seat and a welding gun; the composite crawler calf is characterized in that a transmission switching clutch device is further arranged in the composite crawler calf and is responsible for power transmission and switching, so that the gait mode and the crawler mode are switched. The invention adopts foot type driving and caterpillar driving, autonomously switches driving modes according to different terrains, has wide controllable range of the welding gun pose control mechanism, is suitable for film wall welding, meets the requirements of welding work with complicated special shapes of various large-scale tiled steel structures, and has good universality.
Description
Technical Field
The invention relates to the technical field of welding robots, in particular to a special welding robot system for a membrane wall and a membrane wall welding method.
Background
The film wall is a high-efficiency, reliable, energy-saving and environment-friendly cooling steel structural member and is widely applied to industrial boilers and hearths. The airtight tube panel formed by splicing and welding flat steel and tubes can enhance the tightness of a hearth, reduce the hearth air leakage coefficient of a negative pressure boiler, improve the combustion working condition, increase the effective radiation heating area and save the steel consumption. In addition, the air tightness of the film wall is good, the air leakage of a hearth can be reduced, and the thermal efficiency of the boiler is improved. The outside of the tube panel is coated with a thin heat-insulating material, so that slag bonding can be prevented. The membrane wall is manufactured by welding flat steel and pipes in rows to form a larger module and then assembling the module again. Because of the huge size of the membrane wall, the traditional manual arc welding or gantry membrane wall welding robot is often adopted for modularized welding assembly, however, the traditional manual arc welding has low efficiency, great harm to people, high labor intensity and low automation degree; the gantry type film wall welding robot has the advantages of large body weight, wide occupied area, inconvenient movement and poor adaptability, and part of film walls have irregular special-shaped notch structures, so that the traditional welding operation mode can not well meet the requirements of film wall manufacturing.
At present, a welding robot comprises a main robot responsible for welding operation and a slave robot responsible for feeding welding wires, but heavy peripheral equipment such as a welding machine and a welding protection gas cylinder are fixed on the periphery, and are not carried by the welding robot, so that long-distance transmission of welding cables is inconvenient, the operation range and flexibility of the welding robot are greatly limited, the welding robot is not suitable for large-scale welding operation of large-scale steel structural members, meanwhile, the main robot and the slave robot all need to operate on steel members during welding operation, the mutual distances are relatively close, the required operation environment has certain requirements on the steel members, and the welding robot is often not suitable for the steel members under the condition of complex environments such as special-shaped structures.
Patent publication number CN110814472a discloses a master-slave type wall climbing welding robot system suitable for large-scale steel structural members, wall climbing robot relies on adopting permanent magnetism clearance to adsorb and wheeled motion mechanism to operate, only be applicable to convex steel construction wall climbing welding work, operate on the tiling steel spare, permanent magnetism clearance adsorbs on the contrary can influence operating efficiency, and wheeled motion mechanism does not satisfy the large-scale tiling steel construction welding operation requirement that has special-shaped structure such as diaphragm wall, welder fixed establishment's settlement simultaneously, can only satisfy the welding operation demand of its walking direction horizontal weld, can't satisfy multidimensional welding's demand.
Disclosure of Invention
The invention aims to provide a special welding robot system for a diaphragm wall and a welding method for the diaphragm wall, which are used for overcoming the defects of the traditional manual arc welding or the diaphragm wall welding operation mode of a gantry type diaphragm wall welding robot and the problem that the special-shaped notch structure of the diaphragm wall is difficult to deal with. The invention combines excellent trafficability of the foot type robot and excellent walking stability of the crawler robot, replaces the traditional wheel type driving mechanism, improves the traffic capacity, meets the requirements of welding work under various large-scale flat steel structure special-shaped complex environments, and has better universality. Meanwhile, the welding master robot and the welding guarantee slave robot are matched, so that the flexibility of welding operation is further improved, and the welding operation efficiency and quality of the film wall are improved.
In order to achieve the above purpose, the present invention provides the following technical solutions:
the welding robot system special for the diaphragm wall comprises a welding master robot, a welding guarantee slave robot and a control unit, wherein the welding guarantee slave robot is used for bearing heavy welding equipment, and the control unit controls the welding master robot and the welding guarantee slave robot to work in a coordinated manner;
the welding main robot comprises a composite crawler shank, a foot-type robot, a welding gun pose control mechanism, a welding gun fixing seat and a welding gun; the combined crawler belt calf is positioned at the tail end of the thigh of the foot-type robot, the combined crawler belt calf is connected with the thigh of the foot-type robot, the combined crawler belt calf provides a gait mode and a crawler belt mode for the special welding robot for the film wall, the welding gun pose control mechanism is positioned at the back of the foot-type robot, the welding gun fixing seat is positioned at the tail end of the welding gun pose control mechanism, and the welding gun is fixed on the welding gun fixing seat;
the novel welding robot is characterized in that a transmission switching clutch device is further arranged inside the lower leg of the composite track and is responsible for power transmission and switching, so that the switching of a gait mode and a track mode is realized, the gait mode is suitable for a special-shaped notch structure of a steel pipe on a crossing film type wall and a position where the track mode cannot pass, and the track mode is suitable for enabling the welding main robot to stably move along a surface welding seam on the surface of the film type wall.
Further, a shank driving motor is arranged at the front end of the thigh of the foot-type robot, and the transmission switching clutch device is connected with the shank driving motor through a synchronous belt; an electromagnet, a synchronous pulley, a track driving wheel and a spline shaft are arranged in the transmission switching clutch device, a track is arranged in the composite track shank through a plurality of rotating shafts and the track driving wheel, and the track driving wheel and the synchronous pulley are in the same axle center; the transmission switching clutch device controls whether the spline shaft is combined with the synchronous pulley or the composite crawler belt calf or not to realize the switching of the advancing mode by absorbing the movement of the spline shaft by the electromagnets at two sides.
Further, the welding control slave robot for carrying heavy welding equipment is connected with the welding master robot through a flexible composite cable, and the flexible composite cable comprises an electric wire for transmitting welding current, a gas pipeline for conveying welding protection gas and a signal wire for control.
Further, the welding guarantee slave robot comprises a movable chassis mechanism, a welding machine, a welding protective gas cylinder and a wire feeder, wherein the welding machine, the welding protective gas cylinder and the wire feeder are all arranged on the movable chassis mechanism, the welding protective gas cylinder carries welding protective gas, the wire feeder carries welding wires and feeds the welding wires to the welding master robot, and the movable chassis mechanism is used for driving the welding guarantee slave robot to move outside the film wall.
Further, the control unit is respectively and electrically connected with the welding master robot and the welding guarantee slave robot, and is used for respectively controlling the welding master robot to switch a walking mode on the surface of the film wall, move along a welding seam and adjust the position and the posture of a welding gun, and controlling the welding guarantee slave robot to walk along with the welding master robot on the periphery of the film wall.
Further, the welding main robot further comprises a sensing module, wherein the sensing module is electrically connected with the control unit and is used for tracking the track of the welding seam, sensing the position of the welding main robot relative to the membrane wall and the welding seam, monitoring the welding quality of the welding seam, correcting the welding thermal deformation of the welding seam and tracking the welding.
Further, the sensing module comprises a welding seam tracking sensor, an industrial camera and a welding gun pose control sensor, wherein the welding seam tracking sensor, the industrial camera and the welding gun pose control sensor are fixedly arranged on the welding gun fixing seat and are respectively and electrically connected with the control unit, the welding seam tracking sensor is used for tracking a welding seam track, the welding gun pose control sensor is used for sensing the position of the welding gun relative to the welding seam and sending position information to the control unit, the control unit controls the welding gun pose control mechanism to adjust the pose of the welding gun, and the industrial camera is used for monitoring the welding process, monitoring the welding quality of the welding seam and calculating the heat distortion tracking offset of the welding seam.
Further, the welding gun pose control mechanism comprises a first rotating shaft, a second rotating shaft arm, a third rotating shaft arm, a fourth rotating shaft arm and a welding gun horizontal sliding rail, wherein the first rotating shaft, the second rotating shaft arm, the third rotating shaft arm, the fourth rotating shaft arm and the welding gun horizontal sliding rail are sequentially connected in series, and the welding gun is installed on the welding gun horizontal sliding rail: the first rotating shaft is used for adjusting the direction of the welding gun when the welding host robot walks; the second rotating shaft arm and the third rotating shaft arm are used for adjusting the distance between the welding gun and the height of the welding seam in a matching manner; the fourth rotating shaft arm is used for adjusting the pitching angle of the welding gun; the welding gun horizontal sliding rail is used for adjusting horizontal transverse displacement of the welding gun relative to the welding seam when welding along the welding seam track.
Further, a visual perception module is further arranged in the welding main robot, the visual perception module comprises an ultrasonic distance sensor, a positioning device and a depth visual camera, the ultrasonic distance sensor, the positioning device and the depth visual camera are integrated in the same shell, the visual perception module is arranged at the front end of the back of the foot-type robot, the ultrasonic distance sensor and the depth visual camera are used for identifying barriers and steel pipe special-shaped gaps of a film wall on a welding path, and the positioning device is used for sensing the current relative position with the welding guarantee slave robot; the visual perception module is electrically connected with the control unit.
Further, the welding guarantee is from among the robot remove chassis mechanism by car base, driving motor, heavy load track drive wheel and heavy load track and constitute, be provided with a driving motor in the four corners of car base respectively, driving motor drive end and heavy load track drive wheel are connected, driving motor with the control unit electricity is connected, heavy load track drive wheel is connected with car base fixed knot constructs.
Further, the welding guarantee slave robot is further provided with a laser radar and a depth vision camera, the laser radar and the depth camera are used for monitoring the running state of the welding master robot, measuring and calculating the parallel distance of the film wall steel pipe and avoiding the front path obstacle, and the laser radar and the depth camera are electrically connected with the control unit.
Further, the special welding robot system for the diaphragm wall further comprises a wireless receiver and a remote control terminal, wherein the wireless transceiver is electrically connected with the control unit, and the remote control terminal sends a control signal to the control unit through the wireless transceiver and is used for controlling the special welding robot system for the diaphragm wall and setting welding parameters.
The welding method of the welding robot special for the diaphragm wall adopts the welding robot system special for the diaphragm wall, and comprises the following steps:
s1, an operator places a welding main robot on a membrane wall, places welding guarantee slave robots on the periphery of the membrane wall, sets relevant welding parameters through a remote control terminal and guides membrane wall drawings to be welded;
s2, connecting a flexible composite cable between the welding master robot and the welding guarantee slave robot;
s3, the welding main robot advances to the surface of a steel pipe of a membrane wall to be welded in a gait mode, squats down to enable the crawler belt of the lower leg of the composite crawler belt to be attached to the surface of the welding flat steel, and switches the walking mode of the welding main robot through a transmission switching clutch device;
s4, identifying the welding seam, transmitting information to a control unit, analyzing the posture of the welding gun, and expanding a posture control mechanism of the welding gun to enable the welding gun to be close to the surface of the welding seam; real-time scanning and recording are carried out on the welding path, and the real-time scanning and recording are fed back to the control unit, and are compared with the imported film wall drawing, so that the path and the advancing mode are automatically planned;
s5, starting a welding main robot, and sending a motion instruction to start welding work; the welding guarantee slave robot moves along with the welding master robot and keeps the relative distance in real time;
s6, after the welding host robot walks and welds one body position, suspending the current welding work, recording the current welding position, rotating the mechanical arm from front to back, welding the welding seam which is not welded by the initial body position, and returning to the position where the welding is recorded until the welding seam of the initial body position is welded, and continuing to finish the welding task;
s7, the welding main robot welds the special-shaped position of the steel pipe reaching the membrane wall, and at the moment, the welding is interrupted and the position information of the welding seam of the current interrupted welding is recorded; then, the welding main robot is switched into a gait mode through the transmission switching clutch device, the gait mode advances into the steel special-shaped notch, after a machine body balance point is automatically found, the welding gun pose control mechanism is controlled to rotate the welding gun to a welding position for interrupting a welding seam, the welding operation is continuously completed, at the moment, the welding main robot stops moving, and the welding gun movement is completed by the welding gun pose control mechanism;
s8, once the welding work of the special-shaped notch structure position of the steel pipe of the membrane wall is finished, the welding main robot switches back to the crawler mode again, and the welding work of the unfinished part of the steel pipe of the remaining membrane wall is continuously finished;
s9, after the welding work of the steel pipes of the membrane wall is finished, the welding main robot is switched to a gait mode at the end of the steel pipes of the membrane wall, spans the next row of steel pipes, is switched back to a crawler walking mode again, and the remaining welding task is finished;
s10, after the welding main robot finishes the welding task of half of the steel pipe of the film wall, when turning around, the control unit calculates a path, moves to the other side at the periphery of the film wall, and maintains the relative distance between the welding guarantee slave robot and the welding main robot in real time;
s11, after all the welding tasks are executed, the welding equipment is closed, and the welding host robot and the welding guarantee are controlled to be driven out of the operation area from the robot.
The beneficial effects of the invention are as follows:
1. the invention overcomes the defects of low efficiency, great harm to people, high labor intensity and low degree of automation of the traditional manual arc welding; the gantry film wall welding robot has the defects of large body weight, wide occupied area, inconvenient movement and poor adaptability. The invention skillfully combines the excellent gait trafficability of the foot type robot and the stable walking capability of the crawler belt, improves the defects of the traditional single advancing mode on the film type wall steel, and enables the welding robot to freely reach the special-shaped notch structure position of the film type wall steel. Meanwhile, the carried mechanical arm can accurately correct the welding thermal deformation of the welding seam and track the welding, so that the welding operation angle is wide in a large range, and the welding feasibility is greatly improved. The invention breaks through the single advancing mode of the traditional welding robot, so that the passing capacity of the welding robot is obviously enhanced, and the efficient, accurate and intelligent welding is realized.
2. According to the welding master robot and the welding guarantee slave robot, heavy welding equipment such as a welding machine, a protective gas cylinder, a welding wire reel and the like are mounted on the welding guarantee slave robot, and only a power supply is needed to be provided outside. Meanwhile, the welding guarantee slave robot does not completely run on the steel part in a close range with the master robot, but can run outside the steel part in a concomitant mode.
Drawings
The accompanying drawings, which are included to provide a further understanding of the invention and are incorporated in and constitute a part of this specification, illustrate exemplary embodiments of the invention and together with the description serve to explain the principles of the invention.
FIG. 1 is a schematic diagram of the general structure of a membrane wall dedicated welding robot system in an embodiment of the invention;
FIG. 2 is a schematic diagram of a welding master robotic crawler of a membrane wall dedicated welding robotic system in an embodiment of the invention;
FIG. 3 is a schematic diagram of a welding master robot gait pattern of a membrane wall dedicated welding robot system in an embodiment of the invention;
fig. 4 is a schematic diagram of a welding guarantee slave robot of a membrane wall dedicated welding robot system in an embodiment of the present invention;
fig. 5 is a schematic diagram of a welding operation state of a special-shaped notch structure of a membrane wall of a special-purpose welding robot system for a membrane wall in an embodiment of the invention;
FIG. 6 is a schematic illustration of a welding master robot of a membrane wall dedicated welding robot system traversing to the next row of steel pipes in an embodiment of the present invention;
FIG. 7 is a schematic diagram of a working state of a tracking weld in a welding process of a welding main robot of a membrane wall dedicated welding robot system in an embodiment of the invention;
FIG. 8 is a schematic diagram of a composite track calf structure of a welding master robot of a membrane wall dedicated welding robot system in an embodiment of the invention;
FIG. 9 is a schematic diagram of a gait pattern driven switching clutch of a welding master robot of a membrane wall dedicated welding robot system in an embodiment of the invention;
FIG. 10 is a schematic view of a crawler mode transmission switching clutch of a welding master robot of a membrane wall dedicated welding robot system in an embodiment of the present invention;
FIG. 11 is a schematic view of a weld joint of a membrane wall steel in an embodiment of the invention.
Reference numerals illustrate: 1-a membrane wall; 2-welding a main robot; 3-welding a guarantee slave robot; 4-flexible composite cable; 5-composite track calf; 6-foot robot thigh; 7-a first rotating shaft; 8-a second pivot arm; 9-a third pivot arm; 10-a fourth pivot arm; 11-welding gun; 12 welding gun fixing seats; 13-a weld tracking sensor; 14-an industrial camera; 15-a horizontal sliding rail of the welding gun; 16-a visual perception module; 17-a welding gun pose control sensor; 18-heavy-duty track drive wheels; 19-a wire feeder; 20-welding a protective gas cylinder; 21-lidar; 22-a control unit; a 23-depth camera; 24-welding machine; 25-a vehicle base; 26-heavy-duty tracks; 100-a transmission switching clutch device; 101-a synchronous pulley; 102-a spline shaft; 103-an electromagnet; 104-a synchronous belt; 105-caterpillar tracks; 106-track drive wheel; 107-foot end; 108-a calf drive motor; 201-a steel tube; 202-flat steel; 203-welding seams; 204-special-shaped notch.
Detailed Description
The present invention will be described in further detail with reference to the drawings and examples, in order to make the objects, technical solutions and advantages of the present invention more apparent. It should be understood that the specific embodiments described herein are for purposes of illustration only and are not intended to limit the scope of the invention.
Example 1
Referring to fig. 1 and 5, a membrane wall dedicated welding robot system, comprising:
the welding main robot 2, as shown in fig. 2 and 3, comprises a foot-type robot main body, a composite track shank 5, a welding gun pose control mechanism, a welding gun fixing seat 12 and a welding gun 11, wherein the composite track shank 5 is positioned at the tail end of a foot-type robot thigh 6, the composite track shank 5 is hard-connected with the foot-type robot thigh 6, the composite track shank 5 is used for providing a gait mode and a track mode for the welding main robot 2, the welding gun pose control mechanism is positioned at the back of the foot-type robot, the welding gun fixing seat 12 is positioned at the tail end of the welding gun pose control mechanism, and the welding gun 11 is fixed on the welding gun fixing seat 12;
a welding guarantee slave robot 3, as shown in fig. 4, is used for carrying welding equipment 24, a wire feeder 19, a welding protection gas cylinder 20 and other peripheral heavy welding equipment, and provides a welding power supply and welding wires for the welding master robot 2 and delivers welding protection gas; the welding guarantee slave robot 3 is connected with the welding master robot 2 through a flexible composite cable 4, and the flexible composite cable 4 comprises an electric wire for transmitting welding current, a pipeline for conveying welding wires and welding protection gas and a signal wire for communication;
the welding guarantee slave robot 3 comprises a movable chassis mechanism, a welding machine 24, a welding protection gas cylinder 20 and a wire feeder 19, wherein the welding machine 24, the welding protection gas cylinder 20 and the wire feeder 19 are arranged on the movable chassis mechanism, the welding protection gas cylinder 20 carries welding protection gas, the wire feeder 19 carries welding wires and conveys the welding wires to the welding master robot 2 through a flexible composite cable 4, and the movable chassis mechanism is used for driving the welding guarantee slave robot 3 to move outside the film wall 1;
the control unit 22 is electrically connected with the welding master robot 2 and the welding guarantee slave robot 3 respectively, and is used for controlling the switching of the running mode of the welding master robot 2 on the film wall 1, the movement along the welding seam and the adjustment of the pose angle of the welding gun 11 respectively, and controlling the welding guarantee slave robot 3 to run around the film wall 1 along with the welding master robot 2.
Example 2
In order to better realize the walking function of the welding main robot 2, this embodiment is further configured on the basis of embodiment 1.
In this embodiment, as shown in fig. 2, the welding main robot 2 adopts a foot robot as a basic frame, the width between two legs can be changed by adjusting a fixing seat of a hip joint driving motor of a machine body so as to adapt to membrane walls 1 with different steel widths, a composite crawler calf 5 is designed, and gait mode and crawler mode switching are flexibly realized by using the composite crawler calf 5. The compound track shank 5 is rotatably arranged at the tail end of the thigh 6 of the foot robot, a transmission switching clutch device 100 is further arranged in the compound track shank 5, and the transmission switching clutch device 100 is responsible for switching between power transmission and operation modes. When the welding main robot 2 is switched to the crawler mode, as shown in fig. 2, the composite crawler calf 5 is parallel to the steel material of the film wall 1, and the crawler 105 is attached to the surface of the steel material of the film wall 1; when the welding master robot 2 switches to gait mode, the composite track calf 5 will switch to a normal foot calf, the track 105 is suspended, as shown in fig. 3.
In this embodiment, as shown in fig. 8 to 10, the front end of the thigh 6 of the foot robot is provided with a shank driving motor 108, and the transmission switching clutch device 100 is connected with the shank driving motor 108 through a timing belt 104. The transmission switching clutch device 100 is internally provided with an electromagnet 103, a synchronous pulley 101, a track driving wheel 106 and a spline shaft 102, wherein a track 105 is arranged in the composite track shank 5 through a plurality of rotating shafts and the track driving wheel 106, and the track driving wheel 106 and the synchronous pulley 101 are coaxial. The transmission switching clutch device 100 controls whether the spline shaft 102 is combined with the synchronous pulley 101 or the compound crawler calf 5 or not to realize the switching of the travelling mode by absorbing the movement of the spline shaft 102 by the electromagnets 103 on two sides. As shown in fig. 9, the spline shafts 102 on two sides are displaced outwards to the transmission switching clutch device 100 in a gait mode, the spline shafts 102 are combined with the compound crawler calf 5, power of the calf driving motor 108 is transmitted to the spline shafts 102 through the synchronous pulley 101, and then the power is transmitted to the compound crawler calf 5 through the spline shafts 102, so that the movement of the compound crawler calf 5 is controlled; as shown in fig. 10, the transmission switching clutch device 100 is switched to a crawler mode, power of the calf driving motor 108 is transmitted to the spline shaft 102 through the synchronous pulley 101, and then transmitted to the crawler driving wheel 106 through the spline shaft 102, and the crawler driving wheel 106 drives the crawler 105 to form complete power transmission. Foot end 107 is spherical silica gel and in track mode foot end 107 is not in contact with the ground.
In this embodiment, as shown in fig. 2 and 3, the welding main robot 2 is further provided with a visual perception module 16, an ultrasonic distance sensor, a positioning device and a depth visual camera are arranged in the visual perception module 16 and integrated in the same housing, the visual perception module 16 is located at the head of the welding main robot 2, the visual perception module 16 is used for observing the obstacle ahead and planning the path, and meanwhile, feedback data is fed back to the control unit 22 to be compared with preset welding data thereof. The positioning device is used for sensing the relative position between the current welding guarantee slave robot.
Example 3
In order to better realize the welding function of the welding main robot 2, this embodiment is further configured on the basis of embodiment 2.
In this embodiment, as shown in fig. 2, the welding gun pose control mechanism includes a first rotating shaft 7, a second rotating shaft arm 8, a third rotating shaft arm 9, a fourth rotating shaft arm 10, a welding gun horizontal sliding rail 15, and a welding gun fixing seat 12.
In this embodiment, the first rotating shaft 7, the second rotating shaft arm 8, the third rotating shaft arm 9, the fourth rotating shaft arm 10, the welding gun horizontal sliding rail 15 and the welding gun fixing seat 12 are sequentially connected in series, wherein the series connection means that the welding gun horizontal sliding rail 15 is installed at the tail end of the fourth rotating shaft arm 10, the third rotating shaft arm 9 is installed at the tail end of the second rotating shaft arm 8, the second rotating shaft arm 8 is installed at the tail end of the first rotating shaft 7, the welding gun fixing seat 12 is slidably installed on the welding gun horizontal sliding rail 15, the whole mechanical part is in a series connection structure, and each part of mechanical mechanism is controlled by a separate motor; the first rotation shaft 7 is mounted on the back of the foot robot body. It should be noted that, the structures of the first rotating shaft 7, the second rotating shaft arm 8, the third rotating shaft arm 9 and the fourth rotating shaft arm 10 and the respective mounting modes of the motors may adopt rotating shaft structures in the prior art, so as to respectively realize the rotation of the rotating planes where the respective rotating shafts are located, and realize the position and angle adjustment of the horizontal sliding rail 15 of the welding gun through the rotation adjustment of different rotating planes, so as to realize the position and angle adjustment of the welding gun 11.
In the present embodiment, a welding gun 11 is mounted on a welding gun holder 12; the horizontal slide rail 15 of the welding gun is used for adjusting the movement of the welding gun 11 along the width direction of the welding seam; the welding gun pose control mechanism is used for adjusting the height direction distance and the angle pose of the welding gun 11 along the welding seam, wherein the height direction distance refers to the distance between the tip of the welding gun 11 and the surface of the welding seam, and the angle pose refers to the angle between the tip of the welding gun 11 and the vertical plane of the welding seam; the welding gun horizontal sliding rail 15 is used for controlling the welding gun 11 to move on the welding seam horizontal plane during welding along the welding seam track; the first rotating shaft 7 is used for adjusting the transverse offset angle of the welding gun 11 according to the welding seam position of the welding main robot 2 relative to the film wall 1, and the angle posture of the welding gun 11 relative to the welding seam is set by welding data.
In this embodiment, as shown in fig. 1 and 7, when the welding main robot 2 welds the surface of the film wall 1 along the welding seam track, the second rotating shaft arm 8 and the third rotating shaft arm 9 jointly control the distance between the welding gun 11 and the height direction of the welding seam so as to ensure the continuity of the welding seam, the horizontal sliding rail 15 of the welding gun adjusts the position of the welding gun 11 in the horizontal direction of the welding seam in real time, and the fourth rotating shaft arm 10 is used for adjusting the angle posture of the welding gun 11 relative to the welding seam, so that the welding gun 11 welds in the welding seam according to the zigzag path in a combined manner, thereby ensuring the requirements of the welding seam forming process.
In this embodiment, the sensing module is mounted at the front end of the welding gun fixing seat 12, and the sensing module includes a welding seam tracking sensor 13, an industrial camera 14 and a welding gun pose control sensor 17, which are vertically disposed in front of the welding gun 11 through the mounting frame and are respectively electrically connected with the control unit 22, the welding seam tracking sensor 13 is used for tracking the track of the welding seam, the industrial camera 14 is used for monitoring the welding quality of the welding seam and tracking the thermal deformation of the welding seam, calculating offset compensation, and the welding gun pose control sensor 17 is used for sensing the height between the welding gun 11 and the welding seam and the horizontal center distance of the welding seam and measuring the vibration offset in the welding process. The control unit 22 is used for tracking the welding seam according to feedback data of the industrial camera 14 and the welding seam tracking sensor 13, the control unit 22 fuses feedback data of the industrial camera 14 and the welding seam tracking sensor 13, the advancing direction of the welding main robot 2, the deflection angle of the first rotating shaft 7 and the upper displacement of the horizontal sliding rail 15 of the welding gun are adjusted in real time, the welding quality is ensured in the welding operation process of the welding gun 11 according to a Z-shaped path and the welding thermal deformation offset compensation. The welding gun pose control sensor 17 feeds information back to the control unit 22, and the control unit 22 performs closed-loop control to realize real-time precise adjustment of the welding gun 11.
Example 4
In order to better realize the task of welding guarantee from the robot 3, as shown in fig. 4, the mobile chassis mechanism is composed of a vehicle base 25, a driving motor and a heavy-duty crawler 26, wherein the driving motor is electrically connected with the control unit 22. The four corners of the vehicle base 25 are respectively internally provided with a driving motor, the driving ends of the driving motors are connected with heavy-load crawler belt driving wheels 18, the heavy-load crawler belt driving wheels 18 are connected with the fixed structure of the vehicle base 25, and heavy-load crawler belts 26 are arranged on the two heavy-load crawler belt driving wheels 18.
In the embodiment, a welding main robot 2 carries a welding gun 11 to track the welding seam to walk, and welding heavy equipment such as a welding guarantee slave robot 3 carrying wire conveying machine 19, a welding machine 24, a welding protection gas cylinder 20 and the like is connected with the welding main robot 2 through a flexible composite cable 4 and synchronously moves, so that a welding power supply, welding protection gas and welding wires are provided for a welding process. The welding main robot 2 and the welding guarantee slave robot 3 cooperate to complete the membrane wall 1 assembly welding operation, compared with the traditional welding equipment, the whole weight of the welding main robot 2 is reduced, the flexible action of the welding main robot 2 and the rapid adjustment of the posture of the welding gun 11 are guaranteed, the welding guarantee slave robot 3 has larger loading capacity and large whole weight, but does not need to run on a steel part in a short distance with the main robot, and can run outside the steel part, thereby reducing the requirement of the welding operation on the environmental condition of the steel part, improving the operation range and the flexibility of the welding main robot 2, and only needing to run on the periphery of the membrane wall 1 steel, and only needing to provide a power supply outside. In this embodiment, considering that the distance is not relatively fixed during the movement of the welding master robot 2 and the welding guarantee slave robot 3, and long-distance wire feeding is avoided, the length of the flexible composite cable 4 is generally selected to be seventy percent of the width of the steel material of the film wall 1, and two ends of the flexible composite cable 4 are respectively fixed at the tail part of the welding master robot 2 and the top part of the welding guarantee slave robot 3.
In the embodiment, the welding guarantee slave robot 3 is further provided with a laser radar 21 and a depth camera 23, and the laser radar 21 and the depth camera 23 are arranged on the top of the welding guarantee slave robot 3 and are used for sensing the surrounding environment and planning path identification of the welding guarantee slave robot 3.
Example 5
In order to better realize the welding guarantee task of the welding guarantee slave robot 3, the special welding robot system for the film wall in the embodiment further comprises a wireless receiver and a remote control terminal, wherein the wireless receiver is arranged inside the control unit 22 and is electrically connected with the control unit 22, and the remote control terminal sends a control signal to the control unit 22 through the wireless receiver and is used for controlling the special welding robot system for the film wall and setting welding parameters.
The control unit 22 of the special welding robot system for the diaphragm wall of the embodiment fuses welding process parameter control, control of the movement gesture of the welding main robot 2 on the surface of the diaphragm wall 1, control of synchronous movement of the welding guarantee slave robot 3 outside the diaphragm wall 1, real-time adjustment of the gesture of the welding gun 11 in the welding process and remote control.
Example 6
Referring to fig. 1, fig. 5, fig. 6, fig. 7 and fig. 11, a welding method for a film wall-dedicated welding robot, which adopts the film wall-dedicated welding robot system provided in embodiment 5, includes the steps of:
s1, an operator places a welding main robot 2 on a membrane wall 1, places welding guarantee from a robot 3 to the periphery of the membrane wall 1, sets relevant welding parameters through a remote control terminal and guides membrane wall drawings to be welded;
s2, connecting a flexible composite cable 4 between the welding master robot 2 and the welding guarantee slave robot 3;
s3, the welding main robot 2 advances to the surface of the steel pipe 201 of the membrane wall 1 to be welded in a gait mode, the crawler belt of the compound crawler belt shank 5 is made to be attached to the surface of the welding flat steel 202 by squatting, and the walking mode of the welding main robot 2 is switched through the transmission switching clutch device 100;
s4, setting a sensor module to be in an initial state, enabling a weld joint tracking sensor 13 to start to identify a weld joint 203, transmitting information to a control unit 22, analyzing the posture of a welding gun 11, and expanding a welding gun posture control mechanism to enable the welding gun 11 to be close to the surface of the weld joint 203; the visual perception module 16 on the welding master robot 2 and the laser radar 21 on the welding guarantee slave robot 3 perform real-time scanning record on the welding path and feed back to the control unit 22, and compare with the imported membrane wall 1 drawing, and automatically plan the path and the travelling mode;
s5, starting the welding main robot 2 through a remote control terminal, and sending a motion instruction to start welding work; the welding guarantee slave robot 3 moves along with the welding master robot 2 and keeps the relative distance in real time;
s6, after the welding main robot 2 walks and welds one body position, suspending the current welding work, recording the current welding position, rotating the mechanical arm from front to back, welding the welding seam 203 which is not welded in the initial body position, and returning to the position where the welding is recorded until the welding seam 203 in the initial body position is welded, and continuing to finish the welding task;
s7, the welding main robot 2 welds the special-shaped position of the steel pipe 201 reaching the membrane wall 1, and at the moment, the welding is interrupted and the position information of the welding seam of the current interrupted welding is recorded; then, the welding main robot 2 is switched into a gait mode through the transmission switching clutch device 100, the gait mode advances into the steel special-shaped notch 204, after the balance point of the machine body is automatically found, the welding gun pose control mechanism is controlled to revolve the welding gun 11 to a position for interrupting welding of the welding seam, the welding operation is continuously completed, at the moment, the welding main robot 2 stops moving, and the movement of the welding gun 11 is completed by the welding gun pose control mechanism;
s8, once the welding work of the structural position of the special-shaped notch 204 of the steel pipe 201 of the film wall 1 is finished, the welding main robot 2 is switched back to the crawler mode again, and the welding work of the unfinished part of the steel pipe 201 of the remained film wall 1 is continuously finished;
s9, after the welding work of the steel pipes 201 of the film wall 1 is finished, the welding main robot 2 is switched to a gait mode at the end of the steel pipes 201 of the film wall 1, spans the next row of steel pipes 201, is switched back to a crawler walking mode again, and the rest welding task is finished;
s10, after the welding main robot 2 finishes the welding task of half of the steel pipe 201 of the film wall 1, when turning around, the control unit 22 calculates a path according to the imported drawing of the film wall 1, the laser radar 21 and the visual perception module 16, moves to the other side at the periphery of the film wall 1, and maintains the relative distance between the welding guarantee slave robot 3 and the welding main robot 2 in real time;
s11, after all the welding tasks are executed, the welding equipment is closed, and the welding main robot 2 and the welding guarantee slave robot 3 are controlled to be driven out of the operation area.
It should be noted that, in this document, the terms "comprises," "comprising," or any other variation thereof, are intended to cover a non-exclusive inclusion, such that a process, apparatus, article, or method that comprises a list of elements does not include only those elements but may include other elements not expressly listed or inherent to such process, apparatus, article, or method. Without further limitation, an element defined by the phrase "comprising one … …" does not exclude the presence of other like elements in a process, apparatus, article or method that comprises the element.
The foregoing description is only of the preferred embodiments of the present invention and is not intended to limit the scope of the invention, and all equivalent structures or equivalent processes using the descriptions and drawings of the present invention or direct or indirect application in other related technical fields are included in the scope of the present invention.
Claims (9)
1. The welding robot system special for the diaphragm wall comprises a welding master robot, a welding guarantee slave robot and a control unit, wherein the welding guarantee slave robot is used for bearing heavy welding equipment, and the control unit controls the welding master robot and the welding guarantee slave robot to work in a coordinated manner; the method is characterized in that:
the welding main robot comprises a composite crawler shank, a foot-type robot, a welding gun pose control mechanism, a welding gun fixing seat and a welding gun; the combined crawler belt calf is positioned at the tail end of the thigh of the foot-type robot, the combined crawler belt calf is connected with the thigh of the foot-type robot, the combined crawler belt calf provides a gait mode and a crawler belt mode for the special welding robot for the film wall, the welding gun pose control mechanism is positioned at the back of the foot-type robot, the welding gun fixing seat is positioned at the tail end of the welding gun pose control mechanism, and the welding gun is fixed on the welding gun fixing seat;
the inside of the compound crawler calf is also provided with a transmission switching clutch device, the front end of the thigh of the foot robot is provided with a calf driving motor, the transmission switching clutch device is connected with the calf driving motor through a synchronous belt, the inside of the transmission switching clutch device is provided with an electromagnet, a synchronous belt pulley, a crawler driving wheel and a spline shaft, the inside of the compound crawler calf is provided with a crawler through a plurality of rotating shafts and the crawler driving wheel, and the crawler driving wheel and the synchronous belt pulley are in the same axle center; the transmission switching clutch device controls whether the spline shaft is combined with the synchronous pulley or the composite crawler calf or not to realize the switching of the advancing mode by absorbing the movement of the spline shaft by the electromagnets at two sides; the transmission switching clutch device is responsible for power transmission and switching, so that the switching of a gait mode and a crawler mode is realized, the gait mode is suitable for a special-shaped notch structure of a steel pipe on a crossing film wall and a position where the crawler mode cannot pass, and the crawler mode is suitable for enabling the welding main robot to stably move along a surface welding seam on the surface of the film wall.
2. A membrane wall dedicated welding robot system according to claim 1, characterized by comprising a welding assurance slave robot for carrying heavy welding equipment, the welding assurance slave robot being connected to a welding master robot by a flexible composite cable comprising wires for transmitting welding current, gas lines for conveying welding shielding gas and signal lines for control.
3. The welding robot system special for the film wall according to claim 2, wherein the welding guarantee slave robot comprises a movable chassis mechanism, a welding machine, a welding shielding gas cylinder and a wire feeder, wherein the welding machine, the welding shielding gas cylinder and the wire feeder are arranged on the movable chassis mechanism, the welding shielding gas cylinder carries welding shielding gas, the wire feeder carries welding wires and feeds the welding wires to the welding master robot, and the movable chassis mechanism is used for driving the welding guarantee slave robot to move outside the film wall.
4. The welding robot system special for the film wall according to claim 2, wherein the control unit is electrically connected with the welding master robot and the welding guarantee slave robot respectively and is used for controlling the welding master robot to switch a walking mode on the surface of the film wall, move along a welding line and adjust the pose of a welding gun respectively and controlling the welding guarantee slave robot to walk along the periphery of the film wall along with the welding master robot.
5. The welding robot system special for the diaphragm wall according to claim 1, wherein the welding main robot further comprises a sensing module, and the sensing module is electrically connected with the control unit and is used for tracking the track of the welding seam, sensing the position of the welding main robot relative to the diaphragm wall and the welding machine, monitoring the welding quality of the welding seam, correcting the welding thermal deformation of the welding seam and tracking the welding.
6. The welding robot system special for film walls according to claim 1, wherein the welding gun pose control mechanism comprises a first rotating shaft, a second rotating shaft arm, a third rotating shaft arm, a fourth rotating shaft arm, a welding gun horizontal sliding rail and a welding gun fixing seat, the first rotating shaft, the second rotating shaft arm, the third rotating shaft arm, the fourth rotating shaft arm, the welding gun horizontal sliding rail and the welding gun fixing seat are sequentially connected in series, the welding gun is installed on the welding gun fixing seat, and the welding gun fixing seat is installed on the welding gun horizontal sliding rail: the first rotating shaft is used for adjusting the direction of the welding gun when the welding host robot walks; the second rotating shaft arm and the third rotating shaft arm are used for adjusting the distance between the welding gun and the height of the welding seam; the fourth rotating shaft arm is used for adjusting the pitching angle of the welding gun; the welding gun horizontal sliding rail is used for adjusting horizontal transverse displacement of the welding gun relative to the welding seam when welding along the welding seam track.
7. The welding robot system special for the film wall according to claim 1, wherein a visual perception module is further arranged in the welding main robot, the visual perception module comprises an ultrasonic distance sensor, a positioning device and a depth visual camera, the ultrasonic distance sensor, the positioning device and the depth visual camera are integrated in the same shell, the visual perception module is arranged at the front end of the back of the foot-type robot, the ultrasonic distance sensor and the depth visual camera are used for identifying obstacles on a welding path and steel pipe special-shaped gaps of the film wall, and the positioning device is used for sensing the relative position between the current welding position and the welding guarantee slave robot; the visual perception module is electrically connected with the control unit.
8. The welding robot system for membrane walls of claim 1, further comprising a wireless transceiver and a remote control terminal, wherein the wireless transceiver is electrically connected to the control unit, and the remote control terminal sends a control signal to the control unit via the wireless transceiver for controlling the welding robot system for membrane walls and the welding parameter setting.
9. A welding method of a welding robot special for a diaphragm wall, adopting the welding robot system special for a diaphragm wall as claimed in any one of claims 1 to 8, comprising the steps of:
s1, an operator places a welding main robot on a membrane wall, places welding guarantee slave robots on the periphery of the membrane wall, sets relevant welding parameters through a remote control terminal and guides membrane wall drawings to be welded;
s2, connecting a flexible composite cable between the welding master robot and the welding guarantee slave robot;
s3, the welding main robot advances to the surface of a steel pipe of a membrane wall to be welded in a gait mode, squats down to enable the crawler belt of the lower leg of the composite crawler belt to be attached to the surface of the welding flat steel, and switches the walking mode of the welding main robot through a transmission switching clutch device;
s4, identifying the welding seam, transmitting information to a control unit, analyzing the posture of the welding gun, and expanding a posture control mechanism of the welding gun to enable the welding gun to be close to the surface of the welding seam; carrying out real-time scanning and recording on the barriers on the welding path and the steel pipe special-shaped gaps of the film wall, feeding back to the control unit, comparing with the imported film wall drawing, and automatically planning the path and the advancing mode;
s5, starting a welding main robot, and sending a motion instruction to start welding work; the welding guarantee slave robot moves along with the welding master robot and keeps the relative distance in real time;
s6, after the welding host robot walks and welds one body position, suspending the current welding work, recording the current welding position, rotating the mechanical arm from front to back, welding the welding seam which is not welded by the initial body position, and returning to the position where the welding is recorded until the welding seam of the initial body position is welded, and continuing to finish the welding task;
s7, the welding main robot welds the special-shaped position of the steel pipe reaching the membrane wall, and at the moment, the welding is interrupted and the position information of the welding seam of the current interrupted welding is recorded; then, the welding main robot is switched into a gait mode through the transmission switching clutch device, the gait mode advances into the steel special-shaped notch, after a machine body balance point is automatically found, the welding gun pose control mechanism is controlled to rotate the welding gun to a welding position for interrupting a welding seam, the welding operation is continuously completed, at the moment, the welding main robot stops moving, and the welding gun movement is completed by the welding gun pose control mechanism;
s8, once the welding work of the special-shaped notch structure position of the steel pipe of the membrane wall is finished, the welding main robot switches back to the crawler mode again, and the welding work of the unfinished part of the steel pipe of the remaining membrane wall is continuously finished;
s9, after the welding work of the steel pipes of the membrane wall is finished, the welding main robot is switched to a gait mode at the end of the steel pipes of the membrane wall, spans the next row of steel pipes, is switched back to a crawler walking mode again, and the remaining welding task is finished;
s10, after the welding main robot finishes the welding task of half of the steel pipe of the film wall, when turning around, the control unit calculates a path, moves to the other side at the periphery of the film wall, and maintains the relative distance between the welding guarantee slave robot and the welding main robot in real time;
s11, after all the welding tasks are executed, the welding equipment is closed, and the welding host robot and the welding guarantee are controlled to be driven out of the operation area from the robot.
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