DE102009049327A1 - Method for controlling a welding robot, for welding with a welding tong and a force detecting device for detecting reaction forces on the welding tong, comprises determining a sum of reaction forces on the welding tong - Google Patents

Abstract

The method for controlling a welding robot (1), for welding with a welding tong (2) and a force detecting device for detecting reaction forces on the welding tong, comprises determining a sum of reaction forces on the welding tong, and regulating the pose of the welding robot on the basis of determined sum of the reaction forces. The sum of the reaction forces is determined on the basis of a difference between reaction forces that influence on two electrodes of the welding tong or on the basis of a power that influences between the welding tong and the welding robot. The method for controlling a welding robot (1), for welding with a welding tong (2) and a force detecting device for detecting reaction forces on the welding tong, comprises determining a sum of reaction forces on the welding tong, and regulating the pose of the welding robot on the basis of determined sum of the reaction forces. The sum of the reaction forces is determined on the basis of a difference between reaction forces that influence on two electrodes of the welding tong or the sum of the reaction forces is determined on the basis of a power that influences between the welding tong and the welding robot. The pose of the welding robot is regulated so that the difference between the reaction forces and/or the power that influences between the welding tong and its storage is regulated. A welding power is determined on the basis of reaction forces that are determined for determining the sum of reaction forces, and is regulated. The reaction forces are determined by piezosensors, strain gauges and/or current sensors. Independent claims are included for: (1) a device for controlling a welding robot; (2) a computer program; and (3) a computer program product with program mode.

Description

The present invention relates to a method and a control device for welding by means of a positioning device, in particular a welding robot.

In resistance spot welding (WPS), for example, sheets to be joined are pressed together by two welding electrodes and a welding current is conducted through the electrodes and sheets, whereby the elevated contact resistance between the sheets increases their temperature to such an extent that the sheets fuse there.

If this is carried out automatically by a positioning device, such as a welding robot, it moves in a positionally regulated manner to position the welding gun and workpiece (s) relative to one another. For this purpose, the positioning device can move the workpiece and / or the welding tongs. For example, a welding robot can attach a robot-guided welding gun to a stationary workpiece or conversely supply a gripped workpiece to a stationary welding gun.

When approaching and / or in the welding pose, the welding tongs are closed by movement of at least one electrode towards the other electrode and a spot weld is produced. The poses for setting the welding points can, for example, be taught beforehand by manual starting or can be programmed offline, for example on the basis of known workpiece and production cell data, and approached, for example, by proportional-integral-differential universal joint controllers.

If the position deviates during operation, i. e. Position and / or orientation, of a workpiece to be welded relative to a tool reference system of the positioning device such as the TCP ("tool center point") of a welding robot from the position with respect to the pose was given, for example, because sheets deformed or inaccurate in one When the feed tool is clamped or the feed tool and positioning device are positioned inaccurately with respect to each other, the position control forcibly tries to reach the reference position. This can lead to a deterioration or failure of the welding process, damage to the workpiece, tool and / or positioning device and the like, in particular in the case of high-strength and ultra-high-strength metal sheets.

Therefore, in practice hitherto floating welding tongs are provided, which decouple the welding tongs from transverse forces during the welding process. In particular with non-stationary, guided welding tongs, this so-called tong compensation must be fixed for approaching the next pose in order to be able to precisely position the welding tongs. This requires heavy, complex, energy-consuming and error-prone mechanics.

The object of the present invention is to improve automated welding.

This object is achieved by a method having the features of claim 1. Claim 8 provides a device, claim 9 or 10, a computer program or a computer program product, in particular a data carrier or a storage medium, for performing a method according to claim 1 under protection. The subclaims relate to advantageous developments.

The present invention provides, with a positioning device, in particular a welding robot to approach one or more Schweißposen regulated. In this case, a regulation is in particular the determination and output of manipulated variables, such as nominal drive forces and / or torques, currents, powers or the like, understood by drive units of the positioning such as electric motors, based on traced actual sizes, in particular poses, joint positions and / or joint speeds. For example, for this purpose, a single joint control, such as a PID control, be provided, the manipulated variables proportional to a control difference between desired and actual joint positions and / or time derivatives and / or integrals thereof determined. The control can equally be done in Cartesian space by comparing setpoint and actual position (or their temporal derivatives and / or integrals) and / or model-based.

According to the invention a softened weld pose of the positioning device during the closing of a welding gun, during the welding process and / or during the opening of the welding gun, hereinafter collectively referred to as activation of the welding gun, is now compliant. The thus "soft" switched in their control positioning can then yield reaction forces that act due to incorrect positioning when starting the workpiece on the welding gun by changing their pose and adjust so with respect to the actual workpiece position, so that a complex mechanical pliers compensation can be omitted the previously compensated between the stiff positionally controlled in their Referenzpose persistent positioning and the staggered workpiece.

In an advantageous embodiment, the welding pose can be kept controlled for this purpose. there In contrast to the regulation explained above, a control is understood to mean, in particular, the determination and output of manipulated variables independent of actual variables, in particular joint positions.

For this purpose, in a preferred embodiment of the present invention, a position control, with which the welding pose is approached precisely, be suppressed during closing of the welding gun, during the welding process and / or during opening of the welding gun, for example by setting control differences to zero or setpoint variables be set to actual sizes, so that there are no following errors. If the position control has a feedforward control, this can still remain active. Preferably, it is possible to switch over between a closed-loop control system and a control without consideration of returned poses or positions of the positioning device.

In a preferred embodiment, the controller can compensate for predetermined forces, in particular weight forces, which act, for example, on the positioning device, for example by determining the manipulated variables required for this purpose, such as drive forces or moments, currents or the like, and storing them during activation of the welding gun Actuation of the actuators of the positioning device can be used.

A control, in particular position control, within the meaning of the present invention may also have a subordinate control layer, for example in the form of a current regulator or the like, the distinction between (position) control and (position) control in particular refers to whether pose or joint positions the positioning are returned and taken into account (control) or not (control).

Is, at the latest when or after the opening of the welding gun, switched back to the position control to approach the next welding pose, the current actual pose of the positioning due to their yielding during activation of the welding gun so different from the approached target pose that a abrupt switching leads to a jump in the system deviation and thus to a vibration excitation or a response of a following error monitoring leads. Therefore, in a preferred embodiment of the present invention, after compliantly holding the welding pose, first, preferably for a predetermined period of time, the current pose is used as the target pose of a control upon completion of closing or opening of the welding gun or welding operation.

In a preferred embodiment, if during the compliant holding of the welding pose, the position control does not ensure that the positioning device holds its weld pose, at least approximately, during the compliant holding of the weld pose, the current pose can be monitored. If the difference between this current pose and the approached, theoretically maintained welding pose too great, a corresponding reaction can take place, in particular a stop, preferably emergency stop of the positioning device.

Instead of a suppression of the position control, which, as explained above, in particular a Cartesian, Posen- or joint position control is understood, this can also be modified accordingly to keep the welding pose yielding during the activation of the welding gun. For example, manipulated variable limitations, such as maximum values, to which the drive forces and / or torques are limited, can be correspondingly reduced so that the positioning device only opposes a reduced shift from its approached welding pose due to the contact with the offset workpiece. This is preferably done for all movement axes of the positioning device. Similarly, it is possible to use a force control, in particular to switch from position to force control, wherein desired force values of the force control during activation of the welding gun are set correspondingly low. It may also be sufficient to reduce or eliminate the integral portion of a PI (D) control, since the positioner will then oppose dodge due to contact with a staggered workpiece only with a force proportional to that offset, but with remaining Offset does not increase or grows only slightly.

Further advantages and features emerge from the subclaims and the exemplary embodiments. This shows, partially schematized:

1 a welding robot with a control device according to an embodiment of the present invention; and

2 : one by the control device 1 executed method of welding by means of the welding robot.

1 shows a six-axis welding robot 1 with a welding tongs 2 when spot welding a two-ply workpiece 3 ,

A control device 4 detects the joint or motor angle q = (q1, ..., q6) of the articulated robot 1 (undressed in 1 ) and outputs desired motor currents i _s to the drive motors (dash-dotted line in FIG 1 ).

To approach a welding pose, as exemplified in 1 is shown, receives a controller R of the control device 4 Target joint angle q _{s, sPS} , which it compares with the detected actual joint angles q and derives from this control difference a corresponding manipulated variable which is converted into a current controller RS, which detects the actual motor currents i, into corresponding desired motor currents i _s , In addition to or as an alternative to the joint angles, joint angular velocities or other time derivatives and / or integrals of the joint angles can also be used in order, for example, to realize a PID position regulation. Similarly, instead of the joint angles, Cartesian positions of the tool reference system TCP can also be used, which can be imaged onto each other by forward or backward transformation (not shown). Accordingly, switching devices are suitable for approaching a welding pose 4.1 . 4.2 each in the position "➀".

Did the robot approach the taught welding pose q _t ( 2 : S10: "Y"), switches the switching device 4.2 in step S20 in the in 1 shown position "➁" order. As a result, the position controller R is suppressed, the current controller RS receives as a manipulated variable only a stored setpoint value i _t . This corresponds, for example, the current value when switching to the position control, ie the current that the motors to hold the approached Schweißpose against weight, friction and other forces, ie without contact forces from the workpiece 3 on the welding tongs 2 need.

Thus, the welding pose is controlled and thus held compliant, since the manipulated variable for the current controller RS is no longer determined by the position controller R as a function of the actual pose, but independently of this by the controller S based on the predetermined current value. Weight and other impressed forces are approximately compensated by this control, so that the pose of the robot with correspondingly small external forces can be changed.

Now the tongs 2 activated (S30: Z = 1), ie the movable electrode is closed, the welding current is activated and then the pliers are opened again. As soon as the activation of the clamp is finished (S30: "Y"), the switching device switches 4.2 in step S40 back to the position "➀", so that the robot goes back into position control.

Has his pose changed by a yielding when activating the welding gun compared to the originally approached under position control pose, the abrupt specification of this originally approached pose would lead to a large following error with corresponding control problems.

Therefore, to switch to the position control ( 4.2 ➁ → ➀) uses a current pose q as a set pose q _{s of} the control. For this purpose, the switching device switches in step S40 4.1 to the position "➁". In this, over a predetermined time .DELTA.t the target pose q _s , which is supplied to the controller R, from the current pose when switching q to the originally approached under position control pose q _{s, PLC} out, for example according to q _s = q × (Δt - t) / Δt + q _{s, PLC} × t / Δt ⇒ q _s (t = 0) = q; q _s (t = Δt) = q _{s, PLC}

If the setpoint pose q _{s of} the control according to Δt has reached the pose q _{s, SPS} originally approached under position control (S50: "J"), the switching device can 4.1 in step S60 switch back to the position control.

The control device 4 monitored during the activation of the welding gun 2 permanently the deviation between the current pose q and the originally approached pose q _{s, SPS} and triggers an emergency stop when it exceeds a predetermined maximum value (not shown).

LIST OF REFERENCE NUMBERS

1

robot

2

welding gun

3

Workpieces (sheets) / reference configuration

4

control device

R

position controller

RS

current regulator

S

position control

q

current pose (joint angle)

q _s

Desired pose

qs _{, PLC}

Welding desired pose

Claims (10)

Method for automated welding by means of a positioning device, in particular a welding robot ( 1 ), wherein a Schweißpose (q _t ) is approached regulated; characterized in that the welding pose during the closing of a welding tongs ( 2 ) is resiliently held during the welding operation and / or during the opening of the welding gun (S20). A method according to claim 1, characterized in that the welding pose during the closing of the welding tongs ( 2 ), is kept controlled during the welding operation and / or during the opening of the welding gun (S20). A method according to claim 2, characterized in that the controlled holding the welding pose is independent of joint positions (q) and / or joint speeds (dq / dt). Method according to one of the preceding claims 2 to 3, characterized in that the control during the closing of the welding tongs ( 2 ), during the welding operation and / or during the opening of the welding gun predetermined forces, in particular weight forces (i _t ), compensated. Method according to one of the preceding claims, characterized in that for the controlled start of the welding pose joint positions (q) and / or joint speeds (dq / dt) are returned. Method according to one of the preceding claims, characterized in that, after the flexible holding of the welding pose, a current pose (q) is used as a set pose (q _s ) of a regulation (S40). Method according to one of the preceding claims, characterized in that during the flexible holding of the welding pose a current pose is monitored. Control device ( 4 ) for a positioning device, in particular a welding robot ( 1 ), for welding with welding tongs ( 2 ), wherein the device has a regulator (R) for the controlled starting of a welding pose (q _t ), characterized by a switching device ( 4.1 . 4.2 ) for carrying out a method according to one of the preceding claims. Computer program that executes a method according to one of claims 1 to 7, when it runs in a device according to claim 8. A computer program product with program code stored on a machine-readable medium and comprising a computer program according to claim 9.

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