KR20090006915A - The control system and control method of an automatic welding device for vertical and horizontal fillet joint welding - Google Patents

Abstract

A system of controlling an automatic welding apparatus for vertical and horizontal fillet joint welding is provided to provide an operator with convenience by comprising an operating state window, a digital input/output window, a setting button window, an operating program view window, and a message window, thereby easily grasping all circumstances occurred in the process of automatically performing an operating program, and a method of controlling an automatic welding apparatus for vertical and horizontal fillet joint welding using the system is provided. A system of controlling an automatic welding apparatus for vertical and horizontal fillet joint welding comprises an operating program processing module(102), a route locus generating part(106), a motion control part(107), an arc sensor module(105), and a welding condition setting part(109). The operating program processing module includes an operating program for welding one unit cell. The operating program processing module analyzes commands in the operating program to generate route information. The route locus generating part generates trajectory information that should be traced by a welding torch end each sampling time using the route information. The motion control part drives each driving part(108) by producing joint information followed by each shaft using inverse kinetics based on the generated trajectory information. The arc sensor detects welding current during welding to find out a trajectory information amount such that an actual welding line corresponds to pre-programmed coordinate values of the trajectory information according to design values. The arc sensor module inputs the trajectory information into the motion control part by reflecting the found trajectory information amount. The welding condition setting part sets up welding conditions appropriate for the weldments according to an operating program into which welding conditions that are differently set up depending on respective weldments have already been inputted.

Description

CONTROL SYSTEM AND CONTROL METHOD OF AN AUTOMATIC WELDING DEVICE FOR VERTICAL AND HORIZONTAL FILLET JOINT WELDING}

The present invention relates to a control system and a control method of an automatic welding device capable of continuously welding vertical and horizontal fillet welds, and more particularly, to provide intelligence to an existing welding carriage based on an industrial PC. The present invention relates to an advanced welding control system and control method.

Shipbuilding constitutes the hull through blocks forming a multi-layer structure, these blocks are abacus, transverse reinforcement, longitudinal longitudinal reinforcing material is sealed through the butt welding (inner welding part) as shown in FIG. The figure shown for the sake of illustration is represented by an open area) to form a block.

As described above, the welded parts which are butt-butted to each other by the horizontal main plate, the horizontal reinforcement material and the longitudinal reinforcement material (the welded parts where the base materials are butted to each other at right angles are referred to as fillet welds) are hereinafter referred to as "fillet welded parts". It is formed in the vertical direction and the horizontal direction.

The conventional welding work, which is dualized into the vertical and horizontal fillet welds, has been performed by separate welding work along the vertical and horizontal using two simple welding devices which can easily track the welding line.

In this case, after installation of the welding device for the line work, after the first welding work along the tracked welds and then dismantled again, the second welding work along the remaining unwelded welds as a whole welding The result is a low productivity of work.

The present invention devised to solve the above problems, to provide the convenience of the operator, the automatic welding device disclosed in the applicant's patent application No. 2005-126776 in the same place as the above block easily into the double hull block An object of the present invention is to provide a control system and control method for operating and controlling a welding carriage-type robot designed to be injected.

The present invention for achieving the above object comprises a work program for welding one unit cell (cell), a work program processing module for generating a path information by interpreting the instructions in the work program; A path trajectory generation unit generating trajectory information to be tracked by the welding torch end at each sampling time using the path information; A motion controller configured to generate joint information that each axis follows using inverse kinematics based on the generated trajectory information to drive each driver; An arc sensor module which detects a welding current during welding, finds a trajectory correction amount to match a coordinate value of the trajectory information programmed according to a design value, and matches the actual welding line, and inputs the reflected trajectory to the motion control unit; And it provides a control system of the automatic welding device for vertical and horizontal fillet welding including a welding condition setting unit for setting the welding conditions suitable for the welding machine according to the welding program is set differently for each welding unit according to the pre-entered work program.

Preferably, the work program processing module receives the position position coordinate value from the touch sensor module before starting welding, reflects it to the program coordinate value in the database, finds the position value of the actual member, and uses the welding torch to You can create coordinate values for the start point and the end point that the end should follow.

In addition, the present invention comprises the steps of generating a work program for performing a work; Selecting an operation mode through an operation unit; Interpreting the command to perform a command included in the work program when the automatic mode is selected; Selecting a movement mode divided into a simple movement and a welding command; When selecting a welding command, processing a pattern including at least one of touch sensing, welding condition setting, weaving pattern setting, and arc sensor pattern processing; Extracting feature points using touch sensing and extracting coordinates modified for tracking actual weld seams during welding through arc sensing; Generating a path trajectory using the modified coordinate values; Executing motion control according to the generated path trajectory; And when one command is completed, it provides a control method of the automatic welding device for vertical and horizontal fillet welding comprising the step of repeatedly performing the next command.

Preferably, the generating of the work program comprises: creating a work macro definition file for the cell in advance with respect to a block composed of various types of cells, and in the main dimension input window. Inputting a major dimension for the cell, performing a matching between the working macro definition file and a macro source file, extracting a macro portion defined in the working macro definition file from the macro source file, and extracting the main dimension Reflecting may include generating a work program.

The present invention is to provide a convenience for the operator, a welding carriage type designed to easily insert the automatic welding device disclosed in the applicant's patent application No. 2005-126776 in the same place as the block into the double hull block It provides the control system and control method necessary to operate and control the robot.

In order to fully understand the present invention, the advantages of the operability of the present invention, and the objects achieved by the practice of the present invention, reference should be made to the accompanying drawings which illustrate preferred embodiments of the present invention and the contents described in the accompanying drawings.

Hereinafter, exemplary embodiments of the present invention will be described in detail with reference to the accompanying drawings. Like reference numerals in the drawings denote like elements.

Figure 2 shows a working diagram using the automatic welding device according to the present invention, the present invention is an automatic welding device capable of performing continuous welding of the fillet welding portion (A1, A2, A3) having a vertical and horizontal direction To provide a control system and a control method, the welding torch installed in the welding apparatus according to the present invention is a linear drive with respect to the X-axis, Y-axis, Z-axis, the A-axis to rotate by a predetermined inclination angle with respect to the Y-axis, the It provides a rotational drive about the W axis rotating about the Z axis.

First, through the X, Y, Z, A, W axis drive as described above, the automatic welding device continuously tracks the vertical and horizontal fillet welds through the arc sensing function commonly used in automatic welding robots. At this time, the welding drive of the automatic welding device of the 5-axis drive according to the present invention is implemented from the signal of the controller (not shown) which receives the set value of the sensed welding line (welding part).

As shown in Fig. 3, the automatic welding device according to the present invention includes: an X-axis base driving portion 10 which is movable on an X-axis parallel to a horizontal fillet welding portion as a base for supporting the apparatus; A W-axis rotation driver 20 rotatably installed on an upper surface of the X-axis base driver 10; A Y-axis guide part 30 installed and fixed to an upper surface of the W-axis rotation driving part 20; A Y-axis sliding driver 40 sliding along the longitudinal direction of the Y-axis guide part 30; A Z-axis guide part 50 installed and fixed to the Y-axis sliding drive part 40; A Z-axis sliding drive unit 60 sliding along the longitudinal direction of the Z-axis guide part 50; Torch clamp 70 of the A-axis drive is rotatably installed by a predetermined inclination angle with respect to the Y-axis from one side of the Z-axis sliding drive unit 60. At this time, the welding torch T is clamped on the torch clamp 70 in parallel with the Y-axis guide part 30.

More specifically, the X-axis base driving unit 10 senses the distance between the transverse reinforcement (2) located in the front and the longitudinal reinforcement (3, 3 ') located on both sides to sense the distance to maintain a predetermined interval The driving wheel 12 is provided with a sensor (not shown) on the outer surface, and maintains a distance detected by the distance sensor using the driving motor 11 as a driving source, and drives the driving wheel 12 in parallel with the horizontal fillet welding part A2. It is provided in a bottom part.

The W-axis rotary drive unit 20 is a turntable structure that is rotated using the drive motor 12 installed in the X-axis base drive unit 10 as a drive source, and the Y-axis guide unit 30 having a longitudinal direction on the upper surface is fixed and interlocked. Will rotate.

The Y-axis sliding drive unit 40 is seated on the rail formed in the Y-axis guide unit 30, the drive motor 41 provided on one side to the drive source in the longitudinal direction of the Y-axis guide unit 30, After sliding drive.

The upper surface of the Y-axis sliding drive unit 40 is fixed to the Z-axis guide unit 50 provided corresponding to the height of the vertical fillet welds (A1, A3) is linked to the Y-axis sliding drive unit (40).

The Z-axis sliding drive unit 60 is seated on the rail formed on the Z-axis guide unit 50, the drive motor 61 provided on one side as a drive source in the longitudinal direction of the Z-axis guide unit 50, Under sliding drive.

On one side of the Z-axis sliding drive unit 60, the drive motor 71 installed in the Z-axis sliding drive unit 60 as a drive source, the sliding of the Y-axis sliding drive unit 40 from one side of the Z-axis sliding drive unit 60 The torch clamp 70 (A-axis) is configured to rotate by a predetermined inclination angle up and down with respect to the direction. That is, the welding torch T mounted on the torch clamp 70 is installed in parallel with the Y-axis direction.

The sliding means according to the linear motion of the Y-axis and the Z-axis and the publicly known and omitted details, and the rotary movement means of the W-axis and the A-axis are linear slides (L / M guide) or screw used as a conventional automatic control means Adopt a combination.

Each of the X-, Y-, Z-, W-, and A-axis driving units includes drive motors 11, 12, and 41 that are operated independently from preset values sensed according to the arc sensing welding line tracking function of a controller (not shown). The weld line tracking of the welding torch T is performed through, 61, 71.

The welding line tracking function of the welding torch by the arc sensing is a technology that can be applied only when the welding torch performs the operation of weaving based on the center of the welding improvement surface. It finds the center by recognizing the pattern of welding current that depends on the shape of improvement by receiving the welding voltage as the center of the improvement of welding. In other words, when weaving around the welding line during one cycle of weaving, the current is different at the edge and center. Since it is formed and fed back, the average welding current value is calculated during the weaving cycle, and the welding current is continuously tracked by correcting the position of the welding torch using the set current value and the difference value.

4 is an example of a working configuration for welding the cells of the block. In order to weld the left vertical fillet weld A1, first, a coordinate value of the vertical fillet welding start point A5 is found using the touch sensing pattern A4. By using the design values, the coordinate values pre-programmed are corrected to the coordinates of the actual weld. Since the height of the vertical fillet weld A1 is given in advance using design data, vertical welding is performed by the height value.

After the welding of the vertical fillet welds is finished, the next weld is performed on the horizontal fillet welds A2. The starting point of the vertical fillet welds is equally horizontal welded using the values previously found through touch sensing. At this time, the width between longitudinal reinforcements is given in the design data. If this value is out of the work area of the welding carriage robot, the welding carriage base moves at the welding speed and performs welding. In the upper manipulator unit, only the in-situ weaving operation is performed.

When the horizontal fillet welding is finished, the welding start point A7 of the right side is found through the teach-sensing pattern A6 and reflected by welding similarly to the case of performing the welding of the right vertical fillet weld A3 again. Will be performed.

5 is a main configuration diagram of an industrial PC based control system for operation of the present invention.

Referring to FIG. 5, the controller 100 includes an operation unit 101, a work program processing module 102, a database 103, a touch sensor module 104, an arc sensor module 105, and a path trajectory generation unit. It consists of 106, the motion control part 107, the drive part 108, the welding condition setting part 109, the welder part 110, etc. The operation unit 101 is composed of operation buttons necessary for a job, and the work program processing module 102 includes a work program for welding one unit cell, and also provides instructions for working in the work program. It has the function of interpreting and processing. In addition, before the start of welding, the member position coordinate value 122 is reflected from the touch sensor module 104 to the program coordinate value in the database 103 to find the actual member position value, and by using this, the end of the welding torch should follow. Coordinate values of the start point and the end point, that is, the route information 123 are generated. Using the path information 123, the path trace generation unit 106 generates track information 125 to be tracked by the welding torch end at every sampling time. Using the generated locus information 125, the motion controller 107 generates joint information 126 to be followed by each axis by using inverse kinematics to drive each driver 108. During welding, the arc sensor module 105 detects the welding current and finds the trajectory correction amount 124 so that the coordinate value of the trajectory information 125 preprogrammed according to the design value is matched with the actual welding line. 107). Therefore, even though there is a slight difference between the actual welding line and the previously taught welding line, the actual welding is accurately welded by correcting the difference by using the arc sensor. In the welding condition setting unit 109, welding conditions are set to be different according to the length of each welding part, and this value is previously input to the work program. Therefore, the welding condition setting unit 109 sets the welding conditions suitable for the welder 110 according to the work program.

6 shows a flowchart of a program for implementing the present invention.

Referring to FIG. 6, a work program for performing a work is generated (S1), and is divided into an automatic mode and a manual mode according to an operation mode selection (S2) in the operation unit 101 of the controller 100. In the manual mode, a jog operation S3 and a wire inching operation S4 for angular axis movement are performed. In the automatic mode, first, in order to perform the work of FIG. 6, first, the command is interpreted to perform the command included in the work program (S10). In the case of simple movement, only path trajectory generation (S17) and motion control execution (S18) are performed relatively simply. In the welding command, various patterns such as touch sensing, welding condition setting, weaving pattern setting, and arc sensor pattern processing are processed (S12). Then, the feature points using touch sensing are extracted (coordinate values) and the modified coordinate values for actual welding line tracking during welding through arc sensing are extracted (S13 and S16). A path trajectory is generated using this modified value (S14), and motion control is executed according to the trajectory (S15). If one command is finished, the next command is repeatedly executed (S19). According to the above flow chart is to control the automatic welding carriage robot to be welded at the same time vertical and horizontal fillet welds.

7 is an example of a GUI screen for generating the work program.

Referring to Fig. 7, the program consists of a work macro definition file 201, a macro source file 202, a main dimension input window 203, and a generated work program file 204.

8 shows a more detailed procedure for automatic generation of a work program.

Referring to FIG. 8, one block is composed of cells of various types. For this cell, a corresponding work macro definition file (a small work program) is created in advance (S21). Even though the shape is the same, the dimensions may be different, so the dimension part of the macro source file is changed and managed. Therefore, in the main dimension input window, enter only the main dimensions for the target cell (S22), and perform the matching between the macro definition file and the macro work file (S23), while the macro part defined in the work macro definition file in the original file. This time, the work program is finally generated by reflecting the main dimensions (S24).

9 is an example of an execution screen of a controller according to the present invention, which includes an operation status window 301, a digital input / output window 302, a setting button window 303, a work program view window 304, and a message window 305. Consists of. This configuration makes it easy to identify all the situations that occur during the execution of the work program automatically, providing convenience to the operator.

Although the present invention has been described with reference to one embodiment shown in the drawings, this is merely exemplary, and those skilled in the art will understand that various modifications and equivalent other embodiments are possible therefrom. . Therefore, the true technical protection scope of the present invention will be defined by the technical spirit of the appended claims.

1 is a schematic view showing the vertical and horizontal fillet welds of the ship block structure to which the present invention is applied.

Figure 2 is a working view showing the working sequence of the vertical and horizontal fillet welds in accordance with the present invention.

Figure 3 is an exemplary view for showing the configuration of the automatic welding apparatus according to the present invention.

4 is an example of a working configuration for welding one cell according to the present invention.

5 is a main diagram of an industrial computer-based controller for the operation of the present invention.

6 is a program flow diagram for implementing the present invention.

7 is an example of a GUI screen for creating a work program according to the present invention.

8 is a sequence of automatic creation of a work program according to the present invention.

9 is an example of an execution GUI screen of a controller according to the present invention.

Claims (4)

A work program processing module including a work program for welding one unit cell, and generating route information by interpreting a command in the work program; A path trajectory generation unit generating trajectory information to be tracked by the welding torch end at each sampling time using the path information; A motion controller configured to generate joint information that each axis follows using inverse kinematics based on the generated trajectory information to drive each driver; An arc sensor module that detects a welding current during welding, finds a trajectory correction amount to match a coordinate value of the trajectory information preprogrammed according to a design value, and reflects the input to the motion control unit; And Control system of the automatic welding device for vertical and horizontal fillet welding, including a welding condition setting unit for setting the welding conditions suitable for the welding machine according to the work program input welding conditions that are set differently for each weld. The method of claim 1, The work program processing module receives the member position coordinate value from the touch sensor module before welding starts, finds the position value of the actual member by reflecting it to the program coordinate value in the database, and uses the end portion of the welding torch along with this. Control system of automatic welding device for vertical and horizontal fillet welding that generates coordinate values of starting and ending points to go. Generating a work program for performing a work; Selecting an operation mode through an operation unit; Interpreting the command to perform a command included in the work program when the automatic mode is selected; Selecting a movement mode divided into a simple movement and a welding command; When selecting a welding command, processing a pattern including at least one of touch sensing, welding condition setting, weaving pattern setting, and arc sensor pattern processing; Extracting feature points using touch sensing and extracting coordinates modified for tracking actual weld seams during welding through arc sensing; Generating a path trajectory using the modified coordinate values; Executing motion control according to the generated path trajectory; And When one command is completed, the control method of the automatic welding device for vertical and horizontal fillet welding comprising the step of repeatedly performing the next command. The method of claim 3, wherein Generating the work program, Creating a working macro definition file for the cell in advance for a block composed of various types of cells; Inputting the main dimension of the cell to be worked on in the main dimension input window; Performing matching between the working macro definition file and the macro original file, and And extracting a macro part defined in the work macro definition file from the macro source file and generating a work program by reflecting a main dimension.

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