KR20110067901A - Overhead lug welding robot and control method thereof - Google Patents

Abstract

PURPOSE: An overhead lug welding robot system and a control method thereof are provided to improve the working efficiency by reducing the setting and movement time of a cart by classifying speed in multiple steps. CONSTITUTION: An overhead lug welding robot system comprises a radio receiver(20), a PLC(Programmable Logic Controller, 30), a robot controlling unit(40), a traveling motor, traveling motor and steering motor drives(70,90), X, Y, Z-axis tilting inverters(130,140,150), a SMPS(Switched Mode Power Supply), and a laser point(190). The radio receiver receives a signal from a wireless remote-controller(10) and moves along with a cart. The PLC controls the cart according to the signal of the radio receiver. The robot controlling unit selects the task information according to an object. The traveling motor and steering motor drives outputs the 15V of alternating current to a driving motor(60) and a steering motor(80) in order to drive motors, respectively. The laser point sets a robot on a working position.

Description

Overhead Lug Welding Robot and Control Method Thereof}

The present invention relates to an apparatus for welding an overhead lug and a control method thereof, in particular, by replacing the robot freely according to the mounting position of the lug attached upside down to the block and replacing the welding difficulty of high difficulty and disease of the neck musculoskeletal system It relates to a device that can prevent the.

To move a large steel structure to a crane, lugs are attached to the structure to connect ropes or wires. Since the lugs vary in size and shape depending on the weight of the moving object and the application location, and work on the lower part due to the characteristics of the work, the attachment of the lugs is made by manual welding of all the masses, and the worker works with the welding position. Lugs are attached to their corners to move large steel structures such as blocks. This is the part connected to the crane hook, etc., so the welder must weld because the reliability of the welded joint is very important. The welding operation of attaching the lug to the block is generally performed by multi-layer welding to strengthen the joint. Multi-layer welding means to weld over the welded bead surface and the number of multi-layer welding depends on the size and shape of the lug. In addition, it is not automated because it requires consideration of various conditions such as the entry angle, the entry depth, the current, the voltage, the welding speed, and the presence of weaving motion of the welding torch. As the worker welds with the welding position, there is a risk of musculoskeletal disorders such as back, shoulders and arms. For this reason, productivity is inadequate because workers work alternately. In addition, slugs and spatters falling during welding pose a threat to the safety of workers and the work area.

Lug welding robot for automatically welding the lug to solve this; A pendant, which is connected to a controller, a control PC, a motor and a servo drive, a control board equipped with electrical equipment, and a control board, used to manually manipulate each part of the lug welding robot or input a welding condition; A welding device including a welder, a welding torch and a wire feeder; A touch sensor for generating a digital signal and extracting a welding line when the welding wire is in contact with the welding member; A lug welding robot system has been developed that includes a lug welding robot system and a power panel for supplying power to a welder and a touch sensor.

However, the conventional wired remote controller had a problem that it takes a long time due to the inconvenience of moving and setting the balance due to the small operator moving radius. In case of wireless, operation is inconvenient because it cannot give speed in several stages, which also took a long time. In addition, it was difficult to properly cope with the lug mounting state because there was no additional shaft, and the existing truck had difficulty in precise positioning and maintenance by using a DC motor as the battery was used.

According to the present invention, the speed can be divided into several stages even in the case of a wireless remote control method, thereby reducing work balance and setting time, thereby improving workability, and easily using an AC servo motor for precise setting and maintenance even when using a battery. Only the wheel wheels can traverse / rotate, forward / meander, and steer while driving, which reduces the settling time of the truck, improving productivity and reducing manpower, and making it easier to set welding robots even for lug mounting conditions An object of the present invention is to provide a head lug welding robot system and a control method thereof.

In order to achieve the above object, the present invention provides a balance wireless remote control for adjusting the balance wirelessly;

A wireless receiver that receives and outputs a signal transmitted from a wireless remote controller and moves together with the balance moving unit;

A programmable logic controller (PLC) for controlling the balance system (drive 2 axes, steering 4 axes, and additional 5 axes) in accordance with the signal received from the radio receiver;

A robot operating panel that is in charge of selecting a job information according to a job target;

Robot controller having welding operation information according to the type and size of the lug;

A traveling motor comprising a plurality of servomotors integrated with a wheel;

A plurality of driving motor drives receiving the DC 24V and outputting AC15V to the traveling motor to drive the traveling motor;

A plurality of steering motors as a servo motor that determines steering of wheels integrated with the traveling motors;

A plurality of steering motor drives configured to receive DC 24V and output AC 15V to the steering motor to drive the steering motor;

An X-tilting motor composed of an induction motor;

Y-tilting motor composed of induction motor;

A Z-upper motor composed of an induction motor;

An X-axis slide motor designed to be useful when moving a fine drive shaft (50mm) without moving the bogie drive shaft;

A Y-axis slide motor designed to be useful when the fine drive (50 mm) moves without moving the bogie drive shaft;

An X-axis tilting inverter for adjusting the speed by receiving a step command signal from the PLC and controlling the speed of the X-tilting motor in multiple stages;

A Y-axis tilting inverter that adjusts the speed by receiving a step command signal from the PLC and controls the speed of the Y-tilting motor in multiple stages;

A Y-axis tilting inverter for adjusting the speed by receiving a step command signal from the PLC and controlling the speed of the Z up-and-down motor in multiple stages;

Switched Mode Power Supply (SMPS) MC, which is a power supply that converts DC 24V voltage for X-axis slide motor and Y-axis slide motor; And

An apparatus for setting a robot at a reference position for working, characterized in that it comprises a laser point for placing the robot on a workpiece to which the robot can be welded using four line lasers.

According to the present invention, the operator can call the balance even at a distance of 1km, and in many cases, the operator has to move back and forth between the balance storage and the workplace in the case of the wired remote control, but in the case of wireless, the number can be called without going. In addition, it is easy to move the trolley inside the celta field where there are many obstacles, and the additional 5-axis enables precision setting according to the lug mounting state, and the welding quality is excellent. In addition, even when using batteries, AC servomotors are adopted to reduce the balance setting time, and maintenance problems can be improved.

Hereinafter, an embodiment of the present invention will be described in detail with reference to the accompanying drawings.

1 is a control block diagram of an overhead lug welding robot system of the present invention.

In Figure 1, the balance wireless remote control 10, the operator can operate the balance even outside 1km, when moving the truck to the required factory in a wide shipyard factory, the worker does not need to move to the balance, such as a wired remote control, and wirelessly This is useful for avoiding obstacles when moving inside the balance of the cell. Although not shown, the balance wireless remote controller has a button for changing the mode of the four wheels for driving, traversing, and rotating, and before (both) and before (mast) after different actions depending on the movement / position mode in the lower right corner. It has a button, a front / rear, a mast button for tilting left and right, a table for X and Y-axis slides, and a forward / meander mode of traveling (car driving mode) and meandering (four wheel direction modes).

In addition, the wireless receiver (WRC) 20 receives a signal transmitted from the wireless remote controller 10 and transmits a signal to a programmable logic controller (PLC) 30. The wireless receiver 20 is attached to the back of the trolley to move together when the trolley moves.

PLC 30 controls the balance system (drive 2 axis, steering 4 axis, additional axis 5 axis) according to the signal received from the radio receiver 20, and the command signal input from the robot control panel 40 is a robot controller standard. Transfer to the controller 210 (to be described later) serves as an interface with the standard controller to allow the standard controller to work with the robot. And the balance operation function to operate on the trolley operation panel 50 is made. For example, the emergency stop and the balance driving start and the laser point power are included in the balance control panel 50.

In the case of the robot control panel 40, it is attached to the left side of the trolley main panel door and selects the type of lug (A and B type) and the size (40 ~ 100) to select the corresponding job to start / stop / restart the job. You can do this by using the / End Task button. The welding operation information of the lug according to the type and size are all owned by the robot controller, and the robot control panel 40 is only responsible for selecting the operation information according to the operation target. The job information selected on the robot control panel 40 is transmitted to the robot controller by Ethernet communication through the PLC 30.

The trolley operation panel 50 is attached to the right side of the trolley main panel door and performs functions such as emergency stop and driving start and laser point power, which are functions other than the operation of the trolley.

The traveling motor 60 used a servo motor (AC15V) integrated with the wheel, and the traveling motor was installed with two traveling motors at the rear in consideration of the weight being biased at the rear of the truck. In the case of the servo motor, since the operating voltage is the battery [24V], the servomotor of 15V operating voltage was adopted in consideration of PWM (pulse width modulation).

The motor drive 70 is composed of two, in the case of the motor drive is a servo motor drive of a special function that the input voltage is a battery 24V and the output voltage is modulated to AC and applied to the motor. The control of the driving motor 60 is a command for the speed 1,2,3,4 steps and forward / reverse from the wireless remote controller 10 before and after using the joystick, and the PLC 30 corresponds to the analog voltage. Is applied to the motor drive 70 by using the D / A converter module built in the PLC. The motor 60 then speeds in proportion to the applied analog voltage.

Encoder feedback about speed is input from the motor to the motor drive 70.

The control of the steering motor 80 is to press the joystick left and right by the desired angle of the balance wheel (not shown) to change the angle of the balance wheel and then to return to press the joystick. Unlike the driving motor 60, the steering motor is operated by applying a contact instead of giving an analog signal. The position control of the servo motor for steering is performed by comparing the position analog command value corresponding to the step of varying in the wireless joystick with the analog input module of the PLC 30 and the position analog signal value of the servo motor until the difference becomes zero. Motor control is achieved by driving the motor.

The steering speed is different according to the 1st and 2nd stage of the joystick. The speed feedback for the corresponding speed is transmitted from the motor to the motor drive 90, which is a motor drive, and is controlled. The information on the position [four motor wheel position information] is controlled by using the variable resistor A / A of the PLC 30. It receives the input from the D converter module and controls the positions of the four wheels.

X-tilting motor 100 / Y-axis tilting motor Z-axis rising motor 120 is composed of an induction motor. The X-axis tilting inverter 130 adjusts the speed by receiving the step command signal from the PLC 30 and controls the speed of the X-tilting motor 100 in multiple stages. The Y-axis tilting inverter 140 receives the step command signal from the PLC 30 to adjust the speed, and controls the speed of the Y-tilting motor 110 in multiple stages. Z-axis tilting inverter 150 receives the step command signal from the PLC (30) to adjust the speed, and controls the speed of the Z-up and down motor in multiple stages. In the wireless remote controller 10, the 1,2- and 3-stage joysticks are adjusted when they are adjusted. The X-axis slide motor 160 and the Y-axis slide motor 170 are D.C motors, which are precisely moved on / off in the forward / reverse direction within a range of up to 50 mm. As described above of the motor control of the additional 3-axis motor, that is, the X-axis tilting / Y-axis tilting / Z-axis tilting motors 100, 110, and 120, an inverter is used for multi-step speed control. The motor is controlled by open loop speed control. The peculiarity is that the variable resistor is attached to the gear to determine the position of the motor so that the position of the motor can be determined using the PLC A / D converter module. Switched Mode Power Supply (SMPS) is a power supply that converts the DC 24V voltage for the X-axis slide motor 160 and Y-axis slide motor 170. As described above, the X-axis slide motor and the Y-axis slide motor used a DC motor, but when the AC motor is used, it is difficult to attach due to the volume and difficult to install due to the weight. When used, it requires additional inverters for speed control, which makes installation difficult in many ways. In case of DC motor, only DC 24V power is supplied and only on / off control is required, so it is easy to control and install and its volume is also suitable. The slide shaft is designed to be useful when moving fine adjustment (50mm) without moving the bogie drive shaft, and also receives a position using a PLC 30 A / D converter module using a variable resistor for positioning. The laser point 190 is a device for setting the robot at a reference position for working. The laser point 190 is positioned on a workpiece to which the robot can be welded using four line lasers.

In the case of the robot system shown on the left side, the welding robot (6 axes) 200 performs the welding operation, the standard controller 210 controls the welding robot, and the welding robot 200 inside the standard controller 210. It includes six servo drives for driving the servo motor (not shown) of the motor, and a controller is included therein. The standard controller 210 interfaces with a welder 220 for welding to provide a voltage / current signal. As an additional device for welding, there are a wire feeder 230 and a welding torch 250 as a feeding device, and the touch panel 260 is for coping with an error during operation by the robot. Connected to 210). The touch sensor 240 uses the balance driving / steering function and the additional five axes to determine the exact position of the object through the touch function when the robot is placed in the initial position of the object. The attachment device junction box is composed of a control circuit for controlling the attachment device (tool changer, wire, cut), which will be described later. The attachment device 280 is a tool for changing the tool by a robot to a chipper for removing slag after welding. Change and wire cut.

Here, the PLC 30 and the standard controller 210 communicate with each other, and the operator sets up the robot, and then starts and finishes / stops the work and selects the work (selects the lug size and type) to give the work command to the robot. do. The standard controller 210 performs welding by giving a welding voltage and a current command according to the lug size and type.

2 is an additional 5-axis representation of an overhead lug welding robot.

There are five additional axes for setting the separate welding robot of the present invention, and the lug tilt and height vary widely, so that three axes (X, Y tilting and Z-axis) are required when setting the lugs and the driving / steering roughly. After setting, X tilting, Y tilting, and Z-axis setting, X slide and Y slide axis (50 mm stroke) for fine adjustment of the welding robot were configured separately. As shown in the figure, Rx is the x-axis tilting axis of the robot base 300, Ry is the y-axis tilting axis of the robot base 300, Tz is the z-axis shanghai coaxial axis of the robot base 300, and Tx , Ty is the x, y slide axis of the robot base 300. Here, the motor moving to each of the axes of the additional five axes is not shown.

The use of the additional 5-axis is an additional axis for setting the position of the robot to apply the welding conditions obtained in the welding experiment to the actual welding work because the conditions (height, horizontal, and inclination) of the lugs are mounted are different. . Additional five axes are X tilting, Y tilting, Z-axis, up / down, X slide, Y slide operation of the entire robot base (30). The groove in the center of the truck is also a measure to secure the stroke to raise / lower the entire robot base on the Z axis.

3 is a flowchart showing a setting procedure of the overhead lug welding robot system.

Initially, the trolley travel / steering shaft is used to move the cart work celta length (S10), and the bogie is positioned under the lug to be worked in the work celta length (S20). Turn on four laser points (S30). The X axis tilt of the welding robot (6 axes) is set using the X tilting axis (S40), and the Y axis tilt of the welding robot (6 axes) is set using the Y axis tilting axis (S50). The height of the welding robot (6 axes) is set using the Z axis (S60), the X axis of the welding robot is finely adjusted using the X slide axis (S70), and the Y axis of the welding robot is finely adjusted using the Y slide axis. (S80), the final setting of the height of the welding robot (6 axes) using the Z axis (S90) and starts welding (S100).

This completes the setting sequence of the welding robot system.

The apparatus of the present invention is a wall type system mounted on a trolley to weld a lug with an overhead, and includes a six-axis welding robot responsible for welding and a six-axis moving cart moving and a robot for setting the welding robot to the lug. It consists of 17 axes of 5 axes. Unlike the conventional method, the servo drive shaft is used for the precise position setting and maintenance by using the servo motor. The driving motor is located behind the truck, and the speed control for driving adopts the multi-step speed control method using wireless. In order to control the servo motor's position for steering, use the analog input module of PLC to compare the position analog command value corresponding to the variable stage in the wireless joystick with the position analog signal value of the servo motor and operate the motor until the difference becomes zero. Motor control is achieved by driving. In addition, the traversing / rotating / driving mode enables the steering wheel of the bogie to be rotated 90 degrees / 45 degrees / 0 degrees, respectively. To be located. Since there are five additional axes, it is easy to set the mounting state of the lugs according to different tiers.

While an embodiment of the present invention has been described with reference to the drawings, the present invention is not limited thereto, and various modifications and variations are made by those skilled in the art without departing from the spirit and scope of the appended claims below. Such modifications and variations may be interpreted as being within the scope of the present invention.

1 is a control block diagram of an overhead lug welding robot system of the present invention.

2 is an additional 5-axis representation of an overhead lug welding robot.

3 is a flowchart showing a setting procedure of the overhead lug welding robot system.

* Description of the symbols for the main parts of the drawings *

10: balance wireless remote control, 20: wireless receiver

30: PLC 40: Robot Control Panel

50: trolley control panel 60: traveling motor

70: drive motor drive 80: steering motor

90: steering motor drive 100: X tilting motor

110: Y tilting motor 120: Z up and down motor

130: X axis tilting inverter 140: Y axis tilting inverter

150: Z axis up and down inverter 160: X axis slide motor

170: Y-axis slide motor 180: SMPS

190: laser point 200; Welding robot

210: standard controller 220: welding machine

230: wire feeder 240: touch sensor

250: welding touch 260: touch panel

270: attachment device junction box 280: attachment device

300: robot base

Claims (3)

A balance wireless remote control for wirelessly adjusting the balance; A wireless receiver that receives and outputs a signal transmitted from a wireless remote controller and moves together with the balance moving unit; A programmable logic controller (PLC) for controlling the balance system (drive 2 axes, steering 4 axes, and additional 5 axes) in accordance with the signal received from the radio receiver; A robot operating panel that is in charge of selecting a job information according to a job target; Robot controller having welding operation information according to the type and size of the lug; A traveling motor comprising a plurality of servomotors integrated with a wheel; A plurality of driving motor drives configured to receive DC 24V and output AC15V to the traveling motor to drive the traveling motor; A plurality of steering motors as a servo motor that determines steering of wheels integrated with the traveling motors; A plurality of steering motor drives configured to receive DC 24V and output AC 15V to the steering motor to drive the steering motor; An X-tilting motor composed of an induction motor; Y-tilting motor composed of induction motor; A Z-upper motor composed of an induction motor; An X-axis slide motor designed to be useful when moving a fine drive shaft (50mm) without moving the bogie drive shaft; A Y-axis slide motor designed to be useful when the fine drive (50 mm) moves without moving the bogie drive shaft; An X-axis tilting inverter for adjusting the speed by receiving a step command signal from the PLC and controlling the speed of the X-tilting motor in multiple stages;  A Y-axis tilting inverter for adjusting the speed by receiving a step command signal from the PLC and controlling the speed of the Y-tilting motor in multiple stages; A Y-axis tilting inverter for adjusting the speed by receiving a step command signal from the PLC and controlling the speed of the Z up-and-down motor in multiple stages; Switched Mode Power Supply (SMPS) MC, which is a power supply that converts DC 24V voltage for X-axis slide motor and Y-axis slide motor; And An apparatus for setting a robot in a reference position for working, comprising: a laser point for positioning the robot on a workpiece to which the robot can be welded using four line lasers. The method of claim 1, A welding robot (6 axes) for performing a welding operation; A standard controller for controlling the welding robot and including six servo drives for driving a servo motor (not shown) of the welding robot 200 and including a controller; A welder that welds and interfaces with the standard controller for voltage / current signals; An additional apparatus for welding, comprising: a wire feeder 230 welding torch as a feeding device; A touch panel connected to the standard controller 210 as a robot to cope with an error during operation; A touch sensor that detects the exact position of the object through a touch function when the robot is moved to the initial position of the object by using the vehicle traveling / steering function and the additional five axes; Additional devices, such as tool change and wire cut, in which the robot turns the tool into a chipper to shake off the slag after welding; And An overhead lug welding robot system, further comprising an additional device junction box composed of a control circuit for controlling the additional device (tool changer, wire, cut). Moving the balance work cellar using the balance driving / steering shaft; Positioning the bogie under the lug to be worked in the working cellar; Turning on four laser points; Setting an X-axis tilt of the welding robot (6 axes) using the X tilting axis; Setting a Y axis tilt of the welding robot (6 axes) using a Y axis tilting axis; Setting a height of the welding robot (6 axes) using the Z axis; Fine-tuning the X axis of the welding robot using the X slide axis; Fine-adjusting the Y axis of the welding robot using the Y slide axis; Finally setting the height of the welding robot (6 axes) using the Z axis; And And starting the welding.

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