KR20170058720A - Welding robot with lds and calibration method thereof - Google Patents

Welding robot with lds and calibration method thereof Download PDF

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Publication number
KR20170058720A
KR20170058720A KR1020150162688A KR20150162688A KR20170058720A KR 20170058720 A KR20170058720 A KR 20170058720A KR 1020150162688 A KR1020150162688 A KR 1020150162688A KR 20150162688 A KR20150162688 A KR 20150162688A KR 20170058720 A KR20170058720 A KR 20170058720A
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South Korea
Prior art keywords
torch
welding robot
distance sensor
laser distance
target
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KR1020150162688A
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Korean (ko)
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KR101777618B1 (en
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이지형
정성균
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대우조선해양 주식회사
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B25—HAND TOOLS; PORTABLE POWER-DRIVEN TOOLS; MANIPULATORS
    • B25J—MANIPULATORS; CHAMBERS PROVIDED WITH MANIPULATION DEVICES
    • B25J11/00—Manipulators not otherwise provided for
    • B25J11/005—Manipulators for mechanical processing tasks
    • 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
    • B23K37/00—Auxiliary devices or processes, not specially adapted to a procedure covered by only one of the preceding main groups
    • B23K37/02—Carriages for supporting the welding or cutting element
    • B23K37/0241—Attachments between the welding or cutting element and the carriage
    • 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
    • B23K9/095—Monitoring or automatic control of welding parameters
    • 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
    • B23K9/12—Automatic feeding or moving of electrodes or work for spot or seam welding or cutting
    • B23K9/126—Controlling the spatial relationship between the work and the gas torch
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B25—HAND TOOLS; PORTABLE POWER-DRIVEN TOOLS; MANIPULATORS
    • B25J—MANIPULATORS; CHAMBERS PROVIDED WITH MANIPULATION DEVICES
    • B25J19/00—Accessories fitted to manipulators, e.g. for monitoring, for viewing; Safety devices combined with or specially adapted for use in connection with manipulators
    • B25J19/02—Sensing devices
    • B25J19/021—Optical sensing devices
    • B25J19/022—Optical sensing devices using lasers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B25—HAND TOOLS; PORTABLE POWER-DRIVEN TOOLS; MANIPULATORS
    • B25J—MANIPULATORS; CHAMBERS PROVIDED WITH MANIPULATION DEVICES
    • B25J9/00—Programme-controlled manipulators
    • B25J9/16—Programme controls
    • B25J9/1628—Programme controls characterised by the control loop
    • B25J9/1653—Programme controls characterised by the control loop parameters identification, estimation, stiffness, accuracy, error analysis
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B25—HAND TOOLS; PORTABLE POWER-DRIVEN TOOLS; MANIPULATORS
    • B25J—MANIPULATORS; CHAMBERS PROVIDED WITH MANIPULATION DEVICES
    • B25J9/00—Programme-controlled manipulators
    • B25J9/16—Programme controls
    • B25J9/1656—Programme controls characterised by programming, planning systems for manipulators
    • B25J9/1664—Programme controls characterised by programming, planning systems for manipulators characterised by motion, path, trajectory planning
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B25—HAND TOOLS; PORTABLE POWER-DRIVEN TOOLS; MANIPULATORS
    • B25J—MANIPULATORS; CHAMBERS PROVIDED WITH MANIPULATION DEVICES
    • B25J9/00—Programme-controlled manipulators
    • B25J9/16—Programme controls
    • B25J9/1679—Programme controls characterised by the tasks executed

Abstract

The present invention relates to a welding robot including a laser distance sensor and a calibration method thereof. The welding robot including the laser distance sensor comprises: the laser distance sensor which senses a distance with an object; a torch which executes welding; a clamping unit installed in the torch to be rotated in an upward and downward direction, left and right direction, and a forward and backward direction; and an installation block installed in one side of the clamping unit, having the laser distance sensor installed therein. The present invention has a configuration of calibrating a posture and position of the welding robot by rotating the clamping unit based on an offset distance between the laser distance sensor and an end of the torch and a coordinate value of the end of the torch; and adjusting an angle of the laser distance sensor. As such, the laser distance sensor is installed to be rotated in an upward and downward direction, left and right direction, and a forward and backward direction around the torch; and a posture and position of the welding robot is able to be calibrated with a simple calibration work using a target.

Description

BACKGROUND OF THE INVENTION 1. Field of the Invention [0001] The present invention relates to a welding robot having a laser distance sensor,

The present invention relates to a welding robot having a laser distance sensor and a calibration method thereof, and more particularly, to a welding robot equipped with a laser distance sensor for adjusting the position and attitude of a welding robot, A welding robot and a calibration method thereof.

In a typical shipbuilding process, steel structure blocks are supported by block supports, and overhead welding is frequently performed to attach lugs or other various attachments to the bottom of the block.

In order to improve the mobility of the robots, there have been proposed various types of welding machines such as a welding robot, A lender is proposed.

As described above, the position and posture of the robot must be corrected when welding the lug using the welding robot to which the bogie is applied.

That is, the lug is attached through the weld under the block supported by the trough (block support). However, since the flatness of the bottom surface of the block to which the lug is attached varies slightly depending on the position of the lug and the field bottom surface also has a slight inclination, the attitude of the robot performing the overhead welding is set at the attachment position X, Y, Z) and attitude (ROLL, PITCH, YAW).

As a method for correcting the position and attitude of the welding robot, a method using a laser vision sensor and a method using a laser pointer are known.

The laser vision sensor uses three-dimensional information (distance, angle) of the lug and corrects the robot's position and posture accordingly. (X, Y, Z, ROLL, PITCH, YAW) information about the lug attachment position using the laser vision sensor after appropriately positioning the bogie equipped with the welding robot near the lug, To the robot controller so that the robot can grasp the position and angle of the lug.

The method of using the laser pointer is a method of determining the position of the robot and the position information of the lug. That is, after the bogie equipped with the welding robot is appropriately positioned near the lug, the relative position of the robot with respect to the lug attachment position is corrected using the laser pointer.

However, although the laser vision sensor using the above-described method enables accurate position and attitude control, it is very expensive, has a long development period, and requires high-tech image processing technology.

In addition, although the laser pointer using method allows precise position control, it has a disadvantage that it is impossible to set the relative posture of the robot with respect to the lug.

In order to solve such a problem, the applicant of the present invention has filed a patent application for a lug welding robot using a laser pointer and disclosed in Patent Document 1 below.

Patent Document 1 describes a method of setting the position and attitude of a welding robot using a bogie equipped with a separate additional shaft and four laser pointers for welding a welding object (lug) located on the upper part of the robot.

Korea Patent Registration No. 10-1503304 (Announcement on March 17, 2015)

However, in the conventional welding robot including the patent document 1, the laser distance sensor is attached to the welding robot using a clamp type member for simple support.

Accordingly, the welding robot according to the related art has a problem that calibration work for precise measurement of the laser distance sensor is cumbersome and difficult.

An object of the present invention is to provide a welding robot equipped with a laser distance sensor in which a laser distance sensor is installed to be adjustable in a welding robot.

It is another object of the present invention to provide a welding robot having a laser distance sensor capable of easily calibrating the position and attitude of a welding robot by adjusting the angle of the laser distance sensor, and a calibration method therefor.

In order to achieve the above object, a welding robot having a laser distance sensor according to the present invention includes a plurality of shafts, a laser distance sensor for sensing a distance to an object, a torch for performing welding, And a mounting block provided on one side of the clamping part and provided with the laser distance sensor, wherein an offset distance between the laser distance sensor and the end of the torch and an offset distance between the laser distance sensor and the end of the torch, And the position and position of the welding robot are corrected by adjusting the angle of the laser distance sensor by rotating the clamping unit based on the coordinate value.

The clamping unit includes an upper body and a lower body coupled to each other at an upper portion and a lower portion of the torch, the upper body and the lower body, and a rotary member installed between the upper body and the lower body. .

The lower body and the lower body are respectively formed with insertion grooves into which the rotary member is inserted, the rotary member is formed in a spherical shape, and a coupling hole through which the torches are coupled is formed at a central portion of the rotary member .

Wherein the welding robot comprises: a controller for controlling driving of the plurality of servo drivers by communication with a controller to drive a plurality of AC servomotors corresponding to a plurality of axes; a display unit for displaying a state of each of the plurality of servo drivers; Wherein the control unit is configured to move the torch toward the target in a state where the torch is vertically disposed on the plane center portion of the target, and when the touch is completed, The coordinates of the end point of the moved torch and the coordinates of the end point on which the torch is moved on the XY plane are calculated so that the ray of the laser distance sensor is disposed at the center of the target.

The target is formed in a hexahedron shape whose top surface is square, a center hole is formed in the center of the target, and a circle and a square are displayed on the top surface of the target at predetermined intervals.

According to another aspect of the present invention, there is provided a method of calibrating a welding robot including a laser distance sensor, the method comprising the steps of: (a) arranging an end of a torch provided on a welding robot in a vertical direction on a target plane, (B) when the touch signal is received from the touch sensor provided at the end of the torch, the torch is moved in the -Z-axis direction by a preset distance (C) moving the torch on the XY plane so that the light beam emitted from the laser distance sensor is located in the center hole, and calculating an end point coordinate value of the moved torch (D) moving the torch in the Z-axis direction and inspecting whether the light beam is located in the center hole; and (e) Four result, when the light beam is placed in a different location other than the center hole, characterized in that by adjusting the angle of the mounting block is a laser distance sensor provided comprising the step of correcting the position and posture of the welding robot.

In the step (b) and the step (c), the control unit of the welding robot may calculate the Z-axis offset distance between the end of the torch and the center point of the light beam of the laser distance sensor, and the X- and Y- And calculating an end point coordinate value of the torch using the offset distance of the torch.

In the step (e), the angle of the installation block is adjusted by rotating the clamping unit installed to the torch so as to be rotatable up and down, right and left and forward and backward directions.

The method may further include the step of: (f) inspecting whether the light beam is disposed in the center hole after performing the step (e), and if it is determined in step (f) The step (c) to (f) are repeatedly performed until the center hole is disposed in the center hole.

As described above, according to the welding robot including the laser distance sensor according to the present invention and the calibration method thereof, the laser distance sensor can be installed so as to be rotatable up and down, front and rear, and left and right about the torch, An effect of correcting the posture and position of the welding robot can be obtained through the calibration work.

That is, according to the present invention, the position and the position of the welding robot can be easily corrected by adjusting the angle of the laser distance sensor using the end of the torch, the offset distance of the laser beam emitted from the laser distance sensor, and the coordinate value .

Thus, according to the present invention, it is possible to reduce the time required for the calibration work of the welding robot, thereby shortening the working time and improving the workability.

FIG. 1 is a configuration diagram of a welding robot having a laser distance sensor according to a preferred embodiment of the present invention and a welding robot control system for controlling the same.
2 is a partially enlarged perspective view of a welding robot having a laser distance sensor according to a preferred embodiment of the present invention,
3 is an exploded perspective view of the clamping portion,
4 is a perspective view of a target used in a calibration operation of a welding robot,
FIG. 5 is a flowchart for explaining steps of a calibration method of a welding robot having a laser distance sensor according to a preferred embodiment of the present invention,
Figs. 6 to 9 are operation state diagrams for performing a calibration operation according to the calibration method shown in Fig. 5; Fig.

Hereinafter, a welding robot having a laser distance sensor according to a preferred embodiment of the present invention and a calibration method thereof will be described in detail with reference to the accompanying drawings.

1 is a configuration diagram of a welding robot having a laser distance sensor according to a preferred embodiment of the present invention and a welding robot control system for controlling the same.

1, a welding robot with a laser distance sensor according to a preferred embodiment of the present invention and a welding robot control system for controlling the welding robot will be briefly described.

1, a welding robot control system 10 for controlling a welding robot having a laser distance sensor according to a preferred embodiment of the present invention includes a welding robot 20 having a plurality of shafts, A welder 12 connected to the welding robot 20 to perform a welding operation using the welding robot 20 and a controller 13 for controlling the welding robot 20 and the welder 12, .

The welding portion 12 includes a manual welder 14 provided in a yard which is a production site of the ship and a feeder 15 for supplying a welding wire to the torch 21 of the welding robot 20. [

2 is a partially enlarged perspective view of a welding robot having a laser distance sensor according to a preferred embodiment of the present invention.

The welding robot 20 includes a controller (not shown) for controlling the driving of a plurality of servo drivers (not shown) through communication with the controller 13 to drive a plurality of AC servomotors corresponding to a plurality of axes, (Not shown) for displaying the state of each of the plurality of servo drivers, an emergency stop switch (not shown) for stopping the operation of the welding robot 20 when an emergency state of the welding robot 20 occurs, And a torch (21).

The welding robot 20 is equipped with a biaxial traveling and a four-axis steering function and can be mounted on a bogie (not shown) capable of moving in the X and Y directions and adjusting the YAW angle.

For example, the welding robot 20 includes X, Y, Z slide means for moving the base of the welding robot 20 in the 5-axis direction and additional 5-axis means for X and Y tilting means, .

2, the torch 21 is installed at the front end of the welding robot 20 having multiple axes and the torch 21 is provided with a clamping part 23 and a laser distance sensor 22, (24) may be combined.

The laser distance sensor 22 emits a laser beam to an object to be measured for distance, receives light reflected from the object, and measures the distance to the object.

The laser distance sensor 22 may be installed on the front side of the installation block 24 installed on one side of the clamping part 23, for example, the bottom surface, so as to emit a laser beam in a direction parallel to the end of the torch 21 .

In this embodiment, the clamping part 23 can be installed on the torch 21 so as to be rotatable in the directions of Tx, Ty, and Tz, that is, front and back, up and down and left and right directions as shown in FIG.

For example, Fig. 3 is an exploded perspective view of the clamping portion.

3, the clamping portion 23 includes an upper body 31, a lower body 32, and a central portion 32 of the torch 21, which are coupled to each other at upper and lower portions around the torch 21 to form a hexahedron, And a rotary member 33 installed on the outer circumferential surface and inserted and coupled between the upper body 31 and the lower body 32.

The upper body 31 and the lower body 32 are each formed in a substantially rectangular parallelepiped shape and are provided with insertion grooves 34 may be formed.

The rotary member 33 is formed in a substantially spherical shape and inserted into the insertion groove 34 formed in the upper body 31 and the lower body 32 to rotate the clamping part 23.

For this purpose, a coupling hole 35 to which the torch 21 is coupled may be formed at the center of the rotary member 33.

Therefore, the worker rotates the clamping part 23 around the rotary member 33 in a state where the fixing bolt for fixing the upper body 31 and the lower body 32 of the clamping part 23 is released or loosened, The angle of the laser distance sensor 22 provided on the block 24 can be adjusted.

Then, the operator can calibrate the position and position of the welding robot 20 by using the target 40 provided for effectively performing the calibration work.

4 is a perspective view of a target used in a calibration operation of a welding robot.

As shown in FIG. 4, the target 40 may be formed in a hexahedron shape having a square top surface, and a center hole 41 may be formed in the center of the top surface of the target 40.

A large number of squares and circles may be displayed on the upper surface of the target 40 at a predetermined interval, for example, about 10 mm, centered on the center hole 41 so that the movement position of the torch can easily be confirmed.

Here, the center hole 41 may be formed at a predetermined depth, for example, about 1 mm.

Such a target 40 may be made of a metal material such as aluminum and the top surface of the target 40 may be coated with an insulating material such as rubber.

2, 10 is an offset distance in the Tz direction between the center of the light beam and the torch end of the laser distance sensor, d is an offset distance in the Tx and Ty directions between the torch center and the laser distance sensor, l is the distance measured by the laser distance sensor.

Therefore, the coordinates of the torch end point (X 0, Y 0) and referred to, when the coordinates of the laser distance sensors (X, Y) d, d can be calculated by Equation 1 below.

Figure pat00001

If the coordinates of the torch end point at an arbitrary position are (Tx, Ty, Tz), the coordinate L of the final detected point detected by the laser distance sensor is as follows.

L = (Lx, Ly, Lz ) = [Tx- (XX 0), Ty- (YY 0), Tz + ll 0)]

Next, a method of calibrating a welding robot having a laser distance sensor according to a preferred embodiment of the present invention will be described in detail with reference to FIGS. 5 to 7. FIG.

FIG. 5 is a flowchart for explaining a step-by-step calibration method of a welding robot provided with a laser distance sensor according to a preferred embodiment of the present invention. FIGS. 6 to 9 are flowcharts of a calibration process Fig.

5, the operator operates the teaching manipulator 11 to drive the plurality of servomotors provided in the welding robot 20 to arrange the torch 21 in a direction perpendicular to the plane of the target 40, 21 is disposed above the center hole 41 formed at the center of the target 40. [

In step S12, a control unit (not shown) provided in the welding robot 20 controls the driving of each servo motor so as to move the torch 21 in the Tz direction according to an operator's operation command.

Here, a touch sensor (not shown) for sensing a position in a touch manner is installed at the end of the torch 21. [

In step S14, as shown in FIG. 6, the controller checks whether a touch is completed and receives a touch signal from the touch sensor, and moves the end of the torch 21 until a touch signal is received.

When the touch signal is received, the control unit moves the torch 21 in the -Tz direction by a predetermined set distance in step S16.

For example, the predetermined distance may be set to about 11 mm when the depth of the center hole 41 is 1 mm.

Then, in step S18, the controller stores the motor rotation angle and calculates the end point coordinate values (X 0 , Y 0 , Z 0 ) of the torch 21 using forward kinematics.

7, the control unit moves the end of the torch 21 in the Tx and Ty directions to control the laser beam to be placed in the center hole 41 of the target 40, as shown in FIG.

In step S22, the control unit stores the motor rotation angle, and calculates the end point coordinate values (X, Y, Z) of the moved torch.

Subsequently, in step S24, the control unit controls the torch 21 to move in the -Tz direction as shown in Fig.

In step S26, the operator checks whether the laser beam is located in the center hole 41 of the target 40. [

If the laser beam is located in the center hole 41 of the target 40 as a result of the inspection in step S26, the control unit stops driving the welding robot 20 and terminates the calibration operation.

On the other hand, if it is determined in step S26 that the laser beam is located at a position other than the central hole 41 of the target 40, the operator rotates the clamping unit 23 back and forth, left and right, The laser beam is arranged in the center hole 41 of the target 40 by adjusting the angle of the laser beam 22 (S28), as shown in FIG.

In step S30, the control unit controls to move the torch 21 again in the Tz direction.

Then, in step S32, the operator checks whether the laser beam is located in the center hole 41 of the target 40. Then,

If the laser beam is located in the center hole 41 of the target 40 as a result of the inspection in step S32, the control unit stops driving the welding robot 20 and terminates the calibration operation.

On the other hand, if it is determined in step S32 that the laser beam is located at a position other than the center hole 41 of the target 40, the control unit repeats steps S20 to S32 so that the laser beam is focused on the center of the target 40 The calibration operation is repeated so as to be placed in the hole 41. [

According to the present invention, the laser distance sensor is rotatably mounted on the torch in the up-and-down, front-back, and left-right directions, and the posture and position of the welding robot are corrected through a simple calibration operation using the target .

Although the invention made by the present inventors has been described concretely with the above embodiments, the present invention is not limited to the above embodiments, and it goes without saying that various changes can be made without departing from the gist of the present invention.

The present invention is applied to a technique of correcting the position and position of a welding robot by providing a laser distance sensor so as to be rotatable up and down, forward and backward and left and right about a torch and using a target to perform a simple calibration operation.

10: welding robot control system 11: teaching manipulator
12: welding section 13: controller
14: welder 15: feeder
20: welding robot 21: torch
22: laser distance sensor 23: clamping part
24: installation block 31: upper body
32: lower body 33: rotating member
34: insertion groove 35: engaging hole
40: target 41: center hole

Claims (9)

In a welding robot having a plurality of shafts,
A laser distance sensor for detecting the distance to the object,
A torch for performing welding,
A clamping part rotatably installed on the torch in the up and down, left and right and front and back directions,
And a mounting block installed on one side of the clamping part and provided with the laser distance sensor,
Wherein the clamping unit is rotated based on the offset distance between the laser distance sensor and the torch tip and the coordinate value of the torch tip to adjust the angle of the laser distance sensor to correct the position and position of the welding robot. A welding robot equipped with a distance sensor. 2. The apparatus of claim 1, wherein the clamping portion
An upper body and a lower body coupled to each other at an upper portion and a lower portion of the torch,
And a rotary member installed on an outer circumferential surface of the torch and inserted and coupled between the upper body and the lower body. 3. The method of claim 2,
An insertion groove into which the rotary member is inserted is formed on a lower surface of the upper body and an upper surface of the lower body,
The rotating member is formed in a spherical shape,
And a coupling hole for coupling the torch is formed at a central portion of the rotary member. 4. The method according to any one of claims 1 to 3,
Wherein the welding robot includes a controller for controlling driving of the plurality of servo drivers by communicating with the controller to drive a plurality of AC servomotors corresponding to a plurality of axes,
A display unit for displaying the status of each of the plurality of servo drivers,
Further comprising an emergency stop switch for stopping the operation of said welding robot when an emergency state occurs,
Wherein when the touch is completed by moving the torch toward the target in a state where the torch is vertically arranged on the plane center of the target, the end point coordinate value of the torch moved backward by a predetermined distance, And the end point coordinate value is calculated by moving the torch on the XY plane so as to be disposed at the center of the welding robot. 5. The method of claim 4,
Wherein the target is formed in a hexahedron shape whose top surface is square,
A center hole is formed at the center of the target,
Wherein a circle and a rectangle are displayed on the upper surface of the target at predetermined intervals. (a) placing an end of a torch provided on a welding robot in a direction perpendicular to a target plane, and moving the torch in a Z-axis direction to touch-sense a center hole formed in the target center,
(b) moving the torch by a preset distance in the -Z-axis direction and calculating an end point coordinate value of the moved torch when a touch signal is received from a touch sensor installed at an end of the torch,
(c) moving the torch in an XY plane such that a ray of light emitted from the laser distance sensor is located in the center hole and calculating an endpoint coordinate value of the moved torch,
(d) moving the torch in the Z-axis direction and inspecting whether the light beam is in the center hole and
(e) adjusting a position and a posture of the welding robot by adjusting an angle of an installation block provided with the laser distance sensor if the light beam is disposed at a position other than the center hole as a result of the inspection in the step (d) And correcting the welding distance of the welding robot. The method according to claim 6,
In the step (b) and the step (c), the control unit of the welding robot may calculate the Z-axis offset distance between the end of the torch and the center point of the light beam of the laser distance sensor, and the X- and Y- And calculating an end point coordinate value of the torch using the offset distance of the torch. 8. The method according to claim 6 or 7,
Wherein the step (e) adjusts the angle of the installation block by rotating a clamping part provided to the torch so as to be rotatable up and down, right and left and forward and backward directions. 9. The method of claim 8,
(f) inspecting whether the light beam is disposed in the center hole after performing the step (e)
And the step (c) to (f) are repeatedly performed until the light beam is disposed at a position other than the center hole as a result of the inspection in the step (f) And a laser distance sensor for detecting a distance between the welding robot and the welding robot.
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