WO2014080626A1 - 電極チップの研磨方法 - Google Patents
電極チップの研磨方法 Download PDFInfo
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- WO2014080626A1 WO2014080626A1 PCT/JP2013/006817 JP2013006817W WO2014080626A1 WO 2014080626 A1 WO2014080626 A1 WO 2014080626A1 JP 2013006817 W JP2013006817 W JP 2013006817W WO 2014080626 A1 WO2014080626 A1 WO 2014080626A1
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- polishing
- torque
- value
- servo motor
- controller
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Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K11/00—Resistance welding; Severing by resistance heating
- B23K11/30—Features relating to electrodes
-
- 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
- B23K11/00—Resistance welding; Severing by resistance heating
- B23K11/10—Spot welding; Stitch welding
- B23K11/11—Spot welding
- B23K11/115—Spot welding by means of two electrodes placed opposite one another on both sides of the welded parts
-
- 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
- B23K11/00—Resistance welding; Severing by resistance heating
- B23K11/30—Features relating to electrodes
- B23K11/3063—Electrode maintenance, e.g. cleaning, grinding
-
- 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
- B23K11/00—Resistance welding; Severing by resistance heating
- B23K11/30—Features relating to electrodes
- B23K11/31—Electrode holders and actuating devices therefor
- B23K11/314—Spot welding guns, e.g. mounted on robots
- B23K11/315—Spot welding guns, e.g. mounted on robots with one electrode moving on a linear path
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B24—GRINDING; POLISHING
- B24B—MACHINES, DEVICES, OR PROCESSES FOR GRINDING OR POLISHING; DRESSING OR CONDITIONING OF ABRADING SURFACES; FEEDING OF GRINDING, POLISHING, OR LAPPING AGENTS
- B24B19/00—Single-purpose machines or devices for particular grinding operations not covered by any other main group
- B24B19/16—Single-purpose machines or devices for particular grinding operations not covered by any other main group for grinding sharp-pointed workpieces, e.g. needles, pens, fish hooks, tweezers or record player styli
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B24—GRINDING; POLISHING
- B24B—MACHINES, DEVICES, OR PROCESSES FOR GRINDING OR POLISHING; DRESSING OR CONDITIONING OF ABRADING SURFACES; FEEDING OF GRINDING, POLISHING, OR LAPPING AGENTS
- B24B49/00—Measuring or gauging equipment for controlling the feed movement of the grinding tool or work; Arrangements of indicating or measuring equipment, e.g. for indicating the start of the grinding operation
- B24B49/16—Measuring or gauging equipment for controlling the feed movement of the grinding tool or work; Arrangements of indicating or measuring equipment, e.g. for indicating the start of the grinding operation taking regard of the load
Definitions
- the present invention relates to an electrode tip polishing method for polishing using a chip dresser provided with a servo motor device.
- the servo motor device only operates so as to reduce the load when the maximum torque (stopping torque) of the servo motor is generated. This was inconvenient because the abnormal polishing of the electrode tip was not understood.
- This invention solves the above-mentioned subject, and it aims at providing the grinding
- a tip dresser for polishing a pair of electrode tips held by a welding gun includes a holder holding a cutter capable of cutting the tip portions of the pair of electrode tips, and a pair of the tip
- a servo motor device having a servo motor as a drive source for rotating the holder and a servo amplifier for controlling the rotation of the servo motor so that the electrode tip can be cut, and the operation of the servo motor device is controlled.
- a polishing method for an electrode tip wherein the tip dresser can discriminate abnormal polishing of the electrode tip below the maximum torque of the servo motor when the tip dresser polishes the pair of electrode tips.
- a torque generating signal is output to the controller, and the controller determines that the polishing is abnormal when the torque generating signal is not input within a time corresponding to an elapsed time during normal polishing.
- the controller at the time of polishing the electrode tip, the controller must input a torque generation signal having a predetermined intermediate value from the servo motor device within the time corresponding to the elapsed time during normal polishing.
- the electrode tip is not normally polished, so that it can be determined as an abnormal polishing, and an abnormal signal can be output to the control device of the welding robot holding the welding gun.
- the electrode tip polishing method according to the present invention it is understood that there is a cause such as that the welding gun holding the electrode tip is arranged on another tip dresser or the servo motor is idle. It is possible to determine polishing abnormality other than when the maximum torque of the motor is generated.
- the waveform of the load torque of the servo motor during the normal polishing with the passage of time is indicated by the start of polishing (the welding gun as the electrode tip contacts the holder). From the start of pressurization) to a first peak value, and then to a lower waveform. After the decrease, the waveform reaches a second peak value higher than the first peak value and stagnates to complete the polishing.
- the controller When the motor device generates a torque of two or more values that increase in order as the intermediate value in the load torque during normal polishing of the pair of electrode tips, the controller generates two high and low torque generation signals.
- the low torque value having a low value is smaller than the reduced minimum value between the first peak value and the second peak value, and the high torque value having a high value is the second value. From peak value And a value higher than the first peak value, and the controller inputs torque generation signals greater than or equal to the low torque value and greater than or equal to the high torque value within the time corresponding to the elapsed time during normal polishing. If not, it is desirable that the polishing is judged to be abnormal.
- the controller generates a torque greater than the high torque value, even after the start of polishing (after the start of pressurization accompanying the contact of the electrode tip with the holder), although a torque generation signal greater than the lower torque value is input from the servo motor device. If no signal is input, there is no mechanical failure in the tip dresser, but the tip of the electrode tip is deformed (worn) too much, or the electrode tip is properly held in the welding gun shank. It is understood that there is a cause such as idle rotation or insufficient pressure applied to the tip dresser on the welding gun side, and it is possible to determine abnormal polishing other than when the maximum torque of the servo motor is generated.
- the controller sequentially inputs a torque generation signal of a low torque value or more and a high torque value or more from the servo motor device within a predetermined time after the start of polishing, the normal polishing operation of the electrode tip is completed. I can judge.
- the electrode chip with different shape It is understood that there is a cause such as that the cutter has been polished or that the cutter has become uncut due to its life, etc., and even in these cases, it is necessary to judge abnormal polishing other than when the servo motor maximum torque is generated Can do.
- the controller sequentially inputs a torque generation signal of a low torque value or more and a high torque value or more from the servo motor device within a predetermined elapsed time, and if the normal polishing time has elapsed, It can be determined that the polishing operation has been completed, the subsequent polishing can be stopped, the electrode tip can be prevented from being excessively cut, and the consumption of the electrode tip can be reduced.
- the servo motor device has received a torque value not less than a medium torque value between the low torque value and the high torque value in addition to the torque generation signal of the low torque value and the high torque value.
- the torque generation signal is sometimes output, and the medium torque value is set as a value lower than the high torque value and higher than the first peak value. It is configured to determine that polishing is abnormal when a torque generation signal greater than the low torque value, greater than the middle torque value, and greater than the high torque value is not input within a time corresponding to each time. desirable.
- the controller when the electrode tip is polished, the controller also inputs a torque generation signal when the torque value becomes equal to or higher than the middle torque value.
- a polishing abnormality can be determined by the presence or absence of a torque generation signal having an intermediate torque value, and a polishing abnormality can be determined quickly and efficiently.
- the electrode tip is held as described above. It can be seen that there is a cause such as the welding gun being placed on another dresser or the servo motor idling, so that it is possible to determine an abnormal polishing other than when the servo motor generates the maximum torque.
- the controller inputs a torque generation signal greater than the low torque value from the servo motor device after starting polishing, but does not input a torque generation signal greater than the intermediate torque value, a mechanical failure will occur in the chip dresser.
- the tip of the electrode tip is deformed (worn) too much, or the electrode tip is not properly held by the shank of the welding gun, or the tip dresser on the welding gun side It is understood that there is a cause such as insufficient pressurizing force on the head, and it is possible to determine polishing abnormality other than when the maximum torque of the servo motor is generated.
- the controller has sequentially input a torque generation signal of a low torque value or more and a medium torque value or more from the servo motor device after starting polishing, but does not input a torque generation signal of a high torque value or more, the electrode It can be understood that there is a cause such as extreme deformation of the tip of the chip, and it is possible to determine abnormal polishing other than when the servomotor generates the maximum torque.
- the controller sequentially inputs a torque generation signal of a low torque value or more, a medium torque value or more, and a high torque value or more from the servo motor device within a predetermined time after the start of polishing, the electrode tip can be operated normally. It can be determined that the polishing operation has been completed.
- the controller sequentially inputs a torque generation signal of a low torque value or more, a medium torque value or more, and a high torque value or more from the servo motor device within a predetermined time, and if the normal polishing time elapses, the electrode It can be determined that the normal polishing operation of the tip has been completed, the subsequent polishing can be stopped, the electrode tip can be prevented from being excessively cut, and the consumption of the electrode tip can be reduced.
- a welding gun 5 holding a pair of electrode tips 11 and 11 used in the embodiment is an articulated welding robot as shown in FIGS.
- a pair of electrode tips 11, 11 are fitted into shanks 7, 8 facing each other while being held at the tip of one arm 2.
- the welding gun 5 is a general-purpose servo gun, and holds the electrode tip 11 so as to be moved by a servo motor 6 having a built-in encoder, and positions the pair of electrode tips 11 and 11 close to each other equally. It is configured with a control function. Further, the welding gun 5 has an arithmetic function, and can perform position control and pressure control of the electrode tips 11 and 11 by performing rotation speed control and torque control of the servo motor 6.
- W1 and W2 are processing points on the welding line where the welding robot 1 performs welding processing. At these processing points W1 and W2, a predetermined number of spots (spot welding) are performed at predetermined locations, and a sheet metal (not shown) or the like is shown. Are connected by welding.
- the chip dresser 18 includes a dresser main body 24, a servo motor device 36, and a controller 50, as shown in FIGS.
- the dresser body 24 includes a holder 27 that holds a cutter 28 that can cut the distal end portion 12 of the pair of electrode tips 11, 11, and the holder 27 rotates together with the cutter 28 by the rotational drive of the servo motor 37 of the servo motor device 36. Then, the tip 12 of the electrode tip 11 is cut by the cutter 28 and polished.
- the holder 27 includes concave portions 27 a corresponding to the shape of the tip portion 12 of the electrode tip 11 having an appropriate shape on both upper and lower surfaces, and also includes a chip discharge hole portion 27 b and a cutter 28. Is attached to the wall surface of the discharge hole portion 27b by a mounting screw 29, and the cutting blades 28a, 28a are arranged on the inner peripheral surfaces of the recess portions 27a, 27a. Therefore, if the tip portion 12 of the electrode tip 11, 11 is inserted so as to come into contact with the concave portions 27a, 27a of the holder 27 that is rotationally driven, it is consumed by the cutting blades 28a, 28a of the rotating cutter 28. The distal end portion 12 is cut and polished to an appropriate shape.
- the cutting blade 28a polishes the distal end surface 12a of the distal end portion 12 of the electrode tip 11 and the enlarged diameter portion 12b that expands from the distal end surface 12a to the columnar base portion 13 of the electrode tip 11. Is set.
- the holder 27 is housed and fixed in the housing portion 32a of the large gear portion 32 of the gear mechanism 31, and the large gear portion 32 is supported by the bearing 33 so as to be rotatable in the case 24a.
- the gear mechanism 31 includes a drive gear (not shown) provided on a rotation drive shaft 37a (see FIG. 4) of the servo motor 37, an intermediate gear (not shown) meshing with the drive gear and the large gear portion 32, and the large gear portion 32.
- the holder 27 housed in the large gear portion 32 is rotated together with the cutter 28 by the rotational drive of the servo motor 37.
- the servo motor device 36 includes an AC servo motor 37, an encoder 38 that can detect the angular position and rotational speed of the rotational drive shaft 37 a of the servo motor 37, and a servo amplifier 39 that controls the rotational drive of the servo motor 37.
- the AC power supply 45 is connected to the servo amplifier 39.
- the servo amplifier 39 includes a microprocessor and controls the rotation drive shaft 37a of the servo motor 37 to rotate at a predetermined rotation speed by a control signal from the controller 50. Furthermore, in the servo amplifier 39 of the embodiment, when the load torque of the servo motor 37 reaches the maximum torque (resting torque) based on the current value supplied to the servo motor 37 and the like, in order to prevent the servo motor 37 from malfunctioning. In addition, a torque limit (protection mechanism) that stops the drive of the servo motor 37 is provided.
- the servo amplifier 39 is configured so that the controller 50 at the time of generation of three stages of load torque when the load torque of the servo motor 37 varies during normal polishing, based on the current value supplied to the servo motor 37 and the like. Is configured to output an ON signal.
- the waveform of the increase / decrease in the load torque with the elapsed time is as shown in FIG.
- the load torque does not increase during the polishing preparation time from the start of rotation of the servo motor 37 to immediately before the contact of the electrode tip 11 with the holder 27 (start of pressurization), but the load torque is applied to the holder 27 of the electrode tip 11.
- start of pressurization that is, from the polishing start S, it rises while drawing an increasing line L1 that rises to the right, reaches the first peak value P1, and then draws a concave curve L2 and decreases until it reaches the minimum value PV.
- the polishing state in which the increasing line L1 that reaches the first peak value P1 is in a polished state is a partial convex portion generated at the tip 12 when the tip 12 of the electrode tip 11 hits the inner peripheral surface of the recess 27a of the holder 27. Is in a state of being cut while abutting with a large pressure.
- the polishing state when drawing the concave curve L2 is such that the convex portion of the tip portion 12 of the electrode tip 11 is partially hit, but the load torque is reduced, and thereafter the convex portion disappears, and the tip portion 12 is a state where cutting is performed in a wide area over the entire region from a state in which the portions that become the 12 tip surfaces 12a and the enlarged diameter portions 12b partially correspond. And if the 2nd peak value P2 is reached, it will be in the state where the front-end
- the elapsed time TE from the polishing start S to the polishing completion point E is constant (for example, 3 seconds).
- the elapsed time T1 from the polishing start S to the first peak value P1 is set to a time that does not take 1 second (in the example shown, about 0.2 seconds), and the time TV that reaches the minimum value PV is about 1 second,
- the elapsed time T2 from the polishing start S to the second peak value P2 is set to 2 seconds or more and less than 3 seconds (2.6 seconds in the example).
- the electrode tip 11 is ground at a diameter of 16 ⁇ , the welding gun 5 is pressed at 120 kgf / cm 2 , and the holder 27 is rotated at 177 rpm.
- the pressurization preparation time TF from the rotation start to the pressurization start (polishing start) S is set to 3 seconds in the embodiment.
- the servo amplifier 39 is configured so that the controller 50 generates a torque of a low torque value Y1 or higher, a medium torque value Y2 or higher, and a high torque value Y3 or higher that increase in order within the load torque of the servomotor 37.
- a torque generation signal of each torque value Y1, Y2, and Y3 is output. That is, the servo amplifier 39 outputs a low torque value ON signal (LLON signal) to the controller 50 when the low torque value Y1 or more, and outputs a medium torque value ON signal (MLON signal) when the torque value Y2 or more.
- LLON signal low torque value ON signal
- MLON signal medium torque value ON signal
- a high torque value ON signal (HLON signal) is output, and after outputting an ON signal (LLON signal, MLON signal, HLON signal), each torque value Y1, Y2, Y3 is output.
- the output of each ON signal (LLON signal, MLON signal, HLON signal) is stopped.
- the low torque value Y1 is set to a value smaller than the reduced minimum value PV between the first peak value P1 and the second peak value P2, and the intermediate torque value Y2 is set to be smaller than the second peak value P2.
- the value is lower and higher than the first peak value P1.
- the high torque value Y3 is set as a value higher than the middle torque value Y2 and lower than the second peak value P2.
- the controller 50 When the controller 50 receives a signal for polishing the electrode tips 11, 11 when the electrode tips 11, 11 perform a predetermined number of spot weldings from the control device 3 of the welding robot 1, the servo motor device A control signal is output to the servo amplifier 39 of 36 so that the servo motor 37 is rotated at a predetermined rotation number, and the polishing operation is started, and the welding gun 5 is connected to the rotating holder 27 of the dresser body 24 with a pair of When the electrode tips 11 and 11 are pressed and a pressurization signal is received from the welding gun 5, the controller 50 determines the polishing start S. Then, the controller 50 determines a polishing abnormality as shown in FIG.
- step S101 it is determined whether or not the LLON signal has been input. If input has been completed (YES in step S101), the process proceeds to step S102. If not input (NO in step S101), the process proceeds to step S103, and tf seconds have elapsed since the start of the polishing operation (start of rotation). Determine whether or not.
- the time tf is set to 4 seconds in total corresponding to 1 second of the elapsed time from the polishing start S to the minimum value PV and 3 seconds of the pressurization preparation time.
- step S103 if 4 (tf) seconds have elapsed from the start of rotation (YES in step S103), it is determined that polishing is abnormal, the process proceeds to step S104, and the controller 50 outputs polishing abnormality I. .
- this polishing abnormality I there are causes such as the gear of the gear mechanism 31 of the tip dresser 18 being damaged or the welding gun 5 being placed in the holder of the tip dresser at another position.
- An error signal is output to the control device 3 and the servo motor device 36 so that the operation of the welding robot 1 is stopped and the rotation drive of the servo motor 37 is stopped.
- the controller 50 may turn on a predetermined lamp or the like so as to notify a predetermined polishing abnormality I.
- step S101 the controller 50 determines the presence or absence of the MLON signal. If the MLON signal is not input (NO in step S102), the controller 50 proceeds to step S106, and the MLON signal is output. If it has been input (YES in step S102), the process proceeds to step S105.
- step S106 it is determined whether tm seconds (for example, about 2 to 3 times greater than the elapsed time during normal polishing, in the embodiment, 3 times 5 seconds) have passed since the LLON signal was input. If it has not elapsed (NO in step S106), the process returns to step S102. If it has elapsed (YES in step S106), the process proceeds to step S107, and the controller 50 outputs a polishing abnormality II. In the case of this polishing abnormality II, there is no mechanical failure in the tip dresser 18, but the tip 12 of the electrode tip 11 is deformed (worn) too much, or the electrode tip 11 is shank 7 of the welding gun 5.
- tm seconds for example, about 2 to 3 times greater than the elapsed time during normal polishing, in the embodiment, 3 times 5 seconds
- the controller 50 opens the welding gun 5 to make a welding robot 1 is stopped, and an error signal is output to the control device 3 so that the shape error of the electrode tip 11 is displayed, and at the same time, an error is sent to the servo motor device 36 so as to stop the rotational drive of the servo motor 37. Output a signal.
- the controller 50 may turn on a predetermined lamp or the like so as to notify a predetermined polishing abnormality II.
- step S105 the controller 50 determines the presence or absence of the HLON signal. If the HLON signal is not input (NO in step S105), the controller 50 proceeds to step S108, and the HLON signal is output. If it has been input (YES in step S105), the process proceeds to step S109.
- step S108 it is determined whether tb seconds (for example, about 2 to 3 times longer than the elapsed time during normal polishing, or about 3 times 3 seconds in the embodiment) have passed since the MLON signal was input. If not (NO in step S108), the process returns to step S105. If elapsed (YES in step S108), the controller 50 proceeds to step S107, and the controller 50 performs the above-described polishing abnormality II. Output.
- tb seconds for example, about 2 to 3 times longer than the elapsed time during normal polishing, or about 3 times 3 seconds in the embodiment
- step S109 has the controller 50 elapsed from the start of polishing S to tt seconds (for example, 2 seconds, which is slightly shorter than reaching the second peak value P2 of normal polishing)? If two seconds have not elapsed since the polishing start S (NO in step S109), the process proceeds to step S110, and the controller 50 outputs a polishing abnormality III.
- tt seconds for example, 2 seconds, which is slightly shorter than reaching the second peak value P2 of normal polishing
- this polishing abnormality III there are causes such as electrode tips having different shapes being polished, or the cutter being unable to be cut due to the life or the like, or the increased pressure of the welding gun 5.
- 50 opens the welding gun 5 to stop the operation of the welding robot 1, and further outputs an error signal to the control device 3 so as to display the life of the cutter 28 and stops the rotation of the servo motor 37.
- An error signal is output to the servo motor device 36 so as to cause the error to occur.
- the controller 50 may turn on a predetermined lamp or the like so as to notify a predetermined polishing abnormality III.
- step S109 if 2 seconds have elapsed from the start of polishing S (YES in step S109), the process proceeds to step S111, and the polishing operation can be normally completed.
- a polishing completion signal is output to the servo motor device 36 so that the rotational driving of the servo motor 37 is stopped, and the welding gun 5 is opened to perform welding.
- a polishing completion signal is output to the control device 3 so that the robot 1 can move to the next operation.
- the controller 50 generates a torque generation signal (LLON signal, MLON signal, and HLON signal) from the servo motor device 36 at a low torque value Y1 or more, a medium torque value Y2 or more, and a high torque value Y3 or more from a servo motor device 36 within a predetermined time.
- a torque generation signal (LLON signal, MLON signal, and HLON signal) from the servo motor device 36 at a low torque value Y1 or more, a medium torque value Y2 or more, and a high torque value Y3 or more from a servo motor device 36 within a predetermined time.
- TE normal polishing time
- the controller 50 inputs the signal to open the welding gun 5.
- an error signal can be output to the control device 3 so as to stop the welding robot 1.
- the polishing abnormality I is 1.
- the welding gun holding the electrode tip is placed on another tip dresser, 2.
- the servo motor is idle due to a mechanical failure such as a gear mechanism. I understand abnormalities such as.
- the polishing abnormality is detected.
- the tip 12 of the electrode tip 11 is deformed (worn) too much, 4).
- the electrode tip 11 is not properly held by the shanks 7 and 8 of the welding gun 5 and is idle. 5.
- the pressure applied to the tip dresser 18 on the welding gun 5 side is insufficient. I understand abnormalities such as.
- the polishing abnormality III is 6).
- the welding pressure on the welding gun 5 side is higher than a predetermined value, 7).
- the electrode tips with different shapes are polished, 8). Cutting failure of the cutter has occurred due to the life, etc. I understand abnormalities such as.
- polishing abnormalities I, II, III are understood, and polishing abnormalities other than when the servomotor 37 generates the maximum torque can be determined. It is possible to deal with the problem quickly and accurately.
- the polishing method according to the embodiment prevents welding in an unexpected cutting state due to the influence of the cutter life, welding in an uncut state due to a mechanical failure of the tip dresser, and wear (shortening of life) of the electrode tip due to excessive cutting during polishing. can do.
- the controller 50 can make a predetermined determination based on the ON signal of the digital signal from the servo motor device 36, the digital signal input to the control device 3 of the welding robot 1 can be performed.
- the output is also easy, which is suitable for the welding site of the welding robot 1.
- the ON signal output from the servo amplifier 39 is exemplified according to the three stages of the low torque value Y1, the medium torque value Y2, and the high torque value Y3.
- the LLON signal and the HLON signal corresponding to the two stages of the high torque value Y3 may be used.
- the controller 50A eliminates steps S102 and S106 in the flowchart shown in FIG. 6, and the elapsed time tb determined in step S108 is about 2 to 3 times the time during normal polishing after the output of the LLON signal. For example, it may be about 3 times 8 seconds.
- Step S104 can be determined.
- the controller 50A receives a torque generation signal (LLON signal) greater than or equal to the low torque value Y1 from the servo motor device 36 after starting polishing, but does not input a torque generation signal (LLON signal) greater than or equal to the high torque value Y3.
- LLON signal torque generation signal
- there is a cause such as being idled without being held in place, or insufficient pressure applied to the tip dresser 18 on the welding gun 5 side, and the abnormal polishing II except when the maximum torque of the servo motor 37 is generated II. (See step S107 in FIG. 6).
- step S101 in FIG. 6 if the controller 50A sequentially inputs a torque generation signal (LLON signal, HLON signal) having a low torque value Y1 or more and a high torque value Y3 or more from the servo motor device 36 after the polishing is started (step S101 in FIG. 6). It can be determined that the normal polishing operation of the electrode tip 11 has been completed (if the process proceeds to S105, S109, and S201).
- LLON signal LLON signal, HLON signal
- the controller 50A sequentially inputs a torque generation signal (LLON signal, HLON signal) having a low torque value Y1 or more and a high torque value Y3 or more from the servo motor device 36 after the polishing is started, the elapsed time is short. If it is too high (NO in step S109 shown in FIG. 6), it is understood that there are causes such as the electrode tip having a different shape being polished, or the cutter being unable to be cut due to the lifetime, etc. Also in this case, it is possible to determine the polishing abnormality III (see step S110 in FIG. 6) other than when the maximum torque of the servo motor 37 is generated.
- the controller 50A sequentially inputs torque generation signals of the low torque value Y1 or more and the high torque value Y3 or more from the servo motor device 36 within an appropriate time, and if the normal polishing time (TE) elapses, the electrode It can be determined that the normal polishing operation of the tip 11 has been completed, the subsequent polishing can be stopped, the electrode tip 11 can be prevented from being excessively shaved, and the consumption of the electrode tip 11 can be reduced.
- TE normal polishing time
- the ON signal output from the servo amplifier 39 is exemplified according to the three stages of the low torque value Y1, the medium torque value Y2, and the high torque value Y3.
- the torque generation signal may be output when the value is equal to or higher than one of the low torque value Y1, the minimum value PV, and the high torque value Y3.
- the controller 50B in this case can output any one of the polishing abnormalities I, II, and III in FIG. 6, and the polishing abnormalities I, II, and III other than when the servomotor 37 generates the maximum torque. Can be determined.
- step S106 or step S108 it is set so as to determine whether or not there is an elapsed time from the output of the immediately preceding ON signal.
- the elapsed time is determined as the polishing start S during normal polishing. May be set as an elapsed time of 2 to 3 times, for example, 3 times the elapsed time from the start, or may be set as an elapsed time from the start of rotation in consideration of the pressurization preparation time TF .
- the elapsed time tt in step S109 may also be set as the elapsed time from the start of rotation with the pressurization preparation time TF taken into account.
- the various elapsed times described above (which may be confirmation time and standby time) tf, tm, tb, and tt are obtained by adding a certain amount of variation time to the elapsed time during normal polishing. It is not limited to the time of the form, and may be increased or decreased appropriately as long as polishing abnormality I, II, III can be accurately determined.
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- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Robotics (AREA)
- Finish Polishing, Edge Sharpening, And Grinding By Specific Grinding Devices (AREA)
- Constituent Portions Of Griding Lathes, Driving, Sensing And Control (AREA)
- Numerical Control (AREA)
- Grinding And Polishing Of Tertiary Curved Surfaces And Surfaces With Complex Shapes (AREA)
Abstract
Description
本発明に係る電極チップの研磨方法は、溶接ガンに保持された一対の電極チップを研磨するチップドレッサが、一対の前記電極チップの先端部を切削可能なカッタを保持したホルダと、一対の前記電極チップを切削可能に、前記ホルダを回転させるための駆動源としてのサーボモータ及び該サーボモータの回転を制御するサーボアンプを有してなるサーボモータ装置と、該サーボモータ装置の作動を制御するコントローラと、を備えて構成され、前記チップドレッサが一対の前記電極チップを研磨する際に、前記サーボモータの最大トルク以下での電極チップの研磨異常を判別可能な電極チップの研磨方法であって、前記サーボモータ装置が、一対の前記電極チップの正常研磨時における負荷トルク内の中間値のトルク発生時、前記コントローラに、トルク発生信号を出力する構成とし、前記コントローラが、正常研磨時の経過時間に対応する時間内に、前記トルク発生信号を入力しなかった時、研磨異常と判断することを特徴とする。
そして、本発明に係る電極チップの研磨方法では、正常研磨時の前記サーボモータの負荷トルクの時間経過に伴なう波形が、研磨開始(電極チップのホルダヘの当接に伴なう溶接ガンの加圧開始)から上昇して第1のピーク値となり、その後低下し、低下後に、第1のピーク値より高い第2のピーク値を迎えて停滞して、研磨完了となる波形とし、前記サーボモータ装置が、一対の前記電極チップの正常研磨時における負荷トルク内の中間値の値として、順に高くなる二つの値以上のトルク発生時、前記コントローラに、高低の二つの値のトルク発生信号を出力する構成とするとともに、低い値の低トルク値が、前記第1ピーク値と前記第2ピーク値との間の低下した最小値より小さな値とし、高い値の高トルク値が、前記第2ピーク値より低く、かつ、前記第1ピーク値より高い値として、設定され、前記コントローラが、正常研磨時の経過時間にそれぞれ対応する時間内に、低トルク値以上と高トルク値以上のトルク発生信号を入力しなかった時、研磨異常と判断するように構成することが望ましい。
さらに、前記サーボモータ装置が、前記コントローラに、前記低トルク値と前記高トルク値とのトルク発生信号に加えて、前記低トルク値と前記高トルク値との間の中トルク値以上となった時にもトルク発生信号を出力する構成とするとともに、前記中トルク値が、前記高トルク値より低く、かつ、前記第1ピーク値より高い値として、設定され、前記コントローラが、正常研磨時の経過時間にそれぞれ対応する時間内に、前記低トルク値以上、前記中トルク値以上、及び、前記高トルク値以上のトルク発生信号を入力しなかった時、研磨異常と判断するように構成することが望ましい。
1.電極チップを保持した溶接ガンが他のチップドレッサに配置されている、
2.歯車機構等の機械的な故障により、サーボモータが空回りしている、
等の異常が解る。
3.電極チップ11の先端部12が変形(磨耗)しすぎている、
4.電極チップ11が溶接ガン5のシャンク7,8に適切に保持されておらずに空回りしている、
5.溶接ガン5側のチップドレッサ18への加圧力が不足している、
等の異常が解る。
6.溶接ガン5側の加圧力が所定値より上昇している、
7.形状の異なった電極チップが研磨されている、
8.寿命等によりカッタの切削不良が生じている、
等の異常が解る。
P1…第1ピーク値、P2…第2ピーク値、PV…最小値、Y1…低トルク値、Y2…中トルク値、Y3…高トルク値。
Claims (3)
- 溶接ガンに保持された一対の電極チップを研磨するチップドレッサが、
一対の前記電極チップの先端部を切削可能なカッタを保持したホルダと、
一対の前記電極チップを切削可能に、前記ホルダを回転させるための駆動源としてのサーボモータ及び該サーボモータの回転を制御するサーボアンプを有してなるサーボモータ装置と、
該サーボモータ装置の作動を制御するコントローラと、
を備えて構成され、
前記チップドレッサが一対の前記電極チップを研磨する際に、前記サーボモータの最大トルク以下での電極チップの研磨異常を判別可能な電極チップの研磨方法であって、
前記サーボモータ装置が、一対の前記電極チップの正常研磨時における負荷トルク内の中間値のトルク発生時、前記コントローラに、トルク発生信号を出力する構成とし、
前記コントローラが、正常研磨時の経過時間に対応する時間内に、前記トルク発生信号を入力しなかった時、研磨異常と判断することを特徴とする電極チップの研磨方法。 - 正常研磨時の前記サーボモータの負荷トルクの時間経過に伴なう波形が、研磨開始から上昇して第1のピーク値となり、その後低下し、低下後に、第1のピーク値より高い第2のピーク値を迎えて停滞して、研磨完了となる波形とし、
前記サーボモータ装置が、一対の前記電極チップの正常研磨時における負荷トルク内の中間値の値として、順に高くなる二つの値以上のトルク発生時、前記コントローラに、高低の二つの値のトルク発生信号を出力する構成とするとともに、
低い値の低トルク値が、前記第1ピーク値と前記第2ピーク値との間の低下した最小値より小さな値とし、
高い値の高トルク値が、前記第2ピーク値より低く、かつ、前記第1ピーク値より高い値として、設定され、
前記コントローラが、正常研磨時の経過時間にそれぞれ対応する時間内に、低トルク値以上と高トルク値以上のトルク発生信号を人力しなかった時、研磨異常と判断することを特徴とする請求項1に記載の電極チップの研磨方法。 - 前記サーボモータ装置が、前記コントローラに、前記低トルク値と前記高トルク値とのトルク発生信号に加えて、前記低トルク値と前記高トルク値との間の中トルク値以上となった時にもトルク発生信号を出力する構成とするとともに、
前記中トルク値が、前記高トルク値より低く、かつ、前記第1ピーク値より高い値として、設定され、
前記コントローラが、正常研磨時の経過時間にそれぞれ対応する時間内に、前記低トルク値以上、前記中トルク値以上、及び、前記高トルク値以上のトルク発生信号を入力しなかった時、研磨異常と判断することを特徴とする請求項2に記載の電極チップの研磨方法。
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