WO2017079995A1 - 一种机器人焊接系统及其焊接方法 - Google Patents

一种机器人焊接系统及其焊接方法 Download PDF

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Publication number
WO2017079995A1
WO2017079995A1 PCT/CN2015/095306 CN2015095306W WO2017079995A1 WO 2017079995 A1 WO2017079995 A1 WO 2017079995A1 CN 2015095306 W CN2015095306 W CN 2015095306W WO 2017079995 A1 WO2017079995 A1 WO 2017079995A1
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WIPO (PCT)
Prior art keywords
welding
tube
robot
weld
module
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PCT/CN2015/095306
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English (en)
French (fr)
Inventor
杨乘东
唐伟宝
张茂龙
张敏
罗庆
Original Assignee
上海电气核电设备有限公司
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Application filed by 上海电气核电设备有限公司 filed Critical 上海电气核电设备有限公司
Priority to ROA201800125A priority Critical patent/RO133553B1/ro
Priority to TR2017/18224A priority patent/TR201718224T2/tr
Priority to GB1718196.7A priority patent/GB2555262B/en
Priority to KR1020177034739A priority patent/KR101982433B1/ko
Publication of WO2017079995A1 publication Critical patent/WO2017079995A1/zh

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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
    • 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
    • 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
    • B23K9/16—Arc welding or cutting making use of shielding gas
    • B23K9/167—Arc welding or cutting making use of shielding gas and of a non-consumable electrode
    • 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
    • B23K31/00—Processes relevant to this subclass, specially adapted for particular articles or purposes, but not covered by only one of the preceding main groups
    • B23K31/12—Processes relevant to this subclass, specially adapted for particular articles or purposes, but not covered by only one of the preceding main groups relating to investigating the properties, e.g. the weldability, of materials
    • B23K31/125—Weld quality monitoring
    • 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
    • B23K9/02—Seam welding; Backing means; Inserts
    • 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
    • B23K9/02—Seam welding; Backing means; Inserts
    • B23K9/028—Seam welding; Backing means; Inserts for curved planar seams
    • B23K9/0288—Seam welding; Backing means; Inserts for curved planar seams for welding of tubes to tube plates
    • 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
    • B23K9/10—Other electric circuits therefor; Protective circuits; Remote controls
    • B23K9/1006—Power supply
    • B23K9/1043—Power supply characterised by the electric circuit
    • B23K9/1056—Power supply characterised by the electric circuit by using digital means
    • 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
    • B23K9/124—Circuits or methods for feeding welding wire
    • B23K9/125—Feeding of 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
    • B23K9/00—Arc welding or cutting
    • B23K9/12—Automatic feeding or moving of electrodes or work for spot or seam welding or cutting
    • B23K9/127—Means for tracking lines during arc welding or cutting
    • 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
    • B23K9/127—Means for tracking lines during arc welding or cutting
    • B23K9/1272—Geometry oriented, e.g. beam optical trading
    • B23K9/1274—Using non-contact, optical means, e.g. laser means
    • 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
    • B23K9/16—Arc welding or cutting making use of shielding gas
    • B23K9/173—Arc welding or cutting making use of shielding gas and of a consumable electrode
    • 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
    • B23K9/32—Accessories
    • 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
    • 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
    • B25J9/1656—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
    • B25J9/1666—Avoiding collision or forbidden zones
    • 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
    • B25J9/1674—Programme controls characterised by safety, monitoring, diagnostic
    • B25J9/1676—Avoiding collision or forbidden zones
    • 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
    • B23K2101/00—Articles made by soldering, welding or cutting
    • B23K2101/04—Tubular or hollow articles
    • B23K2101/14—Heat exchangers

Definitions

  • the invention relates to an automatic welding system and method in the field of robot welding intelligent technology, in particular to a nuclear island main equipment steam generator tube-tube plate welding robot welding system and a welding method thereof.
  • Nuclear power is an important direction for future energy development due to its advantages of clean, continuous power supply and relatively limited geographic location.
  • the "National Nuclear Power Development Thematic Plan” proposes that by 2020, China's nuclear power installed capacity will reach 40 million kilowatts, nuclear power will account for 4% of all power installed capacity, and annual power generation will reach 260-280 billion kilowatt hours.
  • the length of the nuclear power construction period has a significant impact on its economy.
  • the steam generator is the main equipment of the nuclear island.
  • the welding of the pipe-tube plate during the manufacturing process is a key process.
  • the welding quality and welding efficiency of the pipe-tube plate directly affects Corrosion resistance, sealing performance and manufacturing progress of the steam generator on the primary side of the tube sheet.
  • Steam generator tube-tube plate welds are huge. Take the AP1000 steam generator as an example. There are 20050 pipe-tube plate welds. At present, the manual hand-tube-tube plate welding gun is mainly used for welding, and the welding efficiency is low.
  • the invention aims at the current situation that the steam generator tube-tube plate is mainly manually welded, and proposes a nuclear island main equipment steam generator tube-tube plate welding robot welding system and welding method thereof, and realizes tube-tube plate automatic welding.
  • a nuclear island main equipment steam generator tube-tube plate welding robot welding system and welding method thereof and realizes tube-tube plate automatic welding.
  • pipe-tube plate welding robot automatic welding automatic detection and replacement of tungsten electrodes, online inspection of weld quality.
  • At least one six-degree-of-freedom industrial robot whose working range is superimposed to achieve on the workpiece tube Coverage of the welded position of the pipe-tube sheet weld;
  • each industrial robot separately holds at least one tube-tube plate welding gun corresponding to the corresponding tube hole, and the tube-tube plate welding gun to the tube-tube at each tube hole Plate welds are welded;
  • On-line inspection module for weld quality online inspection of weld quality based on weld profile.
  • the robot welding system further comprises a path planning and offline programming module that is signally connected to and controlled by the central control module, performs welding path anti-collision planning for a plurality of industrial robots, and performs offline programming on the planned solution. .
  • the robot welding system further comprises a laser scanning positioning module that is signally connected to and controlled by the central control module, and obtains the center coordinates of the tube hole according to the scanning result of the laser sensor on the tube hole, as the initial welding position identification and Autonomously guided reference values.
  • a laser scanning positioning module that is signally connected to and controlled by the central control module, and obtains the center coordinates of the tube hole according to the scanning result of the laser sensor on the tube hole, as the initial welding position identification and Autonomously guided reference values.
  • the robot welding system is provided with two industrial robots, each of which holds two tube-tube plate welding guns for automatic tungsten argon arc welding of the tube-tube plate welds.
  • each of the industrial robots is mounted on a vertical bracket corresponding thereto and is capable of horizontal movement with the vertical bracket; the industrial robot is capable of moving up and down on the vertical bracket.
  • each of the vertical brackets is mounted on the system platform and is horizontally movable with the system platform; the system platform can be respectively moved along the ground rails to the front of the tube sheets of the workpieces to be welded;
  • the workpieces are steam generators placed on respective support frames.
  • the following devices are also disposed on the system platform:
  • Tungsten automatic replacement platform which is located within the operable range of the corresponding industrial robot for replacing the tungsten electrode
  • the central control platform is provided with the central control module, the weld quality online detection module, the path planning and offline programming module, and the laser scanning positioning module.
  • each of the vertical brackets is respectively mounted with a corresponding harness bracket for placing the wires of the industrial robot and its corresponding tube-tube plate welding gun;
  • the ground rail of the system platform comprises a lateral rail and a longitudinal rail.
  • the weld quality on-line detection module obtains a three-dimensional reconstructed image of the weld according to the scan result of the laser weld on the weld, and performs on-line inspection on the weld quality according to the weld profile. Measurement.
  • the laser sensor is disposed on a front end of the robot arm of the industrial robot.
  • Another technical solution of the present invention is to provide a welding method of a robot welding system, which comprises the following processes:
  • the system platform is moved to the front of the tube sheet of one of the workpieces by the ground rail so that the robotic welding system can be operated on the system platform:
  • Each industrial robot grasps one of the corresponding welding guns to reach the welding position of the current tube hole to be welded on the tube plate for positioning of the welding gun; after the welding gun is positioned, the industrial robot loosens the welding gun fixture to grasp the corresponding corresponding to the industrial robot.
  • the already positioned welding torch starts the welding according to the command of the central control module, and the welding completion signal is given after the welding of the single pipe-tube plate weld is completed; the industrial robot picks up the welding gun that gives the welding completion signal to the next pipe hole. In order to carry out the welding of the next pipe-tube sheet weld;
  • the system platform is moved to the tube sheets of the other workpiece through the ground rails to complete the welding of all the tube-tube sheet welds. .
  • the welding method further comprises: moving, by each industrial robot, a laser sensor disposed at a front end of the robot arm, scanning a current tube hole to be welded on the tube plate through a laser sensor, and determining a center position of the tube hole through a laser scanning positioning module.
  • a laser sensor disposed at a front end of the robot arm
  • scanning a current tube hole to be welded on the tube plate through a laser sensor and determining a center position of the tube hole through a laser scanning positioning module.
  • the welding method further comprises: after the welding tube completes the single tube-tube plate weld welding, the tube-tube plate weld is scanned by the laser sensor, and the three-dimensional reconstruction image of the weld is obtained by the weld quality on-line detection module. And according to the weld profile, the weld quality is detected online and the defect is exceeded.
  • the welding method further comprises: after installing the plurality of workpieces on the respective support frames, establishing a three-dimensional model proportional to each workpiece, introducing the robot control system; and moving the system platform to any one of the workpieces.
  • manual teaching operation is performed on the industrial robot, and the actual coordinates of the workpiece are confirmed by a plurality of reference points to correct the coordinate system of the three-dimensional model of the workpiece; and the welding path prevention of the plurality of industrial robots is performed by the path planning and the offline programming module. Plan the collision and program the planned solution offline.
  • the welding gun positioning mandrel is inserted into the current hole to be welded, so that the pneumatic auxiliary positioning expansion pipe provided on the upper part of the welding gun is inserted into the nozzle, and the welding torch is After the axial position is in place, the pneumatic positioning expansion tube is automatically tightened, and after the tightening is confirmed, the robot releases the welding gun fixture.
  • the invention discloses a robot welding system and a welding method thereof, and belongs to the technical field of robot welding automation, and is suitable for pipe-tube plate welding of a nuclear island main equipment steam generator.
  • the industrial robot of the invention has the advantages of high work efficiency, stability and reliability, high repetition precision, etc.
  • the use of robots instead of manual welding is very obvious in improving welding efficiency, ensuring product quality stability, improving workers' working environment and reducing labor intensity of workers. The advantages.
  • the invention can realize initial weld seam position identification and autonomous guidance, path planning and off-line programming of the nuclear island main equipment steam generator tube-tube plate welding, automatic welding of the pipe-tube plate robot and on-line detection of the weld quality. It is very important to improve the welding efficiency of pipe-tube sheet, ensure the stability of weld quality, shorten the delivery period of steam generator, and improve the economic efficiency of nuclear power.
  • FIG. 1 is a schematic structural view of a robot welding system for welding a tube sheet of a nuclear island main equipment steam generator according to the present invention
  • FIG. 2 is a schematic view showing the arrangement of the robot welding system of the present invention.
  • FIG. 3 is a schematic flow chart of a welding method of the robot welding system of the present invention.
  • the present invention provides a robotic welding system for a nuclear island main equipment steam generator tube-tube plate welding, which comprises: an industrial robot (two in this case), a path planning and off-line programming module, and a laser. Scanning and positioning module, tube-tube plate welding torch and welding power supply, weld quality online detection module, and central control module for controlling the operation of the above modules and devices.
  • two six-degree-of-freedom industrial robots (hereinafter referred to as robots) are respectively mounted on vertical brackets with rails and horizontal movement.
  • the robot can move up and down on the bracket. Welding of the tube-tube sheet on the tube plate and the lower part; the vertical bracket can be moved on the horizontal guide rail to drive the robot in the horizontal direction to realize the robot-to-tube plate left and right part tube-tube plate Welding. Therefore, by moving the robot in the up, down, left and right directions by means of the vertical bracket, the working range of the two robots can completely cover the plane of the tube sheet, and the welding of all the tube-tube sheet welds can be realized by the double robot. .
  • the path planning and offline programming module can plan the welding path of the dual robot, optimize the welding path through simulation, obtain an optimized path planning scheme, improve welding efficiency, and prevent collision of the double robot in the welding process;
  • the path planning scheme replaces the complicated manual teaching programming with off-line programming to improve the efficiency of the steam generator tube-tube plate welding.
  • the laser scanning positioning module performs laser scanning on the tube hole through the laser sensor, and then obtains the center coordinates of the tube hole by a corresponding algorithm, and the coordinate value is a spatial position coordinate recognizable by the robot; according to the coordinate value, the robot can be controlled to arrive.
  • the center of the tube hole is used to realize the initial welding position identification and autonomous guidance of the tube-tube sheet welding.
  • the invention uses a special tube-tube plate welding torch and a tube-tube plate welding power source; the robot is grasped by the robot, and the welding gun is inserted into the pipe hole through the positioning mandrel for positioning, and the tungsten electrode is automatically protected by the double-layer protective air hood. Rotate to complete the automatic tungsten argon arc welding of the tube-tube plate weld (in this case, specifically for the implementation of unfilled automatic tungsten argon arc welding). With the two robots, the tube-tube plate weld automatic tungsten argon arc welding of the double robot four tube-tube plate welding gun can be completed. That is, one robot separately grabs two corresponding welding torches to perform welding work at different pipe holes.
  • the on-line quality inspection module of the weld seam can realize on-line inspection of the quality of the pipe-tube plate weld. After the welding of each tube-tube sheet weld is completed, the weld seam is scanned by a laser sensor, and then the shape of the tube-tube sheet weld is obtained through three-dimensional reconstruction, and the presence or absence of pores, slag inclusions, bites are automatically determined according to the weld profile. On-line detection of weld quality by edge and other defects.
  • the central control module can control the laser sensor to scan the tube hole to realize initial welding position identification and guidance; control path planning and offline programming module to plan welding path, perform offline programming; control robot to grasp welding torch to tube-tube
  • the board is automatically welded; according to the tungsten shape, the tungsten electrode is automatically detected and replaced; after each tube-tube plate weld is welded, the laser sensor is controlled to scan the weld to obtain the weld profile, and the weld shape is formed. The appearance of the weld quality online detection.
  • FIG. 2 is a schematic view showing the arrangement structure of the robot welding system in the embodiment.
  • the robotic welding system in this example comprises: a system platform 50 disposed on the system platform 50 and along with it Two sets of equipment for moving the lateral rail 301 or the longitudinal rail 302 of the ground; each set of equipment is provided with a vertical bracket 10, a harness bracket 90, a six-degree-of-freedom industrial robot 20, a tube-tube plate welding power source 70, and a tube-tube plate welding gun 30.
  • the tungsten pole automatically replaces the platform 40;
  • the system platform 50 further has a central control platform 60 and a robot control cabinet 80 shared by the two groups of devices (the corresponding functional modules controlled for the two groups of devices are respectively disposed therein).
  • two steam generators 100 and their tube sheets to be welded are shown, and the respective support frames 200 of the two steam generators 100; if two steam generators 100 (hereinafter referred to as workpieces) are disposed.
  • workpieces two steam generators 100 (hereinafter referred to as workpieces) are disposed.
  • the vertical bracket 10 can drive the robot 20 mounted thereon to move horizontally, and can move the robot 20 up and down on the vertical bracket 10; the horizontal movement of the vertical bracket 10 is realized by the movement of the system platform 50, such as It is also possible to further provide a guide rail for moving the vertical bracket 10 on the system platform 50 as needed.
  • the wire harness bracket 90 is mounted on the vertical bracket 10, and can be connected to the brackets of the tube-tube-plate welding torch 30 corresponding to the robot 20 and its welding power source 70 to prevent the mutual entanglement between the wires during the welding process. Interference, open circuit, etc.
  • the tungsten pole automatic changing platform 40 is located within a range to which the corresponding robot 20 can be operated for replacing the tungsten pole; the tungsten pole automatic changing platform 40 can be used as a welding gun placement frame to place the tube-tube plate welding gun 30.
  • a stairway connected to the tungsten electrode automatic changing platform 40 may be provided on the system platform 50 to facilitate the operation of the worker and the status of the related equipment.
  • the path planning and offline programming module, the laser scanning positioning module, the weld quality online detection module, the central control module, and the like described above are disposed in the central control platform 60.
  • the respective robot control system of each robot can be disposed in the central control platform 60 and/or the robot control cabinet 80.
  • the welding method implemented by the robot welding device of the present invention comprises the following steps:
  • the robot reaches the position of the welding gun placement frame and grasps a welding torch from above, and the laser sensor disposed at the front end of the robot arm recognizes the center position of the current pipe hole to be welded, and simultaneously detects the pipe assembly depth and the expansion pipe gap;
  • the robot grabs the welding torch and reaches the welding position.
  • the welding gun positioning mandrel is inserted into the hole to be welded.
  • the upper part of the welding gun is pneumatically assisted to position the expansion tube and simultaneously insert into the corresponding nozzle. After the welding gun is axially positioned, the pneumatic positioning expansion tube automatically tightens. After the tightening is confirmed The robot loosens the welding gun fixture;
  • the tube-tube plate weld is scanned by the robot with the laser sensor, the weld profile is obtained through the three-dimensional reconstruction image, and the over-standard defect is automatically identified according to the weld profile. If there is an over-standard defect, the welding is stopped immediately and the alarm is issued;
  • the robot cooperates with the laser sensor to scan the next tube hole to identify its center coordinate, and detects the tube assembly depth and the expansion tube gap, exceeding the standard alarm;
  • the robot receives a welding torch completion signal, automatically locates and grabs the welding torch, and then performs the welding of the next pipe-tube plate weld.
  • Steps S6-S11 are repeated, that is, one robot performs these operations on the corresponding other welding torch; the pick-and-place times of the two welding guns of one robot are staggered from each other.
  • the other two welding guns of the other robot are similar; in this way, the automatic welding of all the pipe-tube plate welds on one workpiece (steam generator) is completed by two robots with four tube-tube plate welding guns.
  • the invention can realize the initial welding bit identification and guiding of the steam generator tube-tube plate welding of the nuclear power main equipment, the path planning and off-line programming, the robot automatic welding of the pipe-tube plate weld, the automatic detection and replacement of the tungsten electrode, the weld seam Main features such as quality online testing.
  • the steam generator tube-tube plate welding system can effectively improve the efficiency of pipe-tube plate welding, improve the quality stability of the weld seam, and shorten the steaming The delivery cycle of the steam generator.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Physics & Mathematics (AREA)
  • Plasma & Fusion (AREA)
  • Robotics (AREA)
  • Quality & Reliability (AREA)
  • Optics & Photonics (AREA)
  • Geometry (AREA)
  • Butt Welding And Welding Of Specific Article (AREA)
  • Manipulator (AREA)
  • Laser Beam Processing (AREA)
  • Numerical Control (AREA)
  • Lining Or Joining Of Plastics Or The Like (AREA)
  • Arc Welding In General (AREA)

Abstract

一种机器人焊接系统及其焊接方法，通过两台工业机器人（20）配合管子-管板焊枪（30）对一个管板上所有管子-管板焊缝进行焊接。由路径规划与离线编程模块进行焊接路径防碰撞的规划，并进行离线编程；由激光扫描定位模块获得管孔的圆心坐标实现初始焊接位置识别与自主导引；由焊缝质量在线检测模块根据焊缝激光扫描结果获得三维重建图像，并根据焊缝形貌对焊缝质量进行在线检测。

Description

一种机器人焊接系统及其焊接方法 技术领域
本发明涉及的是机器人焊接智能化技术领域的自动化焊接系统及方法，具体涉及一种核岛主设备蒸汽发生器管子-管板焊接的机器人焊接系统及其焊接方法。
背景技术
核电由于具有清洁、持续供电能力强、受地理位置限制相对较少的优点，是未来能源发展的重要方向。《国家核电发展专题规划》提出到2020年，我国核电运行装机容量将达到4000万千瓦，核电占全部电力装机容量的比例提高到4％，年发电量达到2600～2800亿千瓦时。核电建设工期的长短对其经济性有显著的影响，蒸汽发生器作为核岛主设备，其制造过程中管子-管板的焊接是关键工序，管子-管板的焊接质量和焊接效率直接影响到管板一次侧的耐腐蚀性、密封性以及蒸汽发生器的制造进度。蒸汽发生器管子-管板焊缝数量巨大，以AP1000蒸汽发生器为例，有20050道管子-管板焊缝，目前主要采用人工手持管子-管板焊枪进行焊接，焊接效率低。
发明的公开
本发明针对目前蒸汽发生器管子-管板主要采用人工进行焊接的现状，提出一种核岛主设备蒸汽发生器管子-管板焊接的机器人焊接系统及其焊接方法，实现管子-管板自动化焊接过程中的初始焊位识别与导引、路径规划与离线编程、管子-管板焊缝机器人自动化焊接、钨极自动检测与更换、焊缝质量在线检测等功能。
为了达到上述目的，本发明的一个技术方案是提供一种机器人焊接系统，所述机器人焊接系统设有中央控制模块，以及与其信号连接并受其控制的以下设备：
至少一台六自由度的工业机器人，其工作范围叠加实现对工件管板上所 有管子-管板焊缝的焊接位置的覆盖；
至少一把管子-管板焊枪；每个工业机器人分别抓持与之对应的至少一把管子-管板焊枪至相应的管孔处，由各管孔处的管子-管板焊枪对管子-管板焊缝进行焊接；
焊缝质量在线检测模块，根据焊缝形貌对焊缝质量进行在线检测。
优选地，所述机器人焊接系统还设有与中央控制模块信号连接并受其控制的路径规划与离线编程模块，对多个工业机器人进行焊接路径防碰撞的规划，并对规划的方案进行离线编程。
优选地，所述机器人焊接系统还设有与中央控制模块信号连接并受其控制的激光扫描定位模块，其根据激光传感器对管孔的扫描结果获得管孔的圆心坐标，作为初始焊接位置识别与自主导引的参考数值。
优选地，所述机器人焊接系统设有两台工业机器人，每台工业机器人分别抓持两把用来对管子-管板焊缝进行自动钨极氩弧焊的管子-管板焊枪。
优选地，各个所述工业机器人安装在与其对应的竖直支架上并能够随竖直支架进行水平移动；所述工业机器人能够在竖直支架上进行上下移动。
优选地，各个所述竖直支架安装在系统平台上并能够随系统平台水平移动；所述系统平台能够沿地面导轨分别移动至各个待焊接工件的管板前；
所述工件是放置在各自支承架上的蒸汽发生器。
优选地，所述系统平台上还设置有以下设备：
钨极自动更换平台，其位于相应工业机器人可操作的范围内，用于更换钨极；
焊接电源，为各把所述管子-管板焊枪供电；
机器人控制柜，其中设置各个工业机器人的机器人控制设备；
中央控制平台，其中设置有所述中央控制模块、焊缝质量在线检测模块、路径规划与离线编程模块及激光扫描定位模块。
优选地，各个所述竖直支架上分别安装有相应的线束支架，用来放置工业机器人及其对应管子-管板焊枪的导线；
所述系统平台的地面导轨，包含横向导轨及纵向导轨。
优选地，所述焊缝质量在线检测模块是根据激光传感器对焊接焊缝的扫描结果，获得焊缝的三维重建图像，并根据焊缝形貌对焊缝质量进行在线检 测。
优选地，所述激光传感器设置在所述工业机器人的机器人臂前端上。
本发明的另一个技术方案是提供一种机器人焊接系统的焊接方法，其包含以下过程：
将多个工件分别安装在各自的支承架上；
通过地面导轨将系统平台移动到其中一个工件的管板前，以便机器人焊接系统设置在系统平台上的设备能够进行相应操作：
每个工业机器人抓持与之对应的其中一把焊枪到达管板上当前待焊管孔的焊接位置进行焊枪的定位；焊枪定位后，工业机器人松开焊枪夹具，以便抓取与该工业机器人对应的另一把焊枪；
已经定位的焊枪根据中央控制模块的命令启动焊接，在对单个管子-管板焊缝焊接完成后给出焊接完成信号；工业机器人将给出焊接完成信号的焊枪抓放到下一个管孔处定位，以便进行下一个管子-管板焊缝的焊接；
通过多个工业机器人与其各自焊枪的配合完成该工件管板上所有管子-管板的焊接后，通过地面导轨将系统平台移动到另一个工件的管板前，完成所有管子-管板焊缝的焊接。
优选地，所述焊接方法进一步包含：由每个工业机器人带动机器人臂前端设置的激光传感器移动，通过激光传感器扫描管板上当前待焊管孔，并通过激光扫描定位模块确定该管孔的中心位置，以便该工业机器人抓持与之对应的其中一把焊枪到达该管孔的焊接位置进行焊枪的定位。
优选地，所述焊接方法进一步包含：在焊枪完成单个管子-管板焊缝焊接之后，通过激光传感器对管子-管板焊缝进行扫描，通过焊缝质量在线检测模块获得焊缝的三维重建图像，并根据焊缝形貌对焊缝质量进行在线检测及超标缺陷报警。
优选地，所述焊接方法进一步包含：将多个工件分别安装在各自的支承架上之后，建立与各工件等比例的三维模型，导入机器人控制系统；以及，将系统平台移动到任意一个工件的管板前之后，对工业机器人进行人工示教操作，以多个参考点确认工件实际坐标，来校正工件三维模型的坐标系；并且，通过路径规划与离线编程模块执行多个工业机器人的焊接路径防碰撞的规划，并对规划的方案进行离线编程。
优选地，任意一把焊枪被工业机器人抓持到当前待焊管孔的焊接位置时，将焊枪定位芯轴插入当前待焊管孔，使焊枪上部设置的气动辅助定位胀管插入管口，并在焊枪轴向到位后使气动定位胀管自动涨紧，涨紧确认后机器人松开焊枪夹具。
本发明公开了一种机器人焊接系统及其焊接方法，属于机器人焊接自动化技术领域，适用于核岛主设备蒸汽发生器管子-管板焊接。本发明中的工业机器人具有工作效率高、稳定可靠、重复精度高等优点，采用机器人取代人工进行焊接在提高焊接效率、保证产品质量稳定性、改善工人工作环境和降低工人劳动强度等方面具有非常明显的优势。
本发明能够实现核岛主设备蒸汽发生器管子-管板焊接的初始焊缝位置识别与自主导引、路径规划与离线编程、管子-管板机器人自动化焊接以及焊缝质量的在线检测。对于提高管子-管板的焊接效率、保证焊缝质量的稳定性、缩短蒸汽发生器的交货周期、提高核电经济性具有非常重要的意义。
附图的简要说明
图1是本发明所述核岛主设备蒸汽发生器管子管板焊接的机器人焊接系统的结构示意图；
图2是本发明所述机器人焊接系统的布置示意图；
图3是本发明所述机器人焊接系统的焊接方法的流程示意图。
实现本发明的最佳方式
下面结合附图对本发明的实施例做详细说明：本实施例在以本发明技术方案为前提下进行实施，给出了详细的实施方式和具体的操作过程，但本发明的保护范围不限于下述的实施例。
如图1所示，本发明提供一种核岛主设备蒸汽发生器管子-管板焊接的机器人焊接系统，其包括：工业机器人(本例设有两台)、路径规划与离线编程模块、激光扫描定位模块、管子-管板焊枪及焊接电源、焊缝质量在线检测模块，以及对上述模块及器件的工作进行控制的中央控制模块。
其中，两台六自由度的工业机器人(以下或简称为机器人)分别安装在带导轨、可水平移动的竖直支架上。机器人可以在支架上实现上下移动，完 成管板上部分和下部分管子-管板的焊接；竖直支架可以在水平方向的导轨上移动，从而带动机器人在水平方向的移动，实现机器人对管板左部分和右部分管子-管板的焊接。因此，通过借助竖直支架可以实现机器人在上、下、左、右方向的移动，两台机器人的工作范围叠加可以完全覆盖管板平面，以双机器人实现对所有管子-管板焊缝的焊接。
所述的路径规划与离线编程模块，可以对双机器人的焊接路径进行规划，并通过仿真优化焊接路径，得到优化的路径规划方案，提高焊接效率，防止焊接过程中双机器人发生碰撞；对优化的路径规划方案采用离线编程取代繁复的人工示教编程，提高蒸汽发生器管子-管板焊接的效率。
所述的激光扫描定位模块，通过激光传感器对管孔进行激光扫描，然后通过相应算法获得管孔的圆心坐标，该坐标值是机器人可识别的空间位置坐标；根据该坐标值，可以控制机器人到达管孔圆心，从而实现管子-管板焊接的初始焊接位置识别和自主导引。
本发明使用专门的管子-管板焊枪和管子-管板焊接电源；通过机器人抓持焊枪，使焊枪通过定位芯轴插入管孔中进行定位，在双层保护气罩的保护下，钨极自动旋转，完成管子-管板焊缝的自动钨极氩弧焊(本例中具体用于实施不填丝自动钨极氩弧焊)。配合两台机器人，可以完成双机器人四管子-管板焊枪的管子-管板焊缝自动钨极氩弧焊。即，一台机器人分别抓取与之相应的两把焊枪在不同管孔处进行焊接工作。
所述的焊缝质量在线检测模块，可以实现对管子-管板焊缝质量的在线检测。各管子-管板焊缝焊接完成后，通过激光传感器对焊缝进行扫描，然后经过三维重建获得管子-管板焊缝的形貌，根据焊缝形貌自动判断是否存在气孔、夹渣、咬边等缺陷，实现对焊缝质量的在线检测。
所述的中央控制模块，可以控制激光传感器对管孔进行扫描，实现初始焊位识别与导引；控制路径规划与离线编程模块规划焊接路径、进行离线编程；控制机器人抓持焊枪对管子-管板进行自动化焊接；根据钨极形貌，对钨极进行自动检测、更换等；各管子-管板焊缝焊接完成后，控制激光传感器对焊缝进行扫描获得焊缝形貌，通过焊缝形貌实现对焊缝质量的在线检测。
如图2所示是本实施例中机器人焊接系统的布置结构示意图。本例中机器人焊接系统，包含：系统平台50，设置于该系统平台50上并随其一起沿 地面的横向导轨301或纵向导轨302移动的两组设备；每组设备设有竖直支架10、线束支架90、六自由度工业机器人20、管子-管板焊接电源70、管子-管板焊枪30、钨极自动更换平台40；该系统平台50上还设有为两组设备共用的中央控制平台60及机器人控制柜80(针对两组设备控制的相应功能模块在其中分别设置)。
图中还示出两台蒸汽发生器100及其待焊接的管板，和两台蒸汽发生器100各自的支承架200；若两台蒸汽发生器100(以下或称其为工件)的布置位置有所调整，不同于图2所示并排布置的话，则可以适应调整地面导轨的形状排布，以使系统平台50能够顺利地移动到每一个工件待焊接管板前。
如前文所述竖直支架10可以带动其上面安装的机器人20进行水平移动，并可以使机器人20在竖直支架10上进行上下移动；竖直支架10的水平移动随系统平台50移动实现，如有需要还可以进一步在系统平台50上设置供竖直支架10移动的导轨。
线束支架90安装在竖直支架10上，能够将一个机器人20对应的管子-管板焊枪30及其焊接电源70等相互连接的导线绑在支架上，防止焊接过程中导线之间的相互缠绕引起干涉、断路等情况的发生。
钨极自动更换平台40位于相应机器人20可以操作到的范围内，用于更换钨极；该钨极自动更换平台40可以作为焊枪放置架，来放置管子-管板焊枪30。可以在系统平台50上设置连通到钨极自动更换平台40的楼梯，方便工作人员操作及查看相关设备的状态等。
前文所述路径规划与离线编程模块、激光扫描定位模块、焊缝质量在线检测模块、中央控制模块等即设置在中央控制平台60中。各机器人相应的机器人控制系统可以设置在中央控制平台60和/或机器人控制柜80中。
如图3所示，利用本发明所述机器人焊接设备实现的焊接方法，包含如下步骤：
S1.将两台蒸汽发生器(即工件)分别安装固定在各自的支承架上；
S2.建立与各工件等比例的三维模型，导入机器人控制系统。
S3.通过地面横向和纵向导轨，将系统平台移动到一个工件管板的正前方合适位置并固定；
S4.采用人工示教操作，通过3～4个参考点确认工件实际坐标，校正工 件三维模型的坐标系；
S5.对双机器人管子-管板的焊接路径进行优化，获得优化的焊接路径规划方案，并进行离线编程。
S6.机器人到达焊枪放置架位置从上面抓持一把焊枪，由机器人臂前端设置的激光传感器识别当前待焊管孔的中心位置，并同时对管子组装深度和胀管间隙进行检测；
S7.机器人抓持焊枪到达焊接位置，将焊枪定位芯轴插入待焊管孔，焊枪上部气动辅助定位胀管同时插入相应管口，焊枪轴向到位后气动定位胀管自动涨紧，涨紧确认后机器人松开焊枪夹具；
S8.启动管子-管板焊接程序，控制到位的焊枪开始焊接；在单个管子-管板焊缝焊接完成后给出焊接完成信号；
S9.由机器人配合激光传感器对管子-管板焊缝进行扫描，通过三维重建图像获得焊缝形貌，根据焊缝形貌自动识别是否存在超标缺陷，如存在超标缺陷立即停止焊接并报警；
S10.机器人配合激光传感器扫描下一道管孔以识别其中心坐标，并对管子组装深度和胀管间隙进行检测，超标报警；
S11.机器人收到某把焊枪焊接完成信号，自动定位和抓取该焊枪，然后进行下一个管子-管板焊缝的焊接。
S12.重复步骤S6～S11，即一个机器人对其相应的另一把焊枪也执行这些操作；一个机器人的两把焊枪的取放时间相互错开。另一个机器人的两把焊枪以此类推；以此实现由2台机器人配合4把管子-管板焊枪完成一个工件(蒸汽发生器)上所有管子-管板焊缝的自动焊接。
S13.通过地面横向导轨和纵向导轨，移动系统平台到下一个工件管板的正前方合适位置并固定；
S12.重复步骤S4～S11，完成这个工件(蒸汽发生器)所有管子-管板的双机器人自动焊接。
本发明可以实现核电主设备蒸汽发生器管子-管板焊接的初始焊位识别与导引、路径规划与离线编程、管子-管板焊缝的机器人自动化焊接、钨极自动检测与更换、焊缝质量的在线检测等主要功能。该蒸汽发生器管子-管板焊接系统可以有效提高管子-管板焊接的效率、提高焊缝的质量稳定性、缩短蒸 汽发生器的交货周期。
尽管本发明的内容已经通过上述优选实施例作了详细介绍，但应当认识到上述的描述不应被认为是对本发明的限制。在本领域技术人员阅读了上述内容后，对于本发明的多种修改和替代都将是显而易见的。因此，本发明的保护范围应由所附的权利要求来限定。

Claims (15)

  1. 一种机器人焊接系统，其特征在于：
    所述机器人焊接系统设有中央控制模块，以及与其信号连接并受其控制的以下设备：
    至少一台六自由度的工业机器人，其工作范围叠加实现对工件管板上所有管子-管板焊缝的焊接位置的覆盖；
    至少一把管子-管板焊枪；每个工业机器人分别抓持与之对应的至少一把管子-管板焊枪至相应的管孔处，由各管孔处的管子-管板焊枪对管子-管板焊缝进行焊接；
    焊缝质量在线检测模块，根据焊缝形貌对焊缝质量进行在线检测。
  2. 如权利要求1所述的机器人焊接系统，其特征在于：
    所述机器人焊接系统还设有与中央控制模块信号连接并受其控制的路径规划与离线编程模块，对多个工业机器人进行焊接路径防碰撞的规划，并对规划的方案进行离线编程。
  3. 如权利要求1或2所述的机器人焊接系统，其特征在于，
    所述机器人焊接系统还设有与中央控制模块信号连接并受其控制的激光扫描定位模块，其根据激光传感器对管孔的扫描结果获得管孔的圆心坐标，作为初始焊接位置识别与自主导引的参考数值。
  4. 如权利要求1所述的机器人焊接系统，其特征在于，
    所述机器人焊接系统设有两台工业机器人，每台工业机器人分别抓持两把用来对管子-管板焊缝进行自动钨极氩弧焊的管子-管板焊枪。
  5. 如权利要求3所述的机器人焊接系统，其特征在于，
    各个所述工业机器人安装在与其对应的竖直支架上并能够随竖直支架进行水平移动；所述工业机器人能够在竖直支架上进行上下移动。
  6. 如权利要求5所述的机器人焊接系统，其特征在于，
    各个所述竖直支架安装在系统平台上并能够随系统平台水平移动；
    所述系统平台能够沿地面导轨分别移动至各个待焊接工件的管板前；
    所述工件是放置在各自支承架上的蒸汽发生器。
  7. 如权利要求6所述的机器人焊接系统，其特征在于，
    所述系统平台上还设置有以下设备：
    钨极自动更换平台，其位于相应工业机器人可操作的范围内，用于更换钨极；
    焊接电源，为各把所述管子-管板焊枪供电；
    机器人控制柜，其中设置各个工业机器人的机器人控制设备；
    中央控制平台，其中设置有所述中央控制模块、焊缝质量在线检测模块、路径规划与离线编程模块及激光扫描定位模块。
  8. 如权利要求7所述的机器人焊接系统，其特征在于，
    各个所述竖直支架上分别安装有相应的线束支架，用来放置工业机器人及其对应管子-管板焊枪的导线；
    所述系统平台的地面导轨，包含横向导轨及纵向导轨。
  9. 如权利要求1所述的机器人焊接系统，其特征在于，
    所述焊缝质量在线检测模块是根据激光传感器对焊接焊缝的扫描结果，获得焊缝的三维重建图像，并根据焊缝形貌对焊缝质量进行在线检测。
  10. 如权利要求3或9所述的机器人焊接系统，其特征在于，
    所述激光传感器设置在所述工业机器人的机器人臂前端上。
  11. 一种机器人焊接系统的焊接方法，其特征在于，包含以下过程：
    将多个工件分别安装在各自的支承架上；
    通过地面导轨将系统平台移动到其中一个工件的管板前，以便机器人焊接系统设置在系统平台上的设备能够进行相应操作：
    每个工业机器人抓持与之对应的其中一把焊枪到达管板上当前待焊管孔的焊接位置进行焊枪的定位；焊枪定位后，工业机器人松开焊枪夹具，以便抓取与该工业机器人对应的另一把焊枪；
    已经定位的焊枪根据中央控制模块的命令启动焊接，在对单个管子-管板焊缝焊接完成后给出焊接完成信号；工业机器人将给出焊接完成信号的焊枪抓放到下一个管孔处定位，以便进行下一个管子-管板焊缝的焊接；
    通过多个工业机器人与其各自焊枪的配合完成该工件管板上所有管子-管板的焊接后，通过地面导轨将系统平台移动到另一个工件的管板前，完成所有管子-管板焊缝的焊接。
  12. 如权利要求11所述的焊接方法，其特征在于，
    所述焊接方法进一步包含：
    由每个工业机器人带动机器人臂前端设置的激光传感器移动，通过激光传感器扫描管板上当前待焊管孔，并通过激光扫描定位模块确定该管孔的中心位置，以便该工业机器人抓持与之对应的其中一把焊枪到达该管孔的焊接位置进行焊枪的定位。
  13. 如权利要求11所述的焊接方法，其特征在于，
    所述焊接方法进一步包含：
    在焊枪完成单个管子-管板焊缝焊接之后，通过激光传感器对管子-管板焊缝进行扫描，通过焊缝质量在线检测模块获得焊缝的三维重建图像，并根据焊缝形貌对焊缝质量进行在线检测及超标缺陷报警。
  14. 如权利要求11所述的焊接方法，其特征在于，
    所述焊接方法进一步包含：
    将多个工件分别安装在各自的支承架上之后，建立与各工件等比例 的三维模型，导入机器人控制系统；
    以及，将系统平台移动到任意一个工件的管板前之后，对工业机器人进行人工示教操作，以多个参考点确认工件实际坐标，来校正工件三维模型的坐标系；并且，通过路径规划与离线编程模块执行多个工业机器人的焊接路径防碰撞的规划，并对规划的方案进行离线编程。
  15. 如权利要求11所述的焊接方法，其特征在于，
    任意一把焊枪被工业机器人抓持到当前待焊管孔的焊接位置时，将焊枪定位芯轴插入当前待焊管孔，使焊枪上部设置的气动辅助定位胀管插入管口，并在焊枪轴向到位后使气动定位胀管自动涨紧，涨紧确认后机器人松开焊枪夹具。
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