WO2017162280A1 - Robot et procédé pour calibrer le courant électrique du servomoteur appliquant la force de pression d'un pistolet de soudage par points - Google Patents

Robot et procédé pour calibrer le courant électrique du servomoteur appliquant la force de pression d'un pistolet de soudage par points Download PDF

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Publication number
WO2017162280A1
WO2017162280A1 PCT/EP2016/056356 EP2016056356W WO2017162280A1 WO 2017162280 A1 WO2017162280 A1 WO 2017162280A1 EP 2016056356 W EP2016056356 W EP 2016056356W WO 2017162280 A1 WO2017162280 A1 WO 2017162280A1
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WO
WIPO (PCT)
Prior art keywords
arm
servomotor
force
resulting
driving current
Prior art date
Application number
PCT/EP2016/056356
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English (en)
Inventor
Anders Lager
Original Assignee
Abb Schweiz Ag
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Abb Schweiz Ag filed Critical Abb Schweiz Ag
Priority to PCT/EP2016/056356 priority Critical patent/WO2017162280A1/fr
Publication of WO2017162280A1 publication Critical patent/WO2017162280A1/fr

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Classifications

    • 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
    • B25J9/1692—Calibration of manipulator
    • 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
    • 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
    • B23K11/24—Electric supply or control circuits therefor
    • B23K11/25—Monitoring devices
    • B23K11/252—Monitoring devices using digital means
    • B23K11/255—Monitoring devices using digital means the measured parameter being a force

Definitions

  • the present disclosure relates to the field of industrial robots, and to calibration in relation to such industrial robots.
  • the disclosure relates to a calibration method for a force controlled axis device of an industrial robot, and an industrial robot including the force controlled axis device.
  • An industrial robot has several axes that makes the robot movable in a plurality of degrees of freedom.
  • a six degrees of freedom (DOF) robot has six axes that together give the robot full capability to position an end effector in its work space.
  • Each axis is driven by a motor either directly or via a transmission.
  • the axes are often position controlled, such that a certain power input to a motor gives a certain position of the axis.
  • the robot may be equipped with an end effector with a force controlled axis, for example a gripper or a spot welding gun.
  • the force controlled axis includes at least two arms that can be positioned in relation to each other in order to squeeze or hold an object with a clamping or pressure force.
  • the force controlled axis is driven by a servomotor, and as an initial measure before using the force controlled axis, a relationship between the servomotor driving current and the pressure force of the arms may be established in a force calibration.
  • the user or controller controlling the end effector then knows what driving current to the servomotor that corresponds to a certain pressure force of the arms.
  • a typical automotive industry demand of force accuracy for a spot welding gun is ⁇ 3%.
  • the pressure force repeatability of the arms is affected by the servomotor temperature, friction, maintenance and aging. Tests have shown that the pressure force of the arms may for some spot welding guns decrease 10% when the servomotor temperature is increased 60°C.
  • One solution to the accuracy problem is to use water cooled servomotors, since the servomotor temperature then is held more or less constant. However, air cooling is preferred since it is less expensive and require less service.
  • Another known method to improve pressure force accuracy is to adjust the applied servomotor driving current from its nominal value depending on the measured servomotor temperature.
  • An advantage with such a method is that the servomotor temperature may be sampled at any time.
  • the method also has several disadvantages, such as requiring a temperature sensor connected to the controller of the spot welding gun. An extra calibration of the temperature versus force relationship is also required for each spot welding gun. Further, the servomotor temperature model is simplified, as well as spindle temperature, service intervals, and aging that also will have an effect of the resulting pressure force. From US2009302008A1 it is known to use a force sensor continuously during use of the spot welding gun, in order to get a desired pressure force by compensating the driving current to the servomotor.
  • the disclosure relates to a calibration method for a force controlled axis device of an industrial robot.
  • the force controlled axis device includes an arm arrangement with a first arm, a second arm and a servomotor arranged to be fed with a driving current in order to actuate at least one of the first arm and the second arm.
  • the calibration method includes:
  • the duty cycle routine includes closing the arm arrangement to a clamping state and setting the driving current to the servomotor to a predetermined value, and recording resulting servomotor characteristics data of the servomotor;
  • the calibration method is performed automatically by the industrial robot.
  • the servomotor driving current needed to achieve a certain pressure force is calculated using data from both the initial calibration and the duty cycle routine.
  • the mentioned data can be recorded during regular force calibrations and so called tip wear calibrations. The method is thus easy to implement to a low cost, as no extra equipment may be needed. Further is the calibration method more accurate than some previous methods, as no simplified servomotor temperature model is assumed.
  • the resulting servomotor characteristics data includes motor axis positions of the servomotor.
  • the method includes performing the initial calibration while a force sensor is held between the first arm and the second arm sensing the resulting pressure force between the first arm and second arm.
  • the stiffness of the force sensor is preferably very high compared to the stiffness of the force controlled axis, in order to not affect the measurement result.
  • the determining an adjusted current includes to calculate a constant k representing the flexibility of the arm arrangement based on the determined correlation during the initial calibration.
  • the method includes determining an adjusted current based on the constant k, a linear interpolation assumption of the current fed to the servomotor and resulting pressure force, and the recorded resulting servomotor characteristics data of the servomotor during the duty cycle routine.
  • the clamping state includes closing the arm arrangement such that the first arm and the second arm are in contact.
  • the initial calibration includes setting the driving current to a plurality of different predetermined values
  • the duty cycle routine includes setting the driving current to a plurality of different predetermined values.
  • the disclosure relates to an industrial robot arranged with a force controlled axis device.
  • the force controlled axis device includes an arm arrangement with a first arm and a second arm, and a
  • the industrial robot further includes a controller configured to determine a driving current to the servomotor based on a desired pressure force between the first arm and the second arm.
  • the controller is further configured to:
  • the duty cycle routine includes closing the arm arrangement to a clamping state and set the driving current to the servomotor to a predetermined value, and resulting servomotor characteristics data of the servomotor is recorded;
  • the controller is configured to perform the initial calibration while the force sensor is held between the first arm and the second arm in order to sense the resulting pressure force between the first arm and second arm.
  • the controller is configured to determine an adjusted current including to calculate a constant k representing the flexibility of the arm arrangement based on the recorded data during the initial calibration. According to one embodiment, the controller is configured to determine the adjusted current based on the constant k, a linear interpolation assumption of the current fed to the servomotor and resulting pressure force, and the recorded resulting servomotor characteristics data of the servomotor during the duty cycle routine.
  • controller configured to perform the duty cycle routine when the clamping state includes to close the arm arrangement such that the first arm and the second arm are in contact.
  • controller is configured to perform the initial calibration including to set the driving current to a plurality of different
  • the force controlled axis device is a spot welding gun
  • the first arm is movable and includes an electrode with a first electrode tip
  • the second arm is fixed and includes an electrode with a second electrode tip, the first arm being movable against the second arm in order to clamp an object between the first electrode tip and the second electrode tip.
  • Fig. 1 shows an industrial robot arranged with a spot welding device.
  • Fig. 2 shows a power transmission chain for the spot welding device.
  • Fig. 3 illustrates the first arm and the second arm of the spot welding device when clamping two plates.
  • Fig. 4 illustrates in a diagram how force control is applied to the spot welding device.
  • Fig. 5 shows a flow chart of a calibration method according to one embodiment.
  • Fig. 6 illustrates the first arm and the second arm of the spot welding gun clamping a force sensor.
  • Figs. 7-8 shows data retrieved while the first arm and the second arm are clamping in Fig. 6.
  • Fig. 9 illustrates the first arm and the second arm of the spot welding gun when in contact.
  • Fig. 10 shows data retrieved during the initial calibration and the duty cycle routine.
  • Fig. 1 is showing an industrial robot 1 with a plurality of axes 3 giving six degrees of freedom (6 DOF).
  • the term "industrial robot” refers to an automatically controlled, reprogrammable, multipurpose manipulator with a plurality of degrees of freedom and an ability to perform work tasks independently.
  • the industrial robot 1 hereinafter called “the robot 1 " is arranged to be controlled from a robot controller 2.
  • the robot controller 2 includes a processor 8 and a memory 9.
  • the processor 8 may be made up of one or more Central Processing Units (CPU).
  • the memory 9 may be made up of one or more memory units.
  • a memory unit may include a volatile and/or a non-volatile memory, such as a flash memory or Random Access Memory (RAM).
  • the robot 1 is further arranged with a force controlled axis device, here in the shape of a spot welding gun 4.
  • the spot welding gun 4 may be attached to the robot 1 as an end effector to the last arm of the robot 1 .
  • Another kind of force controlled axis device is a robot gripper (not shown), that also can be attached as an end effector to the industrial robot 1 . It should be mentioned that also such force controlled axis devices could be used with the invention.
  • the spot welding gun 4 is driven by a servomotor 5 arranged to the robot 1 .
  • the spot welding gun 4 is integrated as a seventh axis of the robot 1 , and can be positioned in any position in the work space of the robot 1 .
  • the spot welding gun 4 has an arm arrangement 6 for force controlled clamping, which includes a first arm 7A and a second arm 7B.
  • the first arm 7A is in the figure the uppermost arm of the arm arrangement 6 and is moveable along a path.
  • the second arm 7B is the lowermost arm of the arm arrangement 6 and is fixed along the same path.
  • the first arm 7A includes an electrode with a first electrode tip, and the second arm 7B includes an electrode with a second electrode tip.
  • the servomotor 4 is arranged to be fed with a driving current in order to actuate at least one of the first arm 7A and the second arm 7B.
  • the drive chain of the spot welding gun 4 is illustrated with a plurality of boxes in Fig. 2.
  • the box “D” represents the drive of the spot welding gun 4 which may be incorporated in the robot controller 2 or in a separate spot welding gun controller (not shown) of the spot welding gun 4.
  • the robot controller 2 and the separate spot welding gun controller may then be configured for communication with each other.
  • the drive “D” is configured to control power, i.e. current, to the servomotor 5, illustrated with the box "5", in order to apply a certain pressure force between the first arm 7A and second arm 7B.
  • the drive “D” also controls power to the electrodes in the first arm 7A and second arm 7B for application of a certain current during the spot welding.
  • the power can be retrieved from the main power network, or from a separate power source and is conducted via power cables arranged to the robot 1 (Fig 1 ) to the spot welding gun 4.
  • the servomotor 5 is via a transmission “T”, illustrated by the box “T”, connected to the arm arrangement 6, illustrated by the box “6".
  • the robot 1 moves the second arm 7B that is fixed to the arm arrangement 6, into contact with one of the plates 10.
  • the servomotor 5 then moves the first arm 7A into contact with the other plate 10, such that the two plates 10 are clamped between the electrode tip of the first arm 7A and the electrode tip of the second arm 7B.
  • the plates 10 are held together by a fixture (not shown).
  • the first arm 7A and second arm 7B are then pressed together by the servomotor 5 to achieve a certain pressure force F on the plates 10.
  • a current is then passed through the plates 10 via the electrodes in the first arm 7A and the second arm 7B such that the plates 10 are heated by the resistance developed in the plates 10, and the material in the plates 10 becomes molted.
  • the pressure from the arms 7A, 7B forces the molten material to fuse together.
  • the current is then removed but the first arm 7A and second arm 7B are still pressed together to allow the material to cool and solidify.
  • This electro-thermic process is also called resistance spot welding.
  • Fig. 4 a diagram is illustrated where the force control for achieving a certain force "F" on the plates 10 is illustrated.
  • the current fed to the servomotor 5 is ramped up to achieve a certain current "I" to the servomotor 5 as illustrated in the diagram.
  • a current I needed to the servomotor 5 to achieve a certain force F between the first arm 7A and second arm 7B is determined in an initial force calibration and put in a table before the spot welding gun 4 is taken into use.
  • the calibration method includes in a first step A1 performing, or obtaining data from, an initial calibration of a spot welding gun 4 during which the initial calibration the driving current to the servomotor 5 is set to a predetermined value.
  • This initial calibration extends the previously made force calibration with positional recordings. If the initial calibration has already been performed, either with another identical spot welding gun 4or with the same spot welding gun 4, then the data, e.g. the determined correlation, from the initial calibration may be obtained from the memory 9 of the controller.
  • the first arm 7A and the second arm 7B are first set to a state where the pressure force between the first arm 7A and the second arm 7B can be recorded by a force sensor 1 1 . Then, the predetermined value of the driving current of the servomotor 5 is set. When the predetermined value of the driving current has been stabilized as illustrated in Fig. 4, resulting servomotor characteristics data of the servomotor 5 is recorded, and resulting pressure force F between the first arm 7A and second arm 7B is recorded with the force sensor 1 1 .
  • the force and speed of the motor shaft of the servomotor 5 should also be stabilized as shown in Fig. 4 until the data is recorded.
  • the resulting servomotor characteristics data includes at least one motor axis position of the servomotor 5.
  • the robot 1 then includes a sensor (not shown) for recording the motor axis position of the servomotor 5.
  • the initial calibration may be performed while the force sensor 1 1 is held between the first arm 7A and the second arm 7B as illustrated in Fig. 6, in order to sense the resulting pressure force between the first arm 7A and second arm 7B.
  • the driving current is set to the predetermined value 11 and the above mentioned data is recorded.
  • a correlation between the resulting servomotor characteristics data of the servomotor 5 and the recorded resulting pressure force between the first arm 7A and the second arm 7B can now be determined.
  • the driving current may be set to a plurality of predetermined values (11 , I2, I3, I4).
  • the resulting pressure force F0 (F01 , F02, F03, F04%) is recorded as illustrated in the diagram of Fig. 7, and for each predetermined value of the driving current also the motor axis position P0 of the servomotor 5 is recorded as illustrated in Fig. 8 (P01 ; P02; P03; P04). It is assumed that the position P0 of the servomotor 5 is zero when the first arm 7A and the second arm 7B are in contact with the force sensor 1 1 but without acting upon the force sensor 1 1 with any force. It is also assumed that the position P0 of the servomotor 5 is positive when the spot welding gun 4 is opened. After data has been recorded for one predetermined current, the pressure force is removed by setting the driving current to zero and opening up the first arm 7A and second arm 7B of the spot welding gun slightly. In order to set the next
  • the first arm 7A and the second arm 7B are returned to a clamping state where they are holding the force sensor 1 1 , but without a pressure force.
  • the driving current is then ramped up to the next predetermined current, and this procedure is continued for as many times as desired. From the recorded resulting pressure force F0 and resulting motor axis positions P0 of the initial calibration, it is now possible to calculate a constant k representing the flexibility of the arm arrangement 6 in Newton/meter [N/m] according to Hookes law:
  • the method further includes performing a duty cycle routine after a duty cycle of the spot welding gun 4 as illustrated in step A2 of the flow chart of Fig. 5.
  • a duty cycle includes e.g. to perform one or several spot welding tasks with the spot welding gun 4.
  • the duty cycle routine includes closing the arm arrangement 6 to a clamping state and setting the driving current to the servomotor 5 to a
  • the clamping state includes to position the first arm 7A and the second arm 7B such that they clamp an object, but do not affect the object with any pressure force.
  • the clamping state includes to position the first arm 7A and the second arm 7B such that they are in contact, but do not affect each other with any pressure force.
  • the resulting servomotor characteristics data includes motor axis positions of the servomotor 5.
  • the duty cycle routine is performed regularly while the spot welding gun 4 is operated, e.g. every second, third, fourth or fifth minute etc.
  • a plurality of predetermined driving current values may be set.
  • the first arm 7A and the second arm 7B are first set to a clamping state as shown in Fig. 9, thereafter the driving current is set to predetermined values by ramping it up in steps (11 , I2, I3, I4...), and in each step the resulting motor axis position P of the servomotor 5 is recorded as illustrated in Fig. 10 (P1 ; P2; P3; P4). Between each step, the pressure force is returned to zero and the first arm 7A and second arm 7B of the spot welding gun 4 are opened up slightly.
  • the first arm 7A and the second arm 7B are returned to a clamping state before the next predetermined driving current value is set.
  • the method further includes to determine an adjusted driving current to be fed to the servomotor 5 in order to achieve a certain resulting pressure force between the first arm 7A and the second arm 7B.
  • IW can be calculated as a function of FW, F0, P0 and P, where FW is the desired pressure force when welding:
  • F is the i:th fed current to the servomotor 5
  • PQ +1 is tne k+1 :th and PQ the k:th position of the axis of the servomotor 5 during the initial calibration
  • F 0 FC+1 and F 0 FC are the thereto adhering resulting forces measured during the initial calibration
  • F +1 is the i+1 :th
  • F is the i:th fed current to the servomotor 5 during the duty cycle routine
  • P ⁇ +1 and P ⁇ are the thereto adhering recorded positions of the axis of the servomotor 5 during the duty cycle routine.
  • An adjusted current IW when a certain desired force FW is desired can thus be calculated for regular spot welding gun closings.
  • programmed servomotor driving current is calculated by using data collected from the initial calibration and the latest performed duty cycle routine.
  • the controller 2 is configured to calculate an adjusted current IW to be fed to the servomotor 4 based on the most recent recorded data, in order to get a desired pressure force between the first arm 7A and second arm 7B, when the program is run on the processor 8.
  • the program may reside on a computer readable medium such as a memory unit, compact disc or any other by a computer readable medium.
  • the controller 2 is thus configured to make the robot 1 perform the initial calibration of the force controlled axis device 4 as has been previously described, and to make the robot 1 perform the duty cycle routine after a duty cycle of the spot welding gun 4 as has been previously described.
  • the initial calibration may only be performed when installing the spot welding gun 4. It may however be performed again at certain intervals, e.g. once a week or month, or when any parameter changes, like changing of electrodes.
  • the duty cycle routine is performed much more often, preferably many times each hour during operation.
  • the controller 2 may further be configured to make the robot 1 and the spot welding gun 4 clamp the force sensor 1 1 or any other object between the first arm 7A and the second arm 7B.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Robotics (AREA)
  • Resistance Welding (AREA)

Abstract

L'invention concerne un procédé de calibration pour un dispositif à axe commandé par une force, à savoir un pistolet de soudage par points (4) d'un robot industriel (1), et un robot industriel (1) mettant en œuvre le procédé. Le pistolet de soudage par points (4) comprend un agencement de bras (6) avec un premier bras (7A), un second bras (7B) et un servomoteur (5) agencé pour être alimenté par un courant électrique d'actionnement afin d'actionner au moins l'un du premier bras (7A) et du second bras (7B). Le procédé de calibration met en œuvre la réalisation d'un étalonnage initial du pistolet de soudage par points (4) ou d'un autre pistolet de soudage par points identique (4), ou l'obtention de données à partir de ce dernier, pour déterminer une corrélation entre des données du servomoteur (5), par exemple une position axiale du servomoteur (5), et/ou le courant électrique actionnant le servomoteur (5), et la force de pression résultante. Le procédé met de plus en œuvre la détermination d'un courant électrique d'actionnement réglé devant être distribué au servomoteur (5) afin d'obtenir une certaine force de pression résultante sur la base des données à partir de l'étalonnage initial et du sous-programme de rapport cyclique.
PCT/EP2016/056356 2016-03-23 2016-03-23 Robot et procédé pour calibrer le courant électrique du servomoteur appliquant la force de pression d'un pistolet de soudage par points WO2017162280A1 (fr)

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PCT/EP2016/056356 WO2017162280A1 (fr) 2016-03-23 2016-03-23 Robot et procédé pour calibrer le courant électrique du servomoteur appliquant la force de pression d'un pistolet de soudage par points

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PCT/EP2016/056356 WO2017162280A1 (fr) 2016-03-23 2016-03-23 Robot et procédé pour calibrer le courant électrique du servomoteur appliquant la force de pression d'un pistolet de soudage par points

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Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE102017009816A1 (de) * 2017-10-20 2019-04-25 Kuka Deutschland Gmbh Ermittlung einer Antriebsreferenzstellung eines Zangenantriebs
EP3760360A1 (fr) * 2019-07-03 2021-01-06 Robert Bosch GmbH Commande de soudage pour un outil de soudage et procédé permettant d'éviter des vibrations de force d'un outil de soudage
CN116404939A (zh) * 2023-06-06 2023-07-07 德瑞精工（深圳）有限公司 Zr轴电机模组的力控方法

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US5883355A (en) * 1996-06-27 1999-03-16 Nachi-Fujikoshi Corporation Method of adjusting a clamping force of servo-controlled welding gun
DE10300628A1 (de) * 2003-01-10 2004-07-22 Abb Patent Gmbh Verfahren und Messanordnung zum Betrieb von Punktschweißzangen
US20050082340A1 (en) * 2003-08-20 2005-04-21 Gunther Wiedemann Process and device for controlling the pressing force of an electrode holder
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US7600435B2 (en) 2007-07-03 2009-10-13 Fanuc Ltd Method of determining deterioration of pressurizing performance of spot welding gun
US20090302008A1 (en) 2005-04-28 2009-12-10 Nachi-Fujikoshi Corp. Spot Welding Method and Spot Welding System
US20140291300A1 (en) * 2013-03-28 2014-10-02 Fanuc Corporation Spot welding system including spot welding gun

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Publication number Priority date Publication date Assignee Title
US5883355A (en) * 1996-06-27 1999-03-16 Nachi-Fujikoshi Corporation Method of adjusting a clamping force of servo-controlled welding gun
DE10300628A1 (de) * 2003-01-10 2004-07-22 Abb Patent Gmbh Verfahren und Messanordnung zum Betrieb von Punktschweißzangen
US20050082340A1 (en) * 2003-08-20 2005-04-21 Gunther Wiedemann Process and device for controlling the pressing force of an electrode holder
US20090302008A1 (en) 2005-04-28 2009-12-10 Nachi-Fujikoshi Corp. Spot Welding Method and Spot Welding System
EP1990122A1 (fr) * 2007-05-07 2008-11-12 Nimak GmbH Procédé destiné à la commande d'une force de pression à électrodes pour une pince à souder tout comme pince à souder correspondante
US7600435B2 (en) 2007-07-03 2009-10-13 Fanuc Ltd Method of determining deterioration of pressurizing performance of spot welding gun
US20140291300A1 (en) * 2013-03-28 2014-10-02 Fanuc Corporation Spot welding system including spot welding gun

Cited By (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE102017009816A1 (de) * 2017-10-20 2019-04-25 Kuka Deutschland Gmbh Ermittlung einer Antriebsreferenzstellung eines Zangenantriebs
DE102017009816B4 (de) 2017-10-20 2024-02-29 Kuka Deutschland Gmbh Ermittlung einer Antriebsreferenzstellung eines Zangenantriebs
EP3760360A1 (fr) * 2019-07-03 2021-01-06 Robert Bosch GmbH Commande de soudage pour un outil de soudage et procédé permettant d'éviter des vibrations de force d'un outil de soudage
CN116404939A (zh) * 2023-06-06 2023-07-07 德瑞精工（深圳）有限公司 Zr轴电机模组的力控方法

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