WO2021024540A1 - 可搬型溶接ロボットの溶接制御方法、溶接制御装置、可搬型溶接ロボット及び溶接システム - Google Patents
可搬型溶接ロボットの溶接制御方法、溶接制御装置、可搬型溶接ロボット及び溶接システム Download PDFInfo
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- WO2021024540A1 WO2021024540A1 PCT/JP2020/011678 JP2020011678W WO2021024540A1 WO 2021024540 A1 WO2021024540 A1 WO 2021024540A1 JP 2020011678 W JP2020011678 W JP 2020011678W WO 2021024540 A1 WO2021024540 A1 WO 2021024540A1
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- welding
- groove shape
- groove
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- robot
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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
- B23K9/127—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
- B23K37/00—Auxiliary devices or processes, not specially adapted to a procedure covered by only one of the preceding main groups
- B23K37/02—Carriages for supporting the welding or cutting element
- B23K37/0211—Carriages for supporting the welding or cutting element travelling on a guide member, e.g. rail, track
- B23K37/0229—Carriages for supporting the welding or cutting element travelling on a guide member, e.g. rail, track the guide member being situated alongside the workpiece
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K37/00—Auxiliary devices or processes, not specially adapted to a procedure covered by only one of the preceding main groups
- B23K37/02—Carriages for supporting the welding or cutting element
- B23K37/0282—Carriages forming part of a welding unit
-
- 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
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K9/00—Arc welding or cutting
- B23K9/095—Monitoring or automatic control of welding parameters
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K9/00—Arc welding or cutting
- B23K9/095—Monitoring or automatic control of welding parameters
- B23K9/0953—Monitoring or automatic control of welding parameters using computing 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
- B23K9/095—Monitoring or automatic control of welding parameters
- B23K9/0956—Monitoring or automatic control of welding parameters using sensing means, e.g. optical
-
- 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
- B23K9/1278—Using mechanical means
Definitions
- the present invention relates to a welding control method for a portable welding robot capable of automatically performing welding by moving on a guide rail, a welding control device, a portable welding robot, and a welding system.
- Patent Document 1 a guide rail using a corner unit having a straight portion and a curved portion is attached to the outer periphery of the square steel pipe to be welded with respect to the square steel pipe used at a construction site. Then, a welding robot is slidably provided on the guide rail. The control unit of the control device welds when the position of the center of curvature of the welded part to be welded by the welding robot is different from the position of the center of curvature of the position where the welding robot is located when welding the welded part in the corner unit. The moving speed of the welding robot is controlled so that the length of the welded portion (welding speed) per unit time by the robot is constant. As a result, polygonal steel pipes of various shapes are efficiently welded.
- the workpiece to be welded is carried to the site with an error from the drawing due to the assembly accuracy and cutting accuracy in the previous process.
- the carried-in workpieces are assembled to each other to form a groove shape to be a welded joint, but of course, an error also occurs in this assembly operation. Therefore, the groove shape of the welded joint to be welded at the site differs depending on the welding location even in the same joint portion.
- the bead width and the extra height of the welded joint are required to satisfy certain standard dimensions. Of course, welding defects such as undercut and overlap are not observed.
- the welding robot in order to satisfy the welding quality, is made to recognize the groove shape in advance, and the welding conditions are set according to the cross-sectional area of the groove shape. It is required to be appropriately controlled so that the height of the weld metal in the weld groove can be kept constant over the entire weld length even if the groove shape changes.
- the positional relationship between the guide rail and the welding groove is the welded joint.
- the current situation is that it differs from one to another.
- the length of the welded portion per unit time that is, the welding speed
- the welding speed is constant with respect to the welded joint having a changing groove shape.
- the height of the weld metal in the weld groove will change according to the change in the groove shape, and in the final finish, the width and remainder of the weld metal will vary depending on the location.
- the height may deviate from the standard value, causing undercut and overlap defects in extreme places, and the welding quality may not be satisfied.
- the welding workability caused by the deviation between the guide rail and the groove shape position due to the guide rail installation accuracy is not taken into consideration, and repair work such as removal of spatter adhering to the work is required, resulting in high work efficiency. There was a risk of deterioration.
- the present invention has been made in view of the above-mentioned problems, and an object of the present invention is that welding can be performed without being affected by changes in groove shape, installation accuracy of guide rails, etc., and improvement of work efficiency and welding quality. It is an object of the present invention to provide a welding control method for a portable welding robot, a welding control device, a portable welding robot, and a welding system capable of achieving the above-mentioned requirements.
- the above object of the present invention is achieved by the configuration of the following (1) relating to the welding control method of the portable welding robot.
- a welding control method for welding a workpiece having a groove by using a portable welding robot that moves along a guide rail.
- the portable welding robot that sets two or more groove shape detection positions in the welding section from the welding start point to the welding end point and moves the groove shape at the groove shape detection position on the guide rail.
- Sensing process that senses through the detection means of
- the groove shape information calculation step of calculating the groove shape information from the detection data obtained in the sensing step, and Welding condition acquisition process to acquire welding conditions based on the groove shape information
- a welding control method for a portable welding robot characterized by having.
- Preferred embodiments of the present invention relating to a welding control method for a portable welding robot relate to the following (2) to (11).
- the intersection of the groove shape detection position and the welding line predetermined on the work is set as the welding line position detection point, and the welding locus when welding is performed between the adjacent welding line position detection points. Is the welding locus line,
- the groove shape detection position is set so that the maximum value of the relative distance between the welding line and the welding locus line is twice or less the diameter of the welding wire.
- the welding condition change between the groove shape detection positions.
- the welding condition is changed in at least one of a linear shape, a step shape, and a curved shape between the groove shape detection positions.
- At least one of the welding conditions is the welding speed.
- the moving direction of the portable welding robot is the X direction.
- the groove width direction perpendicular to the X direction is the Y direction.
- the moving speed in each of the three directions is calculated according to the value of the welding speed at the groove shape detection position acquired in each of the three directions of the X direction, the Y direction, and the Z direction.
- the welding speed between the groove shape detection positions is controlled by the moving speed in each of the three directions.
- the welding control method for the portable welding robot according to (3) above.
- At least one of the welding conditions is the welding speed.
- the moving direction of the portable welding robot is the X direction.
- the groove width direction perpendicular to the X direction is the Y direction.
- the moving speed in each of the three directions is calculated according to the value of the welding speed at the groove shape detection position acquired in each of the three directions of the X direction, the Y direction, and the Z direction.
- the welding distance or movement time between the groove shape detection positions is divided into two or more sections, and the welding speed at each division point is calculated from the movement speed of each division point in each of the three directions.
- the welding speed at each division point is kept constant, and the welding speed between the groove shape detection positions is controlled so as to change in steps.
- the welding control method for the portable welding robot according to (3) above.
- At least one groove shape detection position is provided in the boundary region between the straight portion and the curved portion of the guide rail or the boundary region where the curvature of the curved portion of the guide rail changes.
- a section for controlling the welding condition is provided.
- At least one of weaving condition, welding speed and welding current is selected. Based on the groove shape information between the groove shape detection positions, the weaving condition, the welding speed, and the welding so that the weld metal in the groove has a constant height with respect to the welding direction. Control at least one of the currents, The welding control method for a portable welding robot according to any one of (1) to (7) above.
- the sensing is touch sensing, and is At the groove shape detection position, at least five detection points arranged along the cross section of the groove are provided on the root gap in the groove and the side surfaces of the groove on both sides.
- the groove shape information is calculated based on the detection data obtained from the detection point.
- the welding line is the groove tip of any one of the groove side surfaces on both sides in the groove shape.
- the above object of the present invention is achieved by the configuration of the following (12) relating to the welding control device of the portable welding robot.
- a welding control device for welding a workpiece having a groove by using a portable welding robot that moves along a guide rail.
- the portable welding robot that sets two or more groove shape detection positions in the welding section from the welding start point to the welding end point and moves the groove shape at the groove shape detection position on the guide rail.
- a groove shape information calculation unit that calculates groove shape information from the detection data obtained in the sensing process that senses through the detection means of
- a welding condition acquisition unit that acquires welding conditions based on the groove shape information,
- a welding control device for a portable welding robot characterized by having.
- Detection means, A portable welding robot characterized by having.
- the above object of the present invention is achieved by the configuration of the following (14) relating to the welding system of the portable welding robot.
- a welding system including a portable welding robot that welds a workpiece having a groove while moving on a guide rail, and a welding control device that can control the operation of the portable welding robot.
- the portable welding robot has a detection means for setting two or more groove shape detection positions in a welding section from a welding start point to a welding end point and sensing the groove shape at the groove shape detection position.
- the welding control device includes a groove shape information calculation unit that calculates groove shape information from the detection data obtained by the sensing, and a welding condition acquisition unit that acquires welding conditions based on the groove shape information.
- the groove shape detection obtained when the guide rail and the portable welding robot are installed on the groove Since the groove shape information is acquired based on the detection data at the position and the welding conditions are set based on the groove shape information, the change in the groove shape and the installation error of the guide rail for each groove shape detection position The change in the positional relationship between the guide rail and the groove that occurs in is taken into consideration by being included in the detection data, and the welding conditions can be obtained based on accurate numerical values. As a result, welding can be performed by welding control that is not affected by changes in groove shape or guide rail installation accuracy. As a result, highly accurate welding can be performed. On the welding work surface, the work of assembling the work when forming the groove shape becomes easy, and the positions of the guide rail and the portable welding robot become easy to adjust, so that welding with good work efficiency can be performed. it can.
- FIG. 1 is a schematic view of an embodiment of the welding system of the present invention.
- FIG. 2 is a schematic side view of the portable welding robot shown in FIG.
- FIG. 3 is a perspective view of the portable welding robot shown in FIG.
- FIG. 4A is a schematic perspective view for explaining a groove shape detection position by the portable welding robot shown in FIG.
- FIG. 4B is a perspective view of a portable welding robot in which a linear guide rail is applied to a meandering groove.
- FIG. 4C is an explanatory diagram for explaining the concept showing the positional relationship between the linear guide rail and the groove in FIG. 4B.
- FIG. 4D is a perspective view of a portable welding robot in which a curved guide rail is applied to a meandering groove.
- FIG. 4A is a schematic perspective view for explaining a groove shape detection position by the portable welding robot shown in FIG.
- FIG. 4B is a perspective view of a portable welding robot in which a linear guide rail is applied to a meandering groove
- FIG. 4E is an explanatory diagram for explaining the concept showing the positional relationship between the curved guide rail and the groove in FIG. 4D.
- FIG. 5 is a schematic side view for explaining sensing by the portable welding robot shown in FIG.
- FIG. 6 is a schematic perspective view for explaining sensing by the portable welding robot shown in FIG.
- FIG. 7A is a graph showing a change in the welding speed in the welding control method of the present invention, and is a case where the welding speed is controlled to be curved.
- FIG. 7B is a graph showing a change in the welding speed in the welding control method of the present invention, and is a case where the welding speed is controlled to be linear.
- FIG. 7A is a graph showing a change in the welding speed in the welding control method of the present invention, and is a case where the welding speed is controlled to be curved.
- FIG. 7B is a graph showing a change in the welding speed in the welding control method of the present invention, and is a case where the welding speed is controlled to be
- FIG. 7C is a graph showing a change in the welding speed in the welding control method of the present invention, and is a case where the welding speed is controlled to be stepped.
- FIG. 8A is an explanatory diagram of the welding speed and the welding distance when the tip of the welding wire of the welding torch of the portable welding robot on the linear guide rail moves between the welding line position detection points.
- FIG. 8B is an enlarged explanatory view for explaining the welding speed in the VIII portion shown in FIG. 8A.
- FIG. 8C is an explanatory diagram of the moving distance when the tip of the welding wire of the welding torch of the portable welding robot on the linear guide rail moves between the welding line position detection points.
- FIG. 8A is an explanatory diagram of the welding speed and the welding distance when the tip of the welding wire of the welding torch of the portable welding robot on the linear guide rail moves between the welding line position detection points.
- FIG. 8D is a cross-sectional shape of the welded portion when the present embodiment is applied, and is a diagram for explaining the effect of the present embodiment.
- FIG. 8E is a cross-sectional shape of the welded portion when this embodiment is not applied, and is a diagram for explaining a welding defect when this embodiment is not applied.
- FIG. 9A is an explanatory diagram of the welding speed and the welding distance when the tip of the welding wire of the welding torch of the portable welding robot on the curved guide rail moves between the welding line position detection points.
- FIG. 9B is an explanatory view for explaining the welding speed in which the IX portion shown in FIG. 9A is enlarged.
- FIG. 9C is an explanatory view for explaining the welding speed, in which FIG. 9B is shown in the XY plane.
- FIG. 9A is an explanatory diagram of the welding speed and the welding distance when the tip of the welding wire of the welding torch of the portable welding robot on the curved guide rail moves between the welding line position detection points.
- FIG. 9D is an explanatory diagram of the moving distance when the tip of the welding wire of the welding torch of the portable welding robot on the curved guide rail moves between the welding line position detection points.
- FIG. 10 is a perspective view when the welding robot shown in FIG. 3 is attached to a square steel pipe.
- FIG. 11 is a diagram for explaining the positional relationship between the guide rail and the groove in the region of the guide rail and the 1/4 square portion of the square steel pipe when FIG. 10 is viewed from directly above.
- FIG. 13 is a schematic perspective view for explaining weaving in the welding control method of the present invention.
- this embodiment is an example when a portable welding robot is used, and the welding system of the present invention is not limited to the configuration of this embodiment.
- FIG. 1 is a schematic view showing a configuration of a welding system according to the present embodiment.
- the welding system 50 includes a portable welding robot 100, a feeding device 300, a welding power source 400, a shield gas supply source 500, and a control device 600.
- the control device 600 is connected to the portable welding robot 100 by a robot control cable 610, and is connected to the welding power supply 400 by a power supply control cable 620.
- the control device 600 has a data holding unit 601 that holds teaching data in which the operation pattern, welding start position, welding end position, welding conditions, weaving operation, etc. of the portable welding robot 100 are determined in advance, and is based on the teaching data.
- a command is sent to the portable welding robot 100 and the welding power supply 400 to control the operation and welding conditions of the portable welding robot 100.
- the control device 600 corrects the welding conditions of the teaching data based on the groove shape information calculation unit 602 that calculates the groove shape information from the detection data obtained by the sensing described later and the groove shape information. It has a welding condition acquisition unit 603 and the welding condition acquisition unit 603. Then, the control unit 604 is configured by the groove shape information calculation unit 602 and the welding condition acquisition unit 603.
- control device 600 is formed by integrally forming a controller for teaching and a controller having other control functions.
- the control device 600 is not limited to this, and may be divided into a plurality of controllers depending on the role, such as being divided into a controller for teaching and a controller having other control functions, or a portable type.
- the control device 600 may be included in the welding robot 100.
- the signal is transmitted by using the robot control cable 610 and the power supply control cable 620, but the signal is not limited to this, and may be transmitted wirelessly. From the viewpoint of usability at the welding site, it is preferable to divide the controller into two, a controller for teaching and a controller having other control functions.
- welding power source 400 in accordance with a command from the controller 600, the consumable electrode (hereinafter, "welding wire” also referred to as) 211 and by supplying power to the workpiece W o, arc between the welding wire 211 and the workpiece W o To generate.
- the electric power from the welding power source 400 is sent to the feeding device 300 via the power cable 410, and is sent from the feeding device 300 to the welding torch 200 via the conduit tube 420. Then, as shown in FIG. 2, electric power is supplied to the welding wire 211 via the contact tip at the tip of the welding torch 200.
- the current during welding work may be direct current or alternating current, and its waveform is not particularly limited. Therefore, the current may be a pulse such as a rectangular wave or a triangular wave.
- the welding power source 400 for example, a power cable 410 is connected to the welding torch 200 as a plus (+) electrode, a power cable 430 minus - is connected as an electrode to the workpiece W o (). This is the case where welding is performed with the opposite polarity, and when welding is performed with the positive electrode property, the welding power supply 400 is connected to the work Wo side via the positive (+) power cable 430 and is negative (-). ) May be connected to the welding torch 200 side via the power cable 410.
- the shield gas supply source 500 is composed of a container in which the shield gas is sealed and ancillary members such as a valve. Shielded gas is sent from the shielded gas supply source 500 to the feeding device 300 via the gas tube 510. The shield gas sent to the feeding device 300 is sent to the welding torch 200 via the conduit tube 420. The shield gas sent to the welding torch 200 flows through the welding torch 200, is guided by the nozzle 210, and is ejected from the tip side of the welding torch 200.
- the shield gas used in this embodiment for example, argon (Ar), carbon dioxide gas (CO 2 ), or a mixed gas thereof can be used.
- the feeding device 300 feeds out the welding wire 211 and sends it to the welding torch 200.
- the welding wire 211 fed by the feeding device 300 is not particularly limited, and is selected according to the properties of the work Wo , the welding form, and the like.
- a solid wire or a flux-cored wire (hereinafter, also referred to as “FCW”) is used. Weld.
- FCW flux-cored wire
- the wire diameter of the welding wire is not particularly limited.
- FCW from the viewpoint of welding workability, and it is even more preferable if it is a basic FCW. Furthermore, when basic FCW is applied, it is preferably positive. Further, the preferable wire diameter in this embodiment has an upper limit of 1.6 mm and a lower limit of 0.9 mm.
- a conductive path for functioning as a power cable is formed on the outer skin side of the tube, a protective tube for protecting the welding wire 211 is arranged inside the tube, and a flow path for the shield gas.
- the conduit tube 420 is not limited to this, and for example, a power supply cable and a hose for supplying shield gas are bundled around a protective tube for feeding the welding wire 211 to the welding torch 200. You can also use the one. Further, for example, the welding wire 211, the tube for sending the shield gas, and the power cable can be installed separately.
- the portable welding robot 100 is mounted on the guide rail 120, the robot body 110 which is installed on the guide rail 120 and moves along the guide rail 120, and the robot body 110.
- the torch connection portion 130 is provided.
- Robot body 110 is mainly rotation, a body portion 112 which is installed on the guide rail 120, and the fixed arm 114 which is attached to the main body 112, the rotatable (arrow R 1 direction the fixed arm portion 114 It is composed of a movable arm portion 116 attached in a possible state.
- the torch connection portion 130 is attached to the movable arm portion 116 via the crank 170.
- the torch connection portion 130 includes a torch clamp 132 and a torch clamp 134 for fixing the welding torch 200.
- the main body 112 is provided with a cable clamp 150 that supports a conduit tube 420 that connects the feeding device 300 and the welding torch 200 on the side opposite to the side on which the welding torch 200 is mounted.
- a voltage is applied between the workpiece W o welding wire 211, the welding wire 211 by using the voltage drop phenomenon that occurs when in contact with the workpiece W o, the surface and the like of the groove 10
- a touch sensor for sensing is used as a detection means.
- the detection means is not limited to the touch sensor of the present embodiment, and an image sensor, a laser sensor, or a combination of these detection means may be used, but the touch sensor of the present embodiment may be used because of the simplicity of the device configuration. preferable.
- the main body 112 of the robot main body 110 can be driven in the direction perpendicular to the paper surface, that is, in the X direction in which the robot main body 110 moves along the guide rail 120.
- the main body 112 can also be driven in the Z direction, which moves in the depth direction of the groove 10 which is perpendicular to the X direction.
- the fixed arm portion 114 can be driven with respect to the main body portion 112 in the Y direction, which is the width direction of the groove 10 perpendicular to the X direction, via the slide support portion 113.
- the torch connections 130 welding torch 200 is attached, by the crank 170 is rotated as shown by an arrow R 2 in FIG. 3, it is swingably driven back and forth in the X direction.
- the movable arm 116 as shown by the arrow R 1, rotatably mounted relative to the fixed arm portion 114 can be fixed by adjusting the optimum angle.
- the robot body 110 can drive the welding torch 200, which is the tip thereof, with three degrees of freedom.
- the robot body 110 is not limited to this, and may be driven with an arbitrary number of degrees of freedom depending on the application.
- the tip of the welding torch 200 attached to the torch connection 130 can be directed in any direction.
- the robot body 110 can be driven on the guide rail 120 in the X direction in FIG.
- the welding torch 200 can perform weaving welding by moving the robot body 110 in the X direction while reciprocating in the Y direction.
- the crank 170 by driving by the crank 170, the welding torch 200 can be tilted according to the construction situation such as providing a forward angle or a backward angle.
- the mounting member 140 are provided such as a magnet, the guide rail 120 is attached to and detached from the workpiece W o is easily configured by the attachment member 140.
- the portable welding robot 100 When setting the portable welding robot 100 to the work W o, an operator by gripping the both sides grip 160 of a portable welding robot 100 can be easily set to a portable welding robot 100 on the workpiece W o.
- FIG. 4A shows a perspective view of the groove portion of the workpiece W o, groove 10 meanders to the welding direction X which is the longitudinal direction, further, an open root gap G is changed in the width direction Y of the groove 10 It is a schematic perspective view at the time of welding the tip 10.
- FIG. 4B is a schematic perspective view when a portable welding robot 100 to which a linear guide rail 120 is applied is installed on a meandering groove 10 as shown in FIG. 4A.
- FIG. 4C is a conceptual diagram showing the positional relationship between the groove 10 and the guide rail 120 on a plane, and the groove shape detection position Pn .
- the welding conditions at the time of welding are acquired by using the robot body 110 that moves along the guide rail 120 before the start of welding. Specifically, for example, based on the operation signal of the control device 600, the robot body 110 is driven to start automatic sensing of the groove shape, the groove shape information is calculated, the welding condition is further calculated, and the welding condition is automatically calculated. Achieve gas shielded arc welding.
- the above-mentioned touch sensor is used to perform sensing steps such as groove shape, plate thickness, start and end, etc. as follows.
- the groove meanders, the root gap G also changes, and the groove shape changes from place to place.
- the cross-sectional shape of the groove 10 which is an inverted trapezoidal cross-sectional shape, is set to a plurality of groove shape detection positions P n (P 0 , P 2 , ..., P 5 ). In this embodiment, six locations are provided.
- the groove shape detection position P n closest to the welding start point 10 s is set as the first groove shape detection position P s (P 0 ), and the groove shape detection position closest to the welding end point 10 e is set.
- P n as the second groove shape detection position P e (P 5 )
- the robot body 110 performs sensing by the touch sensor while moving on the guide rail 120.
- the IchiHiraki destination shape detection position P s and the second open tip profile detection position P e enhance the accuracy of detection data.
- / L" is preferably 0.6 or more, more preferably 0.7 or more, and further preferably 0.8 or more.
- the first IchiHiraki destination shape detection position P s is preferably set in the vicinity of the welding start point, the second GMA shape detection position P e, it is preferable to set in the vicinity of the welding end point.
- the position setting of the IchiHiraki destination shape detection position P s and the second open destination shape detection position P e is the teaching etc., may be inputted in advance controller 600. Further, it may be automatically set by sensing. Moreover, to calculate the distance L between the workpiece ends W e by the sensing may be determined automatically the first GMA shape detection position P s and the second open tip profile detection position P e in the range satisfying the above formula ..
- the groove shape information is obtained from the groove cross-sectional shape detection data at each groove shape detection position P n (P 0 to P 5 ) obtained in the sensing step. included angle theta 1 of the groove shape, theta 2, the thickness H 1, H 2, the root gap G, and calculates the distance L or the like between the work end W e (groove shape information calculating step).
- the control The welding conditions generated or preset in the apparatus 600 are corrected (welding condition acquisition process), and the welding conditions when actually performing welding are acquired. Then, using this welding condition, the robot body 110 is driven to start welding.
- the interval of the groove shape detection position Pn is set so as to satisfy the following conditions.
- the groove 10 shown in FIG. 4A meanders, the root gap G changes, and a welded portion having a different groove shape for each location is formed by using a linear guide rail 120.
- the case of welding will be described.
- the details of the conditions for determining the interval of the groove shape detection position Pn in this case will be described with reference to FIG. 4C.
- defining a weld line WL in advance. For example, the relative distance L 1 between the curved welding line WL and the guide rail 120 (specifically, the rail center R c ) changes.
- the intersection of the groove shape detection position P n and the welding line WL is defined as the welding line position detection point T n (T 0 to T 5 ).
- the weld line position detection point T n is important for obtaining the detection data in groove shape detecting position within P n. Further, the trajectory of the welding time of actually welded between welding line position detecting point T n adjacent to the welding trajectory line TWL, to drive the robot body 110 along the welding wire 211 distal to the welding locus line TWL.
- the welding locus line TWL is a straight line.
- a relative distance ⁇ d between the welding line WL and the welding locus line TWL is generated.
- the relative distance ⁇ d it is preferable to set the interval so that the maximum value max ⁇ d of the relative distance is made as small as possible.
- the relative distance is considered to increase the groove shape detection position P n, sensing efficiency decreases with increasing the groove shape detection position P n.
- groove shape detection it is preferable to narrow the distance between the positions P n and leave a space in the linear portion where the welding line WL is relatively not curved.
- the relative distance ⁇ d is given in consideration of the relative distance in the three-dimensional space.
- the groove 10 shown in FIG. 4A meanders, the root gap G changes, and the welded portion having a different groove shape for each location is formed by using the curved guide rail 120.
- the robot body 110 travels around the center of curvature O of the guide rail 120, and the welding locus line TWL at this time affects the curvature of the guide rail 120 and becomes a curved line.
- the interval of the groove shape detection position Pn to which the curved guide rail 120 as shown in FIG. 4D is applied is set as shown in FIG. 4E as in the case where the linear guide rail 120 is applied. ..
- the welding locus line TWL becomes a curved line under the influence of the curvature of the guide rail 120, but as in the case of the linear guide rail 120 shown in FIG. 4C, the maximum value max ⁇ d of the relative distance should be made as small as possible. It is still preferable to set the interval.
- the groove shape detection position Pn it is preferable to set the groove shape detection position Pn so that the maximum value max ⁇ d of the relative distance is not more than twice the diameter of the welding wire, and the groove shape is not less than the diameter of the welding wire. It is more preferable to set the detection position P n . Specifically, when a welding wire diameter of 1.2 mm is used, it is preferable to provide the groove shape detection position Pn so that the maximum value max ⁇ d of the relative distance is 2 mm or less. Setting the maximum value max ⁇ d of the relative distance to twice or less of the welding wire diameter means that the margin that can ensure good welding quality for the welding line WL that should be welded is 2 of the welding wire diameter. It means that the error is within double.
- the weld line WL is in the workpiece W o, of the cross-sectional shape of the groove 10, FIG. 4A, FIG. 4B and FIG. 5, the open distal end which is the upper end angle portions 11 e, 12 e (workpiece upper surface W u, the intersection of the W i and the groove side surfaces 11 and 12), or, among the both ends of the route 13, it is either, from the viewpoint of clarity.
- the open tip edges 11 e and 12 e are welded lines WL, the change in the groove shape that appears due to misalignment, welding deformation, dimensional defects, etc. can be accurately grasped, so that the clarity is improved. , More preferred.
- the welding line WL is set so as to pass through the inside (center) of the groove 10.
- the sensing method of the touch sensor for obtaining the groove shape data is not particularly limited, but can be as follows.
- the detection point by the touch sensor starts from point A0, and performs sensing while moving in the order of point A1, point A2, ..., Point A14 in the direction indicated by the arrow in the figure. In this sensing, the following items are detected.
- A1 point by the detection of the point A3 and A10 points, calculates the thickness H 1, by using the thickness H 1, detects the A11 point and A12 point close to the root portion 13 of the groove 10, By detecting points A12 and A6, a more accurate inclination angle ⁇ 1 of the groove side surface 11 on one end side is detected. Further, by detecting the points A11 and A5, the more accurate inclination angle ⁇ 2 on the groove side surface 12 on the other end side is determined.
- a line connecting points A6 and A12 that is, an inclined surface on one end side
- a line connecting points A5 and A11 that is, an inclined surface on the other end side
- the route gap G is calculated from the intersection with the straight line passing through the point A10 in parallel with.
- it is detected at point A13 whether or not there is a wall forming the groove side surface 12 on the other end side of the groove 10.
- the groove is a spur joint that does not have a wall.
- a threshold value is set in advance in the step D, and if it is more than the threshold value, it is regarded as the groove of the T joint instead of the groove of the spur joint, and the welding condition of the T joint is selected. [11] When the step D is equal to or less than the threshold value, it is considered that the spur joint is misaligned, and the welding conditions for the spur joint are selected.
- the sensing procedure is not limited to the trapezoidal groove 10 shown in the figure.
- a V-shaped groove can also detect the groove shape by the same procedure.
- the detection pitch S p between the detection points in the sensing can be set as appropriate is not particularly limited.
- the detection point for obtaining the information on the cross-sectional shape of the groove 10 needs to maintain sufficient accuracy as the groove shape information.
- the number of detection points is preferably 5 or more. Further, by selecting the position of the detection point, the detection data can be obtained with higher accuracy. As shown in FIG. 5, the five detection points are, for example, four corner portions C 1 , C 2 , C 3 , and C 4 , including the upper and lower ends of the groove side surfaces 11 and 12 on both the left and right sides. it may take a point in the portion C 5 root portion 13. Further, from the viewpoint of sensing efficiency, it is preferable that the number of detection points for obtaining groove shape information is 10 or less.
- the detection data necessary for calculating the groove shape information of the groove shape detection position P n is obtained, and the relative distance between the position of the robot body 110 and the groove shape detection position P n is also obtained. It can be obtained as detection data.
- the sensing step in addition to sensing the groove shape at the groove shape detection position Pn, it is preferable to sense the shape around the groove 10. Specifically, as shown in FIG. 6, the tip of the welding wire 211, and at a predetermined distance from the workpiece W o in the X direction, with movement between a position in contact with the workpiece W o, the workpiece W o surface by moving the inner in the Y direction, carried workpiece W workpiece upper surface of the side where the groove 10 is provided in the o W u, detection of W i, and the sensing of the workpiece end W e in the weld line direction of the workpiece W o Is preferable.
- the shape of the periphery of the groove 10 it can obtain a correlation distance between the position and the robot body 110 position of the workpiece W o and the workpiece end W e as the detection data.
- the root gap G changes, the groove shape differs from place to place, and an installation error of the guide rail occurs.
- the detection data required for accurate automatic welding with the portable welding robot 100 can be obtained in the sensing process of this embodiment.
- groove shape information is calculated from the detection data obtained in the sensing process, and welding conditions are acquired based on the groove shape information.
- the welding conditions to be acquired include the aiming position of the arc point inside the groove 10 (as described later, the aiming position of the arc point is the same as the position of the tip of the welding wire 211. Includes the number of weld metal layers, etc.
- the welding conditions can be controlled as shown in the graphs shown in FIGS. 7A to 7C.
- the value of the welding speed is obtained for each groove shape detection position P n W n (welding conditions) in accordance, between the adjacent groove shape detection position P n (for example, between P 1 and P 2), the welding speed W n, is varied in a predetermined shape over time.
- control so as to change the welding speed W n while moving from groove shape detection position P 1 to the groove shape detection position P 2 in curved.
- control so as to change the welding speed W n while moving from groove shape detection position P 1 to the groove shape detection position P 2 straight.
- FIG. 7C stepped welding speed W n while moving from groove shape detection position P 1 to the groove shape detection position P 2, i.e. control so as to change stepwise.
- the gaps between the groove shape detection positions P n are according to the values of the welding conditions acquired for each groove shape detection position P n.
- the welding conditions are controlled to be changed by at least one of a linear shape, a step shape, and a curved shape. Therefore, even if the welding conditions change significantly between the groove shape detection positions P n , the welding conditions can be gradually changed, and a sudden change in the welding conditions between the groove shape detection positions P n can be avoided. Allows for smooth welding. As a result, highly accurate welding can be performed.
- FIG. 8A is an explanatory diagram of the welding speed W and the welding distance DW n when the tip of the welding wire 211 of the robot body 110 on the linear guide rail 120 moves between the welding line position detection points T n .
- FIG. 8B is an explanatory diagram for enlarging the VIII portion shown in FIG. 8A and explaining the welding speed W at an arbitrary point between the welding line position detection points T n (T n-1 to T n ).
- FIG. 8C is an explanatory diagram showing the relationship between the welding distance DW n and the moving distances (VDX n , VDY n , VDZ n ) in the three directions of the X direction, the Y direction, and the Z direction.
- the tip of the welding wire 211 of the robot body 110 is regarded as the same as the arc point of the tip of the welding wire 211 generated in actual welding, and the welding speed, welding distance, and welding time described later are, that is, the welding wire 211. It is synonymous with the movement speed, movement distance, and movement time of the tip.
- v velocity
- v o initial velocity
- ⁇ acceleration
- x moving distance
- x o initial position
- s displacement distance
- t time
- W n-1 a welding speed at the weld line position detection point T n-1
- the calculated value W n at the welding condition obtaining unit 603 a welding speed at the weld line position detection point T n
- W n + 1 Welding speed at welding line position detection point T n + 1 , calculated value in welding condition acquisition section 603
- W n-1 , W n , and W n + 1 are the respective grooves. Based on the groove shape information of the shape detection positions (P n-1 , P n , P n + 1 ), the height of the weld metal in the weld groove should be the same at each groove shape detection position P n. , Calculated by the welding condition acquisition unit 603.
- VDX n, VDY n, VDZ n T n-1 ⁇ 3 direction between two points T n a (X direction, Y direction, Z direction) the welding wire 211 distal movement distance of the robot body 110 of the sensing step
- Detection data VX, VY, VZ Welding wire 211 of the robot body 110 in three directions (X direction, Y direction, Z direction) t seconds after the welding start of the welding line position detection point Tn-1.
- the moving speed of the tip VDX n and VX are the same as the traveling distance and traveling speed of the robot main body 110 traveling on the guide rail 120.
- a mathematical formula for controlling the moving speed of the tip of the welding wire 211 in the three directions (X direction, Y direction, Z direction) of the robot body 110 can be obtained by the following formula.
- the welding distance DW n between two points from T n-1 to T n is expressed by the following equation by synthesizing VDX n , VDY n , and VDZ n .
- Welding distance DW n is determined from the above, the welding speed W n-1 in T n-1 and T n, W for n is also known, the acceleration a of the welding speed to be changed between two points, the basic formula From equation (3), it can be obtained by the following equation.
- the moving speeds (VX, VY, VZ) of the tips of the welding wires 211 in the three directions (X direction, Y direction, Z direction) t seconds after the start of the welding line position detection point Tn-1 are determined.
- it is a speed component of the welding speed W in three directions.
- the velocity component in each direction is expressed by the following equation obtained by multiplying the ratio of the moving distances VDX n , VDY n , and VDZ n in each of the three directions to the welding distance DW n by the welding speed W.
- T n-1 between two points of ⁇ T n, a weld line position detection point T n-1 from the welding start welding speed W n-1, the welding speed W at the weld line position detection point T n Equations (7), (8) and (9) that control the moving speeds (VX, VY, VZ) of the robot body 110 in three directions so as to reach n can be obtained.
- the moving speeds (VX, VY, VZ) of the robot body 110 in three directions can be calculated in advance between the adjacent groove shape detection positions Pn , so that the calculation result is held in the data holding unit 601.
- the drive of the robot body 110 is controlled based on the calculation result.
- the welding wire 211 distal (regarded as arcs point in the actual welding position) of the robot body 110 by applying these equations, it is changes in the welding speed W n as shown in FIG. 7B, T in n-1 in the welding GMA between two points ⁇ T n, welding speed W n is changed to match the change in the groove shape, the height of the weld metal of the weld in the GMA is kept constant.
- FIG. 8D is a cross-sectional shape of the welded portion when the present embodiment is applied, and is a diagram for explaining the effect of the present embodiment.
- the cross-sectional shape after welding of the groove shape detection position P 0 (P s ) on the welding start side and the groove shape detection position P 5 (P e ) on the welding end position side shown in FIG. 4A is represented.
- the circled numbers 1 to 3 in the figure indicate the order of welding, and the boundary line in the groove 10 indicates the boundary of the weld metal.
- the gap G changes at the groove shape detection positions P 0 and P 5 , and the groove shape is different, but in this embodiment, the heights of the weld metals in the same welding order (D 1 , D). 2 , D 3 ) can be made constant at the groove shape detection positions P 0 and P 5 regardless of the size of the gap G.
- it may be a constant height of the weld metal of the same welding order. That is, the welding speed is set so that the heights of the weld metals in the welding groove are the same at the groove shape detection positions P n (P 0 to P 5 ), and the above-mentioned gaps between the groove shape detection positions P n are set.
- the welding speed changes smoothly between the adjacent groove shape detection positions P n according to the equations (7), (8) and (9), which are the control equations for the movement speed of the robot body 110 in three directions.
- equations (7), (8) and (9) which are the control equations for the movement speed of the robot body 110 in three directions.
- a constant height of the weld metal can be obtained in the groove even between the adjacent groove shape detection positions P n .
- the bead width m causes undercuts and overlap defects regardless of the size of the gap G over the entire welding length.
- the width is equal to or greater than the groove width, and the surplus height h can secure a height that passes the welding quality standard regardless of the size of the gap G, and welding with good welding quality and high accuracy. Can be carried out.
- the change in the groove shape can be obtained not only for the gap G but also for the change in the inclination of the groove side surfaces (groove wall) 11 and 12.
- FIG. 8E the cross-sectional shapes of the groove shape detection positions P 0 and P 5 after welding are compared and shown when the welding speed is constant without applying this embodiment. That is, welding is performed with the welding speed obtained based on the groove shape information calculated from the detection data of the groove shape detection position P 0 being constant.
- the height of the weld metal of the groove shape detection position P 5 in the same welding order of the welding end side of the gap G is increased It does not change constantly (D 1 ⁇ D 1 ', D 2 ⁇ D 2 ', D 3 ⁇ D 3 '), and the inside of the groove cannot be filled with welding metal, which induces welding defects. ..
- the amount of metal melted from the welding wire 211 is almost determined by the welding current and voltage.
- the amount of metal melted from the welding wire 211 is fixed (welding current and voltage are constant), and the welding speed is adjusted according to the change in volume per unit length in the welding direction surrounded by the groove. By controlling the above, the height of the weld metal deposited in the groove can be kept constant.
- the moving distances VDY n and VDZ n in the Y direction and the Z direction are regarded as a slight distance, and the moving speeds VY and VZ in the Y direction and the Z direction are assumed to move at a constant speed, and the following equation is obtained.
- the welding time t n becomes the following equation from the basic equations (1) and (10). If the maximum value max ⁇ d of the relative distance between the welding line WL and the welding locus line TWL shown in FIG. 4C is twice or less the diameter of the welding wire, the equations (11), (12) and (13) are simply expressed. Even if the moving speed of the robot main body 110 is controlled in three directions by using the equation (7), the same effect as when the equation (8) and the equation (9) are used can be obtained.
- FIG. 9A is an explanatory diagram of the welding speed W and the welding distance DW n when the tip of the welding wire 211 of the robot body 110 on the curved guide rail 120 moves between the welding line position detection points T n .
- FIG. 9B enlarges the IX portion shown in FIG. 9A, shows the welding speed W at an arbitrary point between the welding line position detection points T n (T n-1 to T n ), and the tip of the welding wire 211 of the robot body 110. It is a figure explaining the relationship between the moving speed (AX, VY, VZ) in three directions (X direction, Y direction and Z direction) and the traveling speed (VX) of a robot body traveling on a curved guide rail 120.
- FIG. 9C is a view showing FIG.
- FIG. 9D shows the welding distance DW n , the moving distance (ADX n , VDY n , VDZ n ) in the three directions (X direction, Y direction and Z direction) of the tip of the welding wire 211 of the robot body 110, and a curved shape. It is explanatory drawing which showed the relationship of the mileage (VDX n ) of a robot main body traveling on a guide rail 120.
- VX When the welding wire 211 end of the robot body 110 from the weld line position detection point T n-1 to T n is moved, the moving speed of the robot body 110 running the guide rail 120 on AX: weld line position detection point T from n-1 when the welding wire 211 end of the robot body 110 to T n is moved, the moving speed VDX n in the X direction: welding wire 211 end of the robot body 110 from the weld line position detection point T n-1 to T n Is the moving distance of the robot body 110 traveling on the guide rail 120 when the is moved, and the detection data obtained in the sensing process ADX n : Welding of the robot body 110 from the welding line position detection points T n-1 to T n.
- Movement distance in the X direction when the tip of the wire 211 moves GR Curved guide rail radius, a numerical value to be input to the welding condition acquisition unit 603 in advance
- O Center of curvature of the curved part YR n-1 : Weld line position
- O Center of curvature of the curved part YR n-1 : Weld line position
- O Center of curvature of the curved part YR n-1 : Weld line position
- O Center of curvature of the curved part YR n-1 : Weld line position
- the distance on the XY plane from the detection point T n-1 to the center of curvature O, and the detection data obtained in the sensing process YR The tip of the welding wire 211 of the robot body 110 starts at the welding line position detection point T n-1.
- O VDY The tip of the welding wire
- YR n-1 and YR include VDY and have the following relational expression. From the above, as in the case of the curved guide rail, the formula for controlling the moving speed of the tip of the welding wire 211 in the three directions (X direction, Y direction, Z direction) of the robot body 110 after obtaining the welding speed is described below. It can be calculated by an equation.
- the welding distance DW n between two points from T n-1 to T n is approximately obtained by synthesizing ADX n , VDY n , and VDZ n . Further, by substituting the equation (14 ′′), the welding distance DW n becomes the following equation, which is obtained in the same manner as the equation (4).
- the welding speed acceleration a and the welding speed W t seconds after the start of the welding line position detection point T n-1 are the following formulas as in the formulas (5) and (6). It becomes.
- the moving speeds (AX, VY, VZ) of the tip of the welding wire 211 of the robot body 110 in three directions are obtained from the welding speed W.
- the moving speeds (AX, VY, VZ) of the tips of the welding wires 211 of the robot body 110 in the three directions are velocity components of the welding speed W in the three directions.
- the velocity component in each direction is expressed by the following equation obtained by multiplying the ratio of the moving distances ADX n , VDY n , and VDZ n in each of the three directions to the welding distance DW n by the welding speed W.
- the moving speeds VY and VZ of the tip of the welding wire 211 of the robot main body 110 in the Y direction and the Z direction are directly connected to the driving portion of the main body 112 and the welding torch 200, the Y and Z in the driving portion of the main body 112 It is the same as the moving speed in the direction.
- the moving speed AX of the equation (16) further substituting the equations (14'), the equation (14'') and the equation (14''') and rearranging them, the traveling direction of the robot body 110 shown by the following equation The moving speed VX of is obtained.
- the VDY of the formula (18') (moving distance in the Y direction at the point where the tip of the welding wire 211 is located after t seconds) is the basic formula (2) because the moving speed in the Y direction is obtained by the formula (17). ) Is used to obtain the following equation.
- the welding speed W n changes as shown in FIG. 7A, and within the welding groove between the two points T n-1 to T n , the welding speed W n changes according to the change in the groove shape.
- the height of the weld metal in the weld groove is kept constant and the same effect as shown with reference to FIG. 8D is obtained. Further, in the final finish, the width and the extra height of the weld metal can obtain a welded joint that meets the standard of welding quality, and the welding can be performed with high accuracy.
- the welding speed W and the welding distance DW n are the welding line position detection points T. it may be regarded the same as the moving speed AX and the moving distance ADX n in the X direction when the n-1 to T n are the welding wire 211 end of the robot body 110 moves.
- the moving distances VDY n and VDZ n in the Y direction and the Z direction are regarded as a slight distance, and the moving speeds VY and VZ in the Y direction and the Z direction are assumed to move at a constant speed, and the following equation is obtained.
- the welding time t n becomes the following equation from the basic equations (1) and (20).
- VDY of the equation (21) (the moving distance in the Y direction at the point where the tip of the welding wire 211 is located after t seconds) is the following equation because the moving speed is obtained by the equation (22).
- the portable welding robot 100 is used along the welding line WL.
- the height of the weld metal in the welding groove is kept constant according to the change in the groove shape, and welding is possible while obtaining good welding quality.
- the width and the extra height of the weld metal can obtain a welded joint that meets the standard of welding quality, and the welding can be performed with high accuracy.
- FIG. 10 showing an embodiment of the present invention is a perspective view when the portable welding robot 100 shown in FIG. 3 is attached to a square steel pipe.
- the guide rail 120, the workpiece W o polygonal steel pipes, it is attached along the steel pipe outer surface in the circumferential direction.
- the guide rail 120 is provided so as to go around the outer surface of the steel pipe via the mounting member 140, and has a shape having a straight portion 121 and a curved portion 122.
- the portable welding robot 100 is mounted on the guide rail 120 with the welding torch 200 facing downward.
- the guide rail 120 shown in FIG. 10 has a boundary region 128 in which the guide route changes between the straight portion 121 and the curved portion 122.
- the groove shape detection position P n (including the welding line position detection point T n ) in this case is set to include a position corresponding to the boundary region 128. As a result, groove shape information corresponding to the boundary region 128 can be acquired.
- At least one groove shape detection position Pn is provided in the boundary region 128 where the guide route of the portable welding robot 100 by the guide rail 120 changes, and the groove shape provided in the boundary region 128.
- FIG. 11 the positional relationship between the guide rail 120 and the groove 10 in the region of the guide rail 120 and the 1/4 square portion of the square steel pipe when FIG. 10 is viewed from directly above is shown.
- the welding speed W and the moving speed VX in the traveling direction (X direction) of the robot main body 110 are the same in the straight portion 121, but the boundary region 128 Since the robot body 110 travels around the center of curvature O of the curved portion 122 after passing through, the welding speed W is smoothly connected in the boundary region 128 (at the groove shape detection position Pn point in the drawing). It is necessary to abruptly change the moving speed VX in the traveling direction of the robot main body 110 by [GR / YR n ].
- the moving speed VX in order to avoid a sudden change in the moving speed VX in the X direction in the robot body 110, the moving speed VX suddenly changes immediately before or after the groove shape detection position Pn provided in the boundary region 128.
- a section for controlling the welding conditions is provided so that the height of the weld metal in the groove 10 is constant before and after the boundary region 128 even if it does not change.
- at least one groove shape detection position Pn is provided in the boundary region 128, the position where the moving speed VX suddenly changes cannot be known, and the welding conditions around the boundary region 128 cannot be controlled. Therefore, the welding becomes unstable.
- FIG. 12 the welding distance DW n is controlled to be gradually changed so as to have a uniform welding speed during the evenly divided distance with respect to the equally divided horizontal axis.
- the welding distance DW n is divided by the preset division distance Q to obtain the division number m.
- the number of divisions m is rounded off from the equation (25) to obtain an integer value.
- the difference in welding speed between adjacent welding line position detection positions (P n-1 , P n ) is divided by the number of divisions m to obtain the welding speed ⁇ W which is the increase for each division distance Q.
- the vertical axis of FIG. 12 increases the welding speed by ⁇ W as the number of divisions increases, so that the welding speed remains constant during the division distance Q.
- k is an integer value from 0 to m. This allows control diagram graded welding speed between the weld line position detection point T n shown in FIG. 12.
- the division distance Q is set so that the increase ⁇ W of the welding speed is within a range that does not affect the welding.
- the moving speeds (VX, VY, VZ) of the robot body 110 in the three directions (X, Y, Z) are also divided by the number of divisions m and obtained in the same manner as in the equation (27).
- a control diagram of the moving speeds in the three directions (X, Y, Z) of the robot body 110 can be obtained.
- the stepwise moving speeds in the three directions (X, Y, Z) in the robot body 110 obtained in this way the stepwise welding speeds shown in FIG. 12 can be controlled.
- the control of the portable welding robot 100 is easily handled by regarding the welding speed between the welding line position detection positions (P n-1 , P n ) as an aggregate of constant speeds that change stepwise. be able to.
- the welding speed control method as shown in FIGS. 7A and 7B, it is necessary to obtain the acceleration of the welding speed and formulate it in advance.
- Control data can be acquired simply by calculating the information on the welding speed (W n-1 , W n ) of the above using a simple mathematical formula. Further, it is an effective control method in weaving welding described later.
- the robot body 110 swings the welding torch 200 in the root gap G while advancing in the X direction so as to have a constant height, so-called weaving welding as shown in FIG. 13 is performed.
- the sawtooth-shaped locus in FIG. 13 is the weaving line UL, and the moving distances YO n-1 and YO n of the weaving line UL in the Y direction indicate the weaving width.
- the moving distances YO n-1 and YO n in the Y direction are set by the size of the root gap G that can be acquired when detecting the groove shape at the groove shape detection positions (P n-1 , P n ), and between them.
- the weaving width is set to asymptotically approach from YO n-1 to YO n .
- the weaving is performed by the reciprocating motion of the robot body 110 in the Y direction, but originally, the amount of movement in the Y direction between the groove shape detection positions (P n-1 , P n ) is also set in consideration. Further, the weaving cycle (length of 2 ⁇ Q in FIG. 13) is set at the same timing for each division distance Q in which the welding distance DW n is evenly divided. At this time, the stepwise welding speed control described above is effective. As shown in FIG. 14, the weaving half cycle is adjusted for each division distance Q, and the weaving speed during the division distance Q (that is, the moving speed in the Y direction in the robot body 110, and the directions are plus and minus. (Alternating) is also set to be constant. By doing so, both the welding speed and the weaving speed become constant during the division distance Q, and the welding speed and the weaving speed can be controlled to change stepwise for each division distance Q.
- the division distance Q needs to be set in units of several millimeters in order to secure a sufficient penetration width by weaving and to keep the height of the weld metal constant.
- the division distance Q is set to 1 to 3 mm.
- the oscillation width also needs to be finely set every half cycle of weaving so as to asymptotically approach from YO n-1 to YO n .
- the groove shape changes between the groove shape detection positions (P n-1 , P n ) depending on the accuracy of the assembly work for forming the groove 10, and the groove 10 also has a meandering state. Furthermore, while deviations occur due to the guide rail installation accuracy, good welding quality can be obtained by accurately setting and controlling the welding speed and weaving speed for each division distance Q in this way.
- the positions of the guide rail 120 and the portable welding robot 100 during the welding preparation work can be easily adjusted, and welding can be performed with high work efficiency.
- the present invention is not limited to the above embodiment, and can be appropriately modified as needed.
- one robot main body 110 is provided on the guide rail 120, but a plurality of robot main bodies 110 may be provided.
- sensing using a touch sensor is performed, but sensing may be performed by other laser sensors, visual sensors, or a combination thereof.
- the data used for setting the welding conditions is automatically set by automatic sensing, but the welding conditions set for detecting each groove shape are input to the control device 600 in advance by teaching or the like. You may. For example, a database of groove shape information and welding condition data is recorded in the control device 600, and the optimum welding conditions derived from the database are automatically calculated based on the groove shape detection data obtained by sensing. You may set it. Further, the groove shape information obtained by sensing may be input to the AI (Artificial Intelligence) trained model learned by machine learning or deep learning, and the optimum welding conditions may be output.
- AI Artificial Intelligence
- a welding control method for welding a workpiece having a groove by using a portable welding robot that moves along a guide rail.
- the portable welding robot that sets two or more groove shape detection positions in the welding section from the welding start point to the welding end point and moves the groove shape at the groove shape detection position on the guide rail.
- Sensing process that senses through the detection means of
- the groove shape information calculation step of calculating the groove shape information from the detection data obtained in the sensing step, and Welding condition acquisition process to acquire welding conditions based on the groove shape information
- a welding control method for a portable welding robot characterized by having.
- groove shape information is acquired based on the detection data at the groove shape detection position obtained when the guide rail and the portable welding robot are installed on the groove, and the groove shape information is acquired. Since the welding conditions are set based on the tip shape information, the change in the groove shape for each groove shape detection position and the positional relationship between the guide rail and the groove are taken into consideration by being included in the detection data, and are accurate numerical values. Welding conditions can be obtained based on. As a result, welding can be performed by welding control that is not affected by changes in groove shape or guide rail installation accuracy. As a result, highly accurate welding can be performed. On the welding work surface, it becomes easier to assemble the work when forming the groove shape, and it becomes easier to adjust the positions of the guide rail and the portable welding robot during the welding preparation work, so that welding with good work efficiency can be performed. It can be carried out.
- the intersection of the groove shape detection position and the welding line predetermined on the work is set as the welding line position detection point, and the welding locus when welding is performed between the adjacent welding line position detection points. Is the welding locus line,
- the groove shape detection position is set so that the maximum value of the relative distance between the welding line and the welding locus line is twice or less the diameter of the welding wire.
- the welding condition change between the groove shape detection positions.
- the welding condition is changed in at least one of a linear shape, a step shape, and a curved shape between the groove shape detection positions.
- At least one of the welding conditions is the welding speed.
- the moving direction of the portable welding robot is the X direction.
- the groove width direction perpendicular to the X direction is the Y direction.
- the moving speed in each of the three directions is calculated according to the value of the welding speed at the groove shape detection position acquired in each of the three directions of the X direction, the Y direction, and the Z direction.
- the welding speed between the groove shape detection positions is controlled by the moving speed in each of the three directions.
- the welding control method for the portable welding robot according to (3) above.
- control corresponding to small changes in groove shape can be performed by controlling in each direction.
- control of welding conditions is not limited to the welding speed in the moving direction of the portable welding robot, the effect of welding position deviation due to the accuracy of guide rail installation, groove shape, etc. can be reduced, and high-precision welding is performed. be able to.
- At least one of the welding conditions is the welding speed.
- the moving direction of the portable welding robot is the X direction.
- the groove width direction perpendicular to the X direction is the Y direction.
- the moving speed in each of the three directions is calculated according to the value of the welding speed at the groove shape detection position acquired in each of the three directions of the X direction, the Y direction, and the Z direction.
- the welding distance or movement time between the groove shape detection positions is divided into two or more sections, and the welding speed at each division point is calculated from the movement speed of each division point in each of the three directions.
- the welding speed at each division point is kept constant, and the welding speed between the groove shape detection positions is controlled so as to change in steps.
- the welding control method for the portable welding robot according to (3) above.
- control corresponding to a small change in the groove shape can be easily performed by controlling each direction (X direction, Y direction, Z direction).
- control of welding conditions is not limited to the welding speed in the moving direction of the portable welding robot, the effect of welding position deviation due to the accuracy of guide rail installation, groove shape, etc. can be reduced, and high-precision welding is performed. be able to.
- At least one groove shape detection position is provided in the boundary region between the straight portion and the curved portion of the guide rail or the boundary region where the curvature of the curved portion of the guide rail changes.
- a section for controlling the welding condition is provided.
- the actual welding conditions are controlled in the control section immediately before or after the groove shape detection position. It is possible to control the position close to the site where the groove detection data is obtained without impairing the welding quality, and it is possible to perform highly accurate welding.
- At least one of weaving condition, welding speed and welding current is selected. Based on the groove shape information between the groove shape detection positions, the weaving condition, the welding speed, and the welding so that the weld metal in the groove has a constant height with respect to the welding direction. Control at least one of the currents, The welding control method for a portable welding robot according to any one of (1) to (7) above.
- the height of the molten surface can be stabilized, the accuracy of welding work can be improved, and the welding quality can be improved.
- the sensing is touch sensing, and is At the groove shape detection position, at least five detection points arranged along the cross section of the groove are provided on the root gap in the groove and the side surfaces of the groove on both sides.
- the groove shape information is calculated based on the detection data obtained from the detection point.
- the welding line is the groove tip of any one of the groove side surfaces on both sides in the groove shape.
- the actual shape change of the groove can be detected accurately and easily, and welding control can be performed quickly and accurately. As a result, the accuracy of welding is improved.
- a welding control device for welding a workpiece having a groove by using a portable welding robot that moves along a guide rail.
- the portable welding robot that sets two or more groove shape detection positions in the welding section from the welding start point to the welding end point and moves the groove shape at the groove shape detection position on the guide rail.
- a groove shape information calculation unit that calculates groove shape information from the detection data obtained in the sensing process that senses through the detection means of
- a welding condition acquisition unit that acquires welding conditions based on the groove shape information,
- a welding control device for a portable welding robot characterized by having.
- the welding control device senses the groove through the detection means on the portable welding robot with the guide rail and the portable welding robot installed on the groove. Welding control is possible by calculating groove shape information from the detection data obtained by sensing and acquiring welding conditions based on the calculated groove shape information. As a result, the welding control device can perform high-precision welding control without being affected by changes in the groove shape or the accuracy of guide rail installation, and it is not necessary to improve the guide rail installation accuracy, so welding workability is improved. Can be enhanced.
- Detection means, A portable welding robot characterized by having.
- the portable welding robot has a detecting means for sensing the groove, and in a state of being set on the guide rail with respect to the groove, sensing the groove through the detecting means. Since the control is performed based on the welding conditions obtained from the groove shape information calculated by the welding control device based on the detection data obtained by sensing, the change in the groove shape and the accuracy of guide rail installation are affected. High-precision sensing is possible without receiving. Furthermore, since the portable welding robot is controlled based on the welding conditions acquired by high-precision sensing, it can be controlled with high precision and the welding quality can be improved, and the portable welding robot is a guide. Since it is not necessary to improve the installation accuracy of the rail, welding workability can be improved.
- a welding system including a portable welding robot that welds a workpiece having a groove while moving on a guide rail, and a welding control device that can control the operation of the portable welding robot.
- the portable welding robot has a detection means for setting two or more groove shape detection positions in a welding section from a welding start point to a welding end point and sensing the groove shape at the groove shape detection position.
- the welding control device includes a groove shape information calculation unit that calculates groove shape information from the detection data obtained by the sensing, and a welding condition acquisition unit that acquires welding conditions based on the groove shape information.
- the welding system obtains detection data and detection data obtained through the detection means on the portable welding robot with the guide rail and the portable welding robot installed on the groove. Welding by the portable welding robot is controlled by the welding conditions obtained from the groove shape information calculated based on the above, so high-precision welding is possible without being affected by changes in the groove shape or the accuracy of guide rail installation. Is. Further, since the welding system does not need to improve the installation accuracy of the guide rail, the welding workability can be improved.
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Abstract
Description
特許文献1に開示された可搬型溶接ロボットを用いた溶接においては、開先形状が変化している溶接継手に対して、単位時間あたりの溶接部分の長さ(すなわち、溶接速度)が一定となるように、溶接ロボットの移動速度を制御すると、溶接開先内の溶接金属の高さは開先形状の変化に応じて異なるようになり、最終の仕上がりでは、場所によって溶接金属の幅と余盛高さが基準値を逸脱し、極端な所ではアンダーカット、オーバラップの欠陥を招き、溶接品質を満足できなくなるおそれがあった。更に、ガイドレール設置精度に起因するガイドレールと開先形状位置のズレから生じる溶接作業性については考慮されておらず、ワークに付着したスパッタ除去等の補修作業等が必要となり、作業効率が大きく低下するおそれがあった。
溶接開始点から溶接終了点までの溶接区間において、2箇所以上の開先形状検知位置を設定し、前記開先形状検知位置における開先形状を、前記ガイドレール上を移動する前記可搬型溶接ロボットが有する検知手段を介してセンシングするセンシング工程と、
前記センシング工程で得た検知データから開先形状情報を算出する開先形状情報算出工程と、
前記開先形状情報をもとに、溶接条件を取得する溶接条件取得工程と、
を有することを特徴とする可搬型溶接ロボットの溶接制御方法。
前記溶接線と前記溶接軌跡線との相対距離の最大値が、溶接ワイヤ径の2倍以下となるように前記開先形状検知位置を設定する、
上記(1)に記載の可搬型溶接ロボットの溶接制御方法。
前記開先形状検知位置ごとに取得された前記溶接条件の値にしたがい、前記開先形状検知位置間で、前記溶接条件を、直線状、ステップ状、曲線状のうち少なくとも1つで変化させるように制御する、
上記(1)又は(2)に記載の可搬型溶接ロボットの溶接制御方法。
前記可搬型溶接ロボットの移動方向をX方向、
前記X方向に対し、垂直となる開先幅方向をY方向、
前記X方向に対し、垂直となる開先深さ方向をZ方向、とする場合に、
前記X方向、前記Y方向、前記Z方向の3方向ごとに取得された前記開先形状検知位置における前記溶接速度の値にしたがって、前記3方向ごとの移動速度を算出し、
前記3方向ごとの移動速度によって、前記開先形状検知位置間の前記溶接速度を制御する、
上記(3)に記載の可搬型溶接ロボットの溶接制御方法。
前記可搬型溶接ロボットの移動方向をX方向、
前記X方向に対し、垂直となる開先幅方向をY方向、
前記X方向に対し、垂直となる開先深さ方向をZ方向、とする場合に、
前記X方向、前記Y方向、前記Z方向の3方向ごとに取得された前記開先形状検知位置における前記溶接速度の値にしたがって、前記3方向ごとの移動速度を算出し、
前記開先形状検知位置間の溶接距離又は移動時間を2以上の区間に分割し、各分割点の前記3方向ごとの移動速度によって、前記各分割点の溶接速度を算出し、
前記分割点ごとの溶接速度を一定として、前記開先形状検知位置間の溶接速度をステップ状に変化するように制御する、
上記(3)に記載の可搬型溶接ロボットの溶接制御方法。
上記(2)に記載の可搬型溶接ロボットの溶接制御方法。
上記(6)に記載の可搬型溶接ロボットの溶接制御方法。
前記開先形状検知位置間の前記開先形状情報をもとに、前記開先内の溶接金属が、溶接方向に対し一定の高さになるように、前記ウィービング条件、前記溶接速度及び前記溶接電流のうち少なくとも一つを制御する、
上記(1)~(7)のいずれか1つに記載の可搬型溶接ロボットの溶接制御方法。
上記(1)~(8)のいずれか1つに記載の可搬型溶接ロボットの溶接制御方法。
前記開先形状検知位置において、前記開先の横断面に沿って配置される検知点を、前記開先におけるルートギャップ及び両側の開先側面上に少なくとも5点設け、
前記検知点から得られる前記検知データをもとに前記開先形状情報を算出する、
上記(1)~(9)のいずれか1つに記載の可搬型溶接ロボットの溶接制御方法。
上記(2)に記載の可搬型溶接ロボットの溶接制御方法。
溶接開始点から溶接終了点までの溶接区間において、2箇所以上の開先形状検知位置を設定し、前記開先形状検知位置における開先形状を、前記ガイドレール上を移動する前記可搬型溶接ロボットが有する検知手段を介してセンシングするセンシング工程で得た検知データから、開先形状情報を算出する開先形状情報算出部と、
前記開先形状情報をもとに、溶接条件を取得する溶接条件取得部と、
を有することを特徴とする可搬型溶接ロボットの溶接制御装置。
前記ガイドレール上にセッティングされた状態で、溶接開始点から溶接終了点までの溶接区間において、2箇所以上の開先形状検知位置を設定し、前記開先形状検知位置における開先形状をセンシングする検知手段を、
を有することを特徴とする可搬型溶接ロボット。
前記可搬型溶接ロボットは、溶接開始点から溶接終了点までの溶接区間において、2箇所以上の開先形状検知位置を設定し、前記開先形状検知位置における開先形状をセンシングする検知手段を有し、
前記溶接制御装置は、前記センシングで得た検知データから、開先形状情報を算出する開先形状情報算出部と、前記開先形状情報をもとに、溶接条件を取得する溶接条件取得部と、
を有することを特徴とする可搬型溶接ロボットの溶接システム。
これにより、開先形状の変化やガイドレール設置精度に影響を受けることのない溶接制御により溶接することができる。この結果、精度の高い溶接を行うことができる。なお、溶接作業面では、開先形状を形成する時のワークの組み付け作業が容易になり、また、ガイドレール及び可搬型溶接ロボットの位置調整が容易になり、作業効率の良い溶接を行うことができる。
図1は、本実施形態に係る溶接システムの構成を示す概略図である。溶接システム50は、図1に示すように、可搬型溶接ロボット100と、送給装置300と、溶接電源400と、シールドガス供給源500と、制御装置600と、を備えている。
制御装置600は、ロボット用制御ケーブル610によって可搬型溶接ロボット100と接続され、電源用制御ケーブル620によって溶接電源400と接続されている。
制御装置600は、あらかじめ可搬型溶接ロボット100の動作パターン、溶接開始位置、溶接終了位置、溶接条件、ウィービング動作等を定めたティーチングデータを保持するデータ保持部601を有し、このティーチングデータに基づいて可搬型溶接ロボット100及び溶接電源400に対して指令を送り、可搬型溶接ロボット100の動作及び溶接条件を制御する。
また、制御装置600は、後述するセンシングにより得られる検知データから開先形状情報を算出する開先形状情報算出部602と、該開先形状情報をもとに、上記ティーチングデータの溶接条件を補正して取得する溶接条件取得部603と、を有する。そして、上記開先形状情報算出部602と溶接条件取得部603により、制御部604が構成されている。
溶接電源400は、制御装置600からの指令により、消耗電極(以下、「溶接ワイヤ」とも言う)211及びワークWoに電力を供給することで、溶接ワイヤ211とワークWoとの間にアークを発生させる。溶接電源400からの電力は、パワーケーブル410を介して送給装置300に送られ、送給装置300からコンジットチューブ420を介して溶接トーチ200に送られる。そして、図2に示すように、溶接トーチ200先端のコンタクトチップを介して、溶接ワイヤ211に電力が供給される。なお、溶接作業時の電流は、直流又は交流であっても良く、また、その波形は特に問わない。よって、電流は、矩形波や三角波などのパルスであっても良い。
シールドガス供給源500は、シールドガスが封入された容器及びバルブ等の付帯部材から構成される。シールドガス供給源500から、シールドガスが、ガスチューブ510を介して送給装置300へ送られる。送給装置300に送られたシールドガスは、コンジットチューブ420を介して溶接トーチ200に送られる。溶接トーチ200に送られたシールドガスは、溶接トーチ200内を流れて、ノズル210にガイドされて、溶接トーチ200の先端側から噴出する。本実施形態で用いるシールドガスとしては、例えば、アルゴン(Ar)や炭酸ガス(CO2)又はこれらの混合ガスを用いることができる。
送給装置300は、溶接ワイヤ211を繰り出して溶接トーチ200に送る。送給装置300により送られる溶接ワイヤ211は、特に限定されず、ワークWoの性質や溶接形態等によって選択され、例えば、ソリッドワイヤやフラックス入りワイヤ(以下、「FCW」とも言う)が使用される。また、溶接ワイヤの材質も問わず、例えば、軟鋼でも良いし、ステンレスやアルミニウム、チタンといった材質でも良い。さらに、溶接ワイヤの線径も特に問わない。
可搬型溶接ロボット100は、図2及び図3に示すように、ガイドレール120と、ガイドレール120上に設置され、該ガイドレール120に沿って移動するロボット本体110と、ロボット本体110に載置されたトーチ接続部130と、を備える。ロボット本体110は、主に、ガイドレール120上に設置される本体部112と、この本体部112に取り付けられた固定アーム部114と、この固定アーム部114に回転可能(矢印R1方向に回転可能)な状態で取り付けられた可動アーム部116と、から構成される。
さらに、溶接トーチ200が取りつけられたトーチ接続部130は、クランク170が図3の矢印R2に示すように回動することで、X方向において前後に首振り駆動可能である。また、可動アーム部116は、矢印R1に示すように、固定アーム部114に対して回転可能に取り付けられており、最適な角度に調整して固定することができる。
続いて、本実施形態に係る溶接システム50を用いた溶接条件の制御方法について詳細に説明する。
図4Aは、ワークWoの開先部位の斜視図を示し、開先10がその長手方向である溶接方向Xに蛇行し、さらに、開先10の幅方向YにルートギャップGが変化した開先10を溶接するときの模式斜視図である。また、図4Bは、図4Aのような蛇行した開先10に対し、直線状のガイドレール120を適用した可搬型溶接ロボット100を設置したときの模式的な斜視図である。図4Cは、開先10及びガイドレール120の平面上における位置関係、及び開先形状検知位置Pnを示す概念図である。
例えば、図4Aに示すような、開先10の溶接開始点10sから溶接終了点10eまでの溶接区間において、開先が蛇行し、ルートギャップGも変化して、場所ごとに開先形状が異なるような場合を考える。このような場合、センシング工程において、逆台形状の断面形状である開先10の断面形状を、開先形状検知位置Pn(P0,P2,・・・,P5)として複数箇所、本実施形態では6箇所設ける。詳細には、溶接開始点10sに最も近接する開先形状検知位置Pnを第一開先形状検知位置Ps(P0)とし、溶接終了点10eに最も近接する開先形状検知位置Pnを第二開先形状検知位置Pe(P5)、として、ロボット本体110がガイドレール120上を移動しながらタッチセンサによりセンシングを行う。
溶接開始点10s側に最も近接する第一開先形状検知位置Psと、溶接終了点10e側に最も近接する第二開先形状検知位置Peは、ワーク端部We間の距離Lに対し、第一開先形状検知位置Psと第二開先形状検知位置Peの差である|Ps-Pe|が、下記式を満たすように設定される。
0.5≦|Ps-Pe|/L≦1
このように、第一開先形状検知位置Ps及び第二開先形状検知位置Peの設定位置を規定することで、検知データの精度を高める。なお、上記「|Ps-Pe|/L」の値は、0.6以上であることが好ましく、0.7以上であることがより好ましく、0.8以上であることが更に好ましい。
なお、第一開先形状検知位置Psは、溶接開始点近傍に設定することが好ましく、第二開先形状検知位置Peは、溶接終了点近傍に設定することが好ましい。
この場合において、図4Dのような曲線状のガイドレール120を適用した開先形状検知位置Pnの間隔は、直線状のガイドレール120を適用した場合と同様、図4Eに示すとおり設定される。溶接軌跡線TWLは、ガイドレール120の曲率の影響を受けて曲線となるが、図4Cに示す直線状のガイドレール120の場合と同じく、相対距離の最大値maxΔdを可能な限り小さくするように間隔を設定することがやはり好ましい。
なお、図4Cにおいては、溶接線WLは、開先10の内部(中心)を通るように設定されている。
[2]A4’点では、A1点及びA3点で検知したワーク表面Wuの位置よりも、設定した距離だけ下がったとき、開先の中であると判断し、ワーク表面Wuの直下近傍の高さまで戻り、A5点の検出に向かう。
[3]A6点及びA9点の検知により、開先10の一端側の開先側面11の仮の傾斜角度θ1を検知する。
[4]A5点及びA8点の検知により、開先10の他端側の開先側面12の仮の傾斜角度θ2を検知する。
[5]仮の傾斜角度θ1,θ2の検知により、開先10のルート部13が確実に検知できる位置を決めてから、ルート部13のA10点を検知する。例えば、実際にはA8点から所定の寸法だけ下方側の位置をルート部13として設定する。
[6]A1点、A3点及びA10点の検知により、板厚H1を算出し、板厚H1を利用して、開先10のルート部13に近いA11点及びA12点を検知し、A12点及びA6点の検知により、一端側の開先側面11のより正確な傾斜角度θ1を検知する。また、A11点及びA5点の検知により、他端側の開先側面12における、より正確な傾斜角度θ2を決定する。
[8]また、開先10の他端側に開先側面12を構成する壁があるか否かをA13点で検知する。なお、本実施形態において壁は存在しない平継手の開先としている。
[9]A5点及びA11点を結ぶ線の延長線上を過ぎても壁の検知がなければ、壁がなしであると判断して、そのまま進み、A14点で他端側のワーク表面Wiを検知する。次に、A14点及びA10点の検知により、板厚H2を算出し、板厚H1と板厚H2の差より、開先10の両側の段差Dを算出する。
[10]段差Dには閾値があらかじめ設けられており、それ以上であると、平継手の開先ではなくT継手の開先と見なして、T継手の溶接条件を選定する。
[11]段差Dが閾値以下では、平継手の目違いと見なし、平継手の溶接条件を選定する。
続いて、図4B及び図4Cで示したガイドレール120が直線状の場合における、上述した溶接線位置検知点Tn間の溶接速度の制御について、図8A、図8B及び図8Cを参照して、溶接速度Wの求め方を最初に説明する。その後、上記X方向、Y方向、Z方向の3方向ごとの移動速度の求め方を説明する。
なお、ロボット本体110の溶接ワイヤ211の先端は、実際の溶接で発生する溶接ワイヤ211先端のアーク点と同じと見なしており、後述する溶接速度、溶接距離、溶接時間は、すなわち、溶接ワイヤ211先端の移動速度、移動距離、移動時間と同義としている。
Wn:溶接線位置検知点Tnでの溶接速度であり、溶接条件取得部603での算出値
Wn+1:溶接線位置検知点Tn+1での溶接速度であり、溶接条件取得部603での算出値
なお、Wn-1,Wn,Wn+1は、それぞれの開先形状検知位置(Pn-1,Pn,Pn+1)の開先形状情報をもとに、各開先形状検知位置Pnで溶接開先内の溶接金属の高さが同じになるように、溶接条件取得部603で算出される。
VX,VY,VZ:溶接線位置検知点Tn-1を溶接スタートしてからt秒後の3方向(X方向,Y方向,Z方向)のロボット本体110の溶接ワイヤ211先端の移動速度
なお、VDXn及びVXは、ガイドレール120上を走行するロボット本体110の走行距離及び走行速度と同じになる。
DWn:溶接線位置検知点Tn-1~Tnまでの2点間の溶接距離
tn:溶接線位置検知点Tn-1~Tnまでの2点間の溶接時間
a:溶接速度が溶接線位置検知点Tn-1~Tnまでの2点間で変化するときの加速度
W:溶接線位置検知点Tn-1を溶接スタートしてからt秒後の溶接速度
以下、図4D及び図4Eで示した曲線状のガイドレール120における溶接線位置検知点Tn間の溶接速度の制御において、図9A~図9Dを参照して、溶接速度Wの求め方を最初に説明する。その後、上記X方向、Y方向、Z方向の3方向ごとの移動速度の求め方を説明する。
AX:溶接線位置検知点Tn-1からTnへロボット本体110の溶接ワイヤ211先端が移動するときの、X方向の移動速度
VDXn:溶接線位置検知点Tn-1からTnまでロボット本体110の溶接ワイヤ211先端が移動したときの、ガイドレール120上を走行するロボット本体110の移動距離であり、センシング工程で得られる検知データ
ADXn:溶接線位置検知点Tn-1からTnまでロボット本体110の溶接ワイヤ211先端が移動するときの、X方向の移動距離
GR:曲線状のガイドレール半径であり、あらかじめ溶接条件取得部603に入力する数値
O:曲線部の曲率中心
YRn-1:溶接線位置検知点Tn-1から曲率中心OまでのXY平面上の距離であり、センシング工程で得られる検知データ
YR:溶接線位置検知点Tn-1をロボット本体110の溶接ワイヤ211先端がスタートしてからt秒後に位置した点(図中のQ点)から曲率中心OまでのXY平面上の距離
VDY:溶接線位置検知点Tn-1をロボット本体110の溶接ワイヤ211先端がスタートしてからt秒後に位置した点(図中のQ点)でのY方向の移動距離
なお、その他の記号は、図8A、図8B及び図8Cと同様である。
図12のように、溶接距離DWnを均等分割した横軸に対して、均等分割した距離の間は等速度の溶接速度となるように段階的に変化させるように制御する。まず、溶接距離DWnをあらかじめ設定した分割距離Qで除して、分割数mを求める。
これによって、図12に示す溶接線位置検知点Tn間での階段的な溶接速度の制御図ができる。ただし、溶接速度の増加分ΔWは、溶接に影響のない範囲となるように、分割距離Qは設定される。
溶接開始点から溶接終了点までの溶接区間において、2箇所以上の開先形状検知位置を設定し、前記開先形状検知位置における開先形状を、前記ガイドレール上を移動する前記可搬型溶接ロボットが有する検知手段を介してセンシングするセンシング工程と、
前記センシング工程で得た検知データから開先形状情報を算出する開先形状情報算出工程と、
前記開先形状情報をもとに、溶接条件を取得する溶接条件取得工程と、
を有することを特徴とする可搬型溶接ロボットの溶接制御方法。
前記溶接線と前記溶接軌跡線との相対距離の最大値が、溶接ワイヤ径の2倍以下となるように前記開先形状検知位置を設定する、
上記(1)記載の可搬型溶接ロボットの溶接制御方法。
前記開先形状検知位置ごとに取得された前記溶接条件の値にしたがい、前記開先形状検知位置間で、前記溶接条件を、直線状、ステップ状、曲線状のうち少なくとも1つで変化させるように制御する、
上記(1)又は(2)に記載の可搬型溶接ロボットの溶接制御方法。
前記可搬型溶接ロボットの移動方向をX方向、
前記X方向に対し、垂直となる開先幅方向をY方向、
前記X方向に対し、垂直となる開先深さ方向をZ方向、とする場合に、
前記X方向、前記Y方向、前記Z方向の3方向ごとに取得された前記開先形状検知位置における前記溶接速度の値にしたがって、前記3方向ごとの移動速度を算出し、
前記3方向ごとの移動速度によって、前記開先形状検知位置間の前記溶接速度を制御する、
上記(3)に記載の可搬型溶接ロボットの溶接制御方法。
前記可搬型溶接ロボットの移動方向をX方向、
前記X方向に対し、垂直となる開先幅方向をY方向、
前記X方向に対し、垂直となる開先深さ方向をZ方向、とする場合に、
前記X方向、前記Y方向、前記Z方向の3方向ごとに取得された前記開先形状検知位置における前記溶接速度の値にしたがって、前記3方向ごとの移動速度を算出し、
前記開先形状検知位置間の溶接距離又は移動時間を2以上の区間に分割し、各分割点の前記3方向ごとの移動速度によって、前記各分割点の溶接速度を算出し、
前記分割点ごとの溶接速度を一定として、前記開先形状検知位置間の溶接速度をステップ状に変化するように制御する、
上記(3)に記載の可搬型溶接ロボットの溶接制御方法。
上記(2)に記載の可搬型溶接ロボットの溶接制御方法。
上記(6)に記載の可搬型溶接ロボットの溶接制御方法。
前記開先形状検知位置間の前記開先形状情報をもとに、前記開先内の溶接金属が、溶接方向に対し一定の高さになるように、前記ウィービング条件、前記溶接速度及び前記溶接電流のうち少なくとも一つを制御する、
上記(1)~(7)のいずれか1つに記載の可搬型溶接ロボットの溶接制御方法。
上記(1)~(8)のいずれか1つに記載の可搬型溶接ロボットの溶接制御方法。
前記開先形状検知位置において、前記開先の横断面に沿って配置される検知点を、前記開先におけるルートギャップ及び両側の開先側面上に少なくとも5点設け、
前記検知点から得られる前記検知データをもとに前記開先形状情報を算出する、
上記(1)~(9)のいずれか1つに記載の可搬型溶接ロボットの溶接制御方法。
上記(2)に記載の可搬型溶接ロボットの溶接制御方法。
溶接開始点から溶接終了点までの溶接区間において、2箇所以上の開先形状検知位置を設定し、前記開先形状検知位置における開先形状を、前記ガイドレール上を移動する前記可搬型溶接ロボットが有する検知手段を介してセンシングするセンシング工程で得た検知データから、開先形状情報を算出する開先形状情報算出部と、
前記開先形状情報をもとに、溶接条件を取得する溶接条件取得部と、
を有することを特徴とする可搬型溶接ロボットの溶接制御装置。
前記ガイドレール上にセッティングされた状態で、溶接開始点から溶接終了点までの溶接区間において、2箇所以上の開先形状検知位置を設定し、前記開先形状検知位置における開先形状をセンシングする検知手段を、
を有することを特徴とする可搬型溶接ロボット。
前記可搬型溶接ロボットは、溶接開始点から溶接終了点までの溶接区間において、2箇所以上の開先形状検知位置を設定し、前記開先形状検知位置における開先形状をセンシングする検知手段を有し、
前記溶接制御装置は、前記センシングで得た検知データから、開先形状情報を算出する開先形状情報算出部と、前記開先形状情報をもとに、溶接条件を取得する溶接条件取得部と、
を有することを特徴とする可搬型溶接ロボットの溶接システム。
10e 溶接終了点
10s 溶接開始点
11,12 開先側面
11e,12e 開先端縁
50 溶接システム
100 可搬型溶接ロボット
110 ロボット本体
120 ガイドレール
121 直線部
122 曲線部
128 境界領域
200 溶接トーチ
211 溶接ワイヤ
300 送給装置
400 溶接電源
500 シールドガス供給源
600 制御装置
603 溶接条件取得部
DWn 溶接線位置検知点Tn-1~Tnまでの2点間の溶接距離
G ルートギャップ
L ワーク端部We間の距離
Pn 開先形状検知位置
Ps 第一開先形状検知位置
Pe 第二開先形状検知位置
T 移動時間
Tn 溶接線位置検知点
TWL 溶接軌跡線
We ワーク端部
Wo ワーク
Wi、Wu ワーク表面
WL 溶接線
Claims (14)
- ガイドレールに沿って移動する可搬型溶接ロボットを用いて、開先を有するワークを溶接するための溶接制御方法であって、
溶接開始点から溶接終了点までの溶接区間において、2箇所以上の開先形状検知位置を設定し、前記開先形状検知位置における開先形状を、前記ガイドレール上を移動する前記可搬型溶接ロボットが有する検知手段を介してセンシングするセンシング工程と、
前記センシング工程で得た検知データから開先形状情報を算出する開先形状情報算出工程と、
前記開先形状情報をもとに、溶接条件を取得する溶接条件取得工程と、
を有することを特徴とする可搬型溶接ロボットの溶接制御方法。 - 前記開先形状検知位置と、前記ワーク上にあらかじめ定められた溶接線との交点を、溶接線位置検知点とし、隣接する前記溶接線位置検知点間を溶接するときの溶接の軌跡を溶接軌跡線とする場合において、
前記溶接線と前記溶接軌跡線との相対距離の最大値が、溶接ワイヤ径の2倍以下となるように前記開先形状検知位置を設定する、
請求項1に記載の可搬型溶接ロボットの溶接制御方法。 - 前記開先形状検知位置間で前記溶接条件の変化が生じる場合において、
前記開先形状検知位置ごとに取得された前記溶接条件の値にしたがい、前記開先形状検知位置間で、前記溶接条件を、直線状、ステップ状、曲線状のうち少なくとも1つで変化させるように制御する、
請求項1又は2に記載の可搬型溶接ロボットの溶接制御方法。 - 前記溶接条件のうち少なくとも一つは溶接速度であって、
前記可搬型溶接ロボットの移動方向をX方向、
前記X方向に対し、垂直となる開先幅方向をY方向、
前記X方向に対し、垂直となる開先深さ方向をZ方向、とする場合に、
前記X方向、前記Y方向、前記Z方向の3方向ごとに取得された前記開先形状検知位置における前記溶接速度の値にしたがって、前記3方向ごとの移動速度を算出し、
前記3方向ごとの移動速度によって、前記開先形状検知位置間の前記溶接速度を制御する、
請求項3に記載の可搬型溶接ロボットの溶接制御方法。 - 前記溶接条件のうち少なくとも一つは溶接速度であって、
前記可搬型溶接ロボットの移動方向をX方向、
前記X方向に対し、垂直となる開先幅方向をY方向、
前記X方向に対し、垂直となる開先深さ方向をZ方向、とする場合に、
前記X方向、前記Y方向、前記Z方向の3方向ごとに取得された前記開先形状検知位置における前記溶接速度の値にしたがって、前記3方向ごとの移動速度を算出し、
前記開先形状検知位置間の溶接距離又は移動時間を2以上の区間に分割し、各分割点の前記3方向ごとの移動速度によって、前記各分割点の溶接速度を算出し、
前記分割点ごとの溶接速度を一定として、前記開先形状検知位置間の溶接速度をステップ状に変化するように制御する、
請求項3に記載の可搬型溶接ロボットの溶接制御方法。 - 前記ガイドレールの直線部と曲線部の境界領域、又は、前記ガイドレールの曲線部における曲率が変化する境界領域に、少なくとも1つの前記開先形状検知位置を設ける、
請求項2に記載の可搬型溶接ロボットの溶接制御方法。 - 前記境界領域に設けた前記開先形状検知位置の直前又は直後において、前記溶接条件を制御する区間を設ける、
請求項6に記載の可搬型溶接ロボットの溶接制御方法。 - 前記溶接条件として、ウィービング条件、溶接速度及び溶接電流のうち少なくとも1つを選択し、
前記開先形状検知位置間の前記開先形状情報をもとに、前記開先内の溶接金属が、溶接方向に対し一定の高さになるように、前記ウィービング条件、前記溶接速度及び前記溶接電流のうち少なくとも一つを制御する、
請求項1に記載の可搬型溶接ロボットの溶接制御方法。 - 前記センシング工程は、前記開先形状検知位置における前記開先形状のセンシングに加え、前記ワークにおける前記開先が設けられる側のワーク表面、及び、前記ワークの溶接線方向におけるワーク端部のうち少なくとも1つのセンシングを含む、
請求項1に記載の可搬型溶接ロボットの溶接制御方法。 - 前記センシングは、タッチセンシングであって、
前記開先形状検知位置において、前記開先の横断面に沿って配置される検知点を、前記開先におけるルートギャップ及び両側の開先側面上に少なくとも5点設け、
前記検知点から得られる前記検知データをもとに前記開先形状情報を算出する、
請求項1に記載の可搬型溶接ロボットの溶接制御方法。 - 前記溶接線は、前記開先形状における両側の開先側面のいずれか一方の開先端である、
請求項2に記載の可搬型溶接ロボットの溶接制御方法。 - ガイドレールに沿って移動する可搬型溶接ロボットを用いて、開先を有するワークを溶接するための溶接制御装置であって、
溶接開始点から溶接終了点までの溶接区間において、2箇所以上の開先形状検知位置を設定し、前記開先形状検知位置における開先形状を、前記ガイドレール上を移動する前記可搬型溶接ロボットが有する検知手段を介してセンシングするセンシング工程で得た検知データから、開先形状情報を算出する開先形状情報算出部と、
前記開先形状情報をもとに、溶接条件を取得する溶接条件取得部と、
を有することを特徴とする可搬型溶接ロボットの溶接制御装置。 - ガイドレール上を移動しながら開先を有するワークを溶接する、請求項12に記載の溶接制御装置によって制御される可搬型溶接ロボットであって、
前記ガイドレール上にセッティングされた状態で、溶接開始点から溶接終了点までの溶接区間において、2箇所以上の開先形状検知位置を設定し、前記開先形状検知位置における開先形状をセンシングする検知手段を、
を有することを特徴とする可搬型溶接ロボット。 - ガイドレール上を移動しながら開先を有するワークを溶接する可搬型溶接ロボットと、
前記可搬型溶接ロボットの動作を制御可能な溶接制御装置と、を有する溶接システムであって、
前記可搬型溶接ロボットは、溶接開始点から溶接終了点までの溶接区間において、2箇所以上の開先形状検知位置を設定し、前記開先形状検知位置における開先形状をセンシングする検知手段を有し、
前記溶接制御装置は、前記センシングで得た検知データから、開先形状情報を算出する開先形状情報算出部と、前記開先形状情報をもとに、溶接条件を取得する溶接条件取得部と、
を有することを特徴とする可搬型溶接ロボットの溶接システム。
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CA3145981A CA3145981C (en) | 2019-08-07 | 2020-03-17 | Welding control method and welding control device for portable welding robot, portable welding robot, and welding system |
CN202080056419.2A CN114206544B (zh) | 2019-08-07 | 2020-03-17 | 便携式焊接机器人的焊接控制方法、焊接控制装置、便携式焊接机器人以及焊接系统 |
KR1020217042930A KR102584173B1 (ko) | 2019-08-07 | 2020-03-17 | 가반형 용접 로봇의 용접 제어 방법, 용접 제어 장치, 가반형 용접 로봇 및 용접 시스템 |
US17/630,877 US20220297218A1 (en) | 2019-08-07 | 2020-03-17 | Welding control method and welding control device for portable welding robot, portable welding robot, and welding system |
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JP2023047210A (ja) * | 2021-09-24 | 2023-04-05 | コベルコROBOTiX株式会社 | ウィービング制御方法、溶接制御装置、溶接システム、溶接方法及びウィービング制御プログラム |
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CA3145981A1 (en) | 2021-02-11 |
TWI735215B (zh) | 2021-08-01 |
JP2021023977A (ja) | 2021-02-22 |
CN114206544A (zh) | 2022-03-18 |
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