接管焊接机器人关键技术研究
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摘要
随着科技的发展,机器人已经被广泛应用到焊接领域。在石油、化工、核电、锅炉和管道工程当中存在着大量的接管焊接。现有的机器人难以满足接管焊接需要,接管焊接作业基本上还是手工操作。人工焊接的操作环境恶劣、劳动量大、效率低下。针对现有接管焊接机器人焊接和人工焊接的局限性,在全面总结接管焊接机器人最新研究成果基础上,本文针对接管焊接机器人的若干关键技术问题,在以下方面进行了研究。
本文针对接管相贯线焊接的特殊性,在综合分析现有接管焊接机器人技术特点及应用的基础上,开发了具有多自由度特殊结构的接管焊接机器人。工作现场借助于其它定位装置,将机器人放置到接管上方实现焊接作业,实现了焊接工艺要求。根据实际需要,研发了采用钢带传动的焊枪摆动机构。
本文所研究的接管焊接机器人控制系统采用了CAN总线体系结构和工业PC机为开放性系统核心,集成了以PC机为数据运算处理和以单片机作为关节节点控制的硬件平台。
接管焊接机器人运动模型的建立是实现焊接自动化的一个技术基础。针对研发的接管焊接机器人,利用D-H坐标建立了机器人运动学模型,求解了逆运动学模型,并对其建立了雅可比、力雅可比和动力学模型,为接管焊接机器人的设计开发提供了基础依据。
针对送丝过程当中阻力呈严重非线性的特点,采用状态观测对扰动力进行观测并进行前馈以提高系统的速度响应,利用模糊PI对送丝机进行控制实现了安全可靠送丝。根据接管相贯线的数学模型建立了焊接的速度控制模型,开发了人机控制界面,实现了各个节点的运动控制。
焊接实验结果表明接管焊接机器人能实现接管相贯线的自动焊接,焊缝质量良好,系统运行稳定可靠、效率高,焊接实验证明本文所研究的接管焊接机器人设计合理,能可靠地应用于工业现场,是一种提高效率、减少工人劳动强度和焊接质量优良的机器人。
Robots have been widely applied to the welding field with the development of technology. In the petroleum, the chemical industry, the nuclear power, the boiler and the pipeline project, there are a large number of intersected pipes welding, the current robots cannot meet practical needs, and the nozzle welding tasks are basically completed by manual welding operation, which has characteristics of bad environment, high labor intensity, low efficiency, and poor quality. Aiming at the limitations of the manual welding and the robotic welding, an intersecting pipe robot with special structure was developed. Based on a comprehensive summary of the latest research, the related key technologies were researched, the main results outline as follows.
According to the welding particularity on the intersection of intersected pipe, the multi-freedom robot with special structure was developed based on analyzing the technical features and application foundation of the current robots. By means of other positioning device, the welding operation can be carried out while laying the robot over the top of weldment. A swing mechanism of the gun drived by steel belt was developed according to actual needs.
The control system of the nozzle welding robot is considered the CAN-bus as network, PC as the core of the open system, PC as data processing and single chip microcomputer as nodes control, the hardware platform of the welding robot control system was integrated, the relevant hardware and interface design were achieved, a more open system hardware and software platform were established.
The motion model of the welding robot is a theoretical basis for welding automation, aiming to the joints relationship of the welding robot developed, the robot kinematics model was established according to the D-H coordinate, and the inverse kinematics model was solved by using analytic method; the Jacobian, the force Jacobian and dynamic model were established, all these work provide the foundation for design and development.
The resistances against the wire feeding process show serious nonlinear characteristics, the state observer to observe the interference and feed-forward loop were adopt, which can improve the speed respond, the secure and reliable wire feeding was accomplished by using Fuzzy-PI control. The welding speed control model was established based on the mathematical intersection model, the motion control of each node were realized, and the human-machine interface for system control functions was developed.
The welding experiments indicate the automatic welding of intersecting line can be achieved, the weld was formed well, and the system operates stably and reliably. The welding experiment shows that the practicability and feasibility of welding robot system are reasonable, and the welding robot has the character of high efficiency, good reliability, reducing the labor intensity of workers, and ensuring welding quality.
本文针对接管相贯线焊接的特殊性,在综合分析现有接管焊接机器人技术特点及应用的基础上,开发了具有多自由度特殊结构的接管焊接机器人。工作现场借助于其它定位装置,将机器人放置到接管上方实现焊接作业,实现了焊接工艺要求。根据实际需要,研发了采用钢带传动的焊枪摆动机构。
本文所研究的接管焊接机器人控制系统采用了CAN总线体系结构和工业PC机为开放性系统核心,集成了以PC机为数据运算处理和以单片机作为关节节点控制的硬件平台。
接管焊接机器人运动模型的建立是实现焊接自动化的一个技术基础。针对研发的接管焊接机器人,利用D-H坐标建立了机器人运动学模型,求解了逆运动学模型,并对其建立了雅可比、力雅可比和动力学模型,为接管焊接机器人的设计开发提供了基础依据。
针对送丝过程当中阻力呈严重非线性的特点,采用状态观测对扰动力进行观测并进行前馈以提高系统的速度响应,利用模糊PI对送丝机进行控制实现了安全可靠送丝。根据接管相贯线的数学模型建立了焊接的速度控制模型,开发了人机控制界面,实现了各个节点的运动控制。
焊接实验结果表明接管焊接机器人能实现接管相贯线的自动焊接,焊缝质量良好,系统运行稳定可靠、效率高,焊接实验证明本文所研究的接管焊接机器人设计合理,能可靠地应用于工业现场,是一种提高效率、减少工人劳动强度和焊接质量优良的机器人。
Robots have been widely applied to the welding field with the development of technology. In the petroleum, the chemical industry, the nuclear power, the boiler and the pipeline project, there are a large number of intersected pipes welding, the current robots cannot meet practical needs, and the nozzle welding tasks are basically completed by manual welding operation, which has characteristics of bad environment, high labor intensity, low efficiency, and poor quality. Aiming at the limitations of the manual welding and the robotic welding, an intersecting pipe robot with special structure was developed. Based on a comprehensive summary of the latest research, the related key technologies were researched, the main results outline as follows.
According to the welding particularity on the intersection of intersected pipe, the multi-freedom robot with special structure was developed based on analyzing the technical features and application foundation of the current robots. By means of other positioning device, the welding operation can be carried out while laying the robot over the top of weldment. A swing mechanism of the gun drived by steel belt was developed according to actual needs.
The control system of the nozzle welding robot is considered the CAN-bus as network, PC as the core of the open system, PC as data processing and single chip microcomputer as nodes control, the hardware platform of the welding robot control system was integrated, the relevant hardware and interface design were achieved, a more open system hardware and software platform were established.
The motion model of the welding robot is a theoretical basis for welding automation, aiming to the joints relationship of the welding robot developed, the robot kinematics model was established according to the D-H coordinate, and the inverse kinematics model was solved by using analytic method; the Jacobian, the force Jacobian and dynamic model were established, all these work provide the foundation for design and development.
The resistances against the wire feeding process show serious nonlinear characteristics, the state observer to observe the interference and feed-forward loop were adopt, which can improve the speed respond, the secure and reliable wire feeding was accomplished by using Fuzzy-PI control. The welding speed control model was established based on the mathematical intersection model, the motion control of each node were realized, and the human-machine interface for system control functions was developed.
The welding experiments indicate the automatic welding of intersecting line can be achieved, the weld was formed well, and the system operates stably and reliably. The welding experiment shows that the practicability and feasibility of welding robot system are reasonable, and the welding robot has the character of high efficiency, good reliability, reducing the labor intensity of workers, and ensuring welding quality.
引文
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