相贯线焊接机器人机构设计与运动控制
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摘要
随着焊接机器人的推广,越来越多的自动化设备代替工人完成焊接任务。然而对于管道插接相贯线的焊接,由于空间相贯线焊缝的结构复杂,现有的焊接机器人系统很难满足使用的要求,在一些情况下仍然需要通过工人来完成焊接任务。为了降低工人的劳动强度,提高焊接质量和劳动效率,需要研制一种专门用于相贯线焊缝焊接机器人专机。
本文在分析国内外管道自动焊机研究状况的基础上,深入分析了管道插接相贯线的特征,建立了斜交偏置下的相贯线模型以及相贯线方程。针对相贯线的特点,细化机器人每个自由度的功能。通过比较关节型坐标机器人和圆柱型坐标机器人,建立两种类型机构的运动方程式,求出它们的正解和逆解的方程,比较方程的形式,选择单变量方程来描述机器人运动,确定了一种相贯线轨迹运动解耦的机构形式,采用圆柱坐标型机构作为操作机。
通过分析焊枪与焊缝的姿态关系,并结合焊接工艺涉及的焊枪工作角和行走角,研发了两自由度反球型机器人手腕机构。该手腕具有两个圆弧运动的自由度,分别由角转台和连杆机构来实现。安装在手腕机构上的焊枪可以实现焊枪末端固定的运动,从而实现对焊枪工作角与行走角的解耦控制。
在确定硬件的系统基础上,建立电机与运动控制PMAC卡的连接。在Boland c++ builder开发环境下,通过与PComm32PRO动态链接库,设计出实用直观的操作界面,对一些变量参数可以进行修改与储存。
使用PRO/E三维绘图软件对焊接机器人进行设计。在“机构”模式下进行机器人的运动仿真,校验各个关节运动方程的正确性以及机器人结构的合理性。通过实际的焊接实验,验证机器人的实际焊接效果。实验过程中,机器人能够很好地执行上位机发出的运动程序指令,实现焊缝轨迹、焊枪姿态的独立控制,完成焊接任务。
With the development of welding robot, more and more automated equipments replace the workers to complete welding tasks. However, the existing welding robot system can’t satisfy the requirement of pipe inserting welding for the complex structure of the intersecting line, even in some case, welding tasks is completed by handwork. In order to reduce the labor intensity and to improve the welding quality, a new type of intersecting line welding robot is needed.
Based on the analysis of civil and abroad research condition of intersecting line welding machine, this paper analyzes the characteristic of the intersecting line, and established the intersection model and intersecting line equation under the bias offset. According to the features of intersection, the paper refined the robot function at each degree of freedom. By comparing the joint coordinate robot and cylindrical coordinate robot, the paper established the equations of two types of structure, and then obtained a positive solution and inverse solution of the equations. Compared with the equation form, the single variable equation is chosen to describe the robot movement, and determined one kind of transversal path movement decoupling organization form by using the circular cylindrical coordinate organization to be the operation machine.
By analyzing the relationship between welding torch and weld profile, combined with the torch welding work angle and walk angle, two degree-of-freedom anti-spherical robot wrist mechanism is researched. The new type of wrist consists of two circular tracks, which is realized by rotate mechanism and link mechanism. The torch installed at the end of the wrist can move at the fixed point to satisfy the independent control of the torch angle and travel angel.
On the basis of the hardware’s foundation, PMAC card is connected with motors. Under the developed environment of Boland c++ builder, by link with PComm32PRO dynamic link storehouse, we designed the practical direct-viewing operation contact interface, which can revise and store some variable parameter.
The robot was designed by using PRO/E software. Kinematics simulation is realized in the mode of“mechanism”, the accuracy of motion equations is checked to make sure the structure of the robot is reasonable.
Through the welding experiment, the robot is tested when it works. The result of the experiment showed that the robot performed well when the computer sends the program to the robot system. The robot moved with gun control and weld path control independently.
本文在分析国内外管道自动焊机研究状况的基础上,深入分析了管道插接相贯线的特征,建立了斜交偏置下的相贯线模型以及相贯线方程。针对相贯线的特点,细化机器人每个自由度的功能。通过比较关节型坐标机器人和圆柱型坐标机器人,建立两种类型机构的运动方程式,求出它们的正解和逆解的方程,比较方程的形式,选择单变量方程来描述机器人运动,确定了一种相贯线轨迹运动解耦的机构形式,采用圆柱坐标型机构作为操作机。
通过分析焊枪与焊缝的姿态关系,并结合焊接工艺涉及的焊枪工作角和行走角,研发了两自由度反球型机器人手腕机构。该手腕具有两个圆弧运动的自由度,分别由角转台和连杆机构来实现。安装在手腕机构上的焊枪可以实现焊枪末端固定的运动,从而实现对焊枪工作角与行走角的解耦控制。
在确定硬件的系统基础上,建立电机与运动控制PMAC卡的连接。在Boland c++ builder开发环境下,通过与PComm32PRO动态链接库,设计出实用直观的操作界面,对一些变量参数可以进行修改与储存。
使用PRO/E三维绘图软件对焊接机器人进行设计。在“机构”模式下进行机器人的运动仿真,校验各个关节运动方程的正确性以及机器人结构的合理性。通过实际的焊接实验,验证机器人的实际焊接效果。实验过程中,机器人能够很好地执行上位机发出的运动程序指令,实现焊缝轨迹、焊枪姿态的独立控制,完成焊接任务。
With the development of welding robot, more and more automated equipments replace the workers to complete welding tasks. However, the existing welding robot system can’t satisfy the requirement of pipe inserting welding for the complex structure of the intersecting line, even in some case, welding tasks is completed by handwork. In order to reduce the labor intensity and to improve the welding quality, a new type of intersecting line welding robot is needed.
Based on the analysis of civil and abroad research condition of intersecting line welding machine, this paper analyzes the characteristic of the intersecting line, and established the intersection model and intersecting line equation under the bias offset. According to the features of intersection, the paper refined the robot function at each degree of freedom. By comparing the joint coordinate robot and cylindrical coordinate robot, the paper established the equations of two types of structure, and then obtained a positive solution and inverse solution of the equations. Compared with the equation form, the single variable equation is chosen to describe the robot movement, and determined one kind of transversal path movement decoupling organization form by using the circular cylindrical coordinate organization to be the operation machine.
By analyzing the relationship between welding torch and weld profile, combined with the torch welding work angle and walk angle, two degree-of-freedom anti-spherical robot wrist mechanism is researched. The new type of wrist consists of two circular tracks, which is realized by rotate mechanism and link mechanism. The torch installed at the end of the wrist can move at the fixed point to satisfy the independent control of the torch angle and travel angel.
On the basis of the hardware’s foundation, PMAC card is connected with motors. Under the developed environment of Boland c++ builder, by link with PComm32PRO dynamic link storehouse, we designed the practical direct-viewing operation contact interface, which can revise and store some variable parameter.
The robot was designed by using PRO/E software. Kinematics simulation is realized in the mode of“mechanism”, the accuracy of motion equations is checked to make sure the structure of the robot is reasonable.
Through the welding experiment, the robot is tested when it works. The result of the experiment showed that the robot performed well when the computer sends the program to the robot system. The robot moved with gun control and weld path control independently.
引文
1 John J. Craig,机器人学导论,第三版,机械工业出版社,2006.6:1-2
2唐新化.焊接机器人的现状及发展趋势.电焊机.2006.3
3 Bolmsjo, Gunnar ; Olsson, Magnus; Cederberg, Per ,Robotic arc welding - trends and developments for higher autonomy, Source: Industrial Robot, p 98-104, 2002
4任福深.基于PC+DSP模式的管道插接专用焊接机器人系统研究.北京工业大学博士论文.2009,2-3
5符娅波,边美华,许先果.焊接机器人的应用与发展.焊接.2006,35(11):79-81
6 G.S.Bolmsjo.Robotic Arc Welding-Programming and Control.IFAC Robot Control.1998:541-546
7 World Robot survey sales up 25 percent in 2000. Industrial Robot. 2002, 29(2):7-8
8哈恩晶.焊接机器人的应用现状与发展趋势.机械工人(热加工).2004,(5):16-18
9张柯等.移动焊接机器人的研究现状及发展趋势.2004, 8:5-9
10 Paolo D, Eugenio G, et al. IEEE Robotics and Autamation Magazine ,1996,(9):44
11 Hyosig K. IEEE Engeering in Medicine and Biology,2001,(12):44
12赵匀,武传宇,胡旭东,俞高红.农业机器人的研究进展及存在的问题.农业工程学报.2003,19(1):20-24
13 RyuKH,KimG,HanJS.Developmentofarobotic transplanter forbeding plants.JAgricEngRes.2001,78(2):141-146
14钱善华等.救灾机器人的研究现状与煤矿救灾的应用.机器人.2006,28(3):350-354
15黄政艳.焊接机器人的应用现状与技术展望[J].装备制造技术, 2007,(03)
16 Gunnar Bolmsj?, Magnus Olsson, Per Cederberg ,Robotic arc welding– trends and developments for higher autonomy, Industrial Robot,2002,Volume:29 ,Page:98– 104
17谭一炯;周方明;王江超;黄志杰.焊接机器人技术现状与发展趋势.电焊机.2006.3
18 Coldstein, B. L. M., et al, Technologies for the Integration of Manufacturing Applications, Advanced Technology Program, 1995, 5
19 Wright, Paul K., Principlcs of Open-Architecture Manufacturing, Journal of Manufacturing System, 1995, 14(3)
20陈玮,郑时雄,周学才.基于网络的开放式机器人通用控制系统的研究.华南理工大学学报(自然科学版),2001,29(5):35-37
21 William Rippen, Jim Cilsinn and Lange Flitter. Networking of Welding Applications: A Tutorial. Welding Journal. 79(1), 2000:49-53
22 Jahng-Hyon Park,Joonyoung park. Real Time Bilateral Control for Internet based TeleroboticSystem. Proceedings of the IEEE/RSJ Intl. Conf. On Intelligent Robotics and Systems, Las Vegas, Nevada. 2003:1106-1110
23 Xiao-Gang Wang, M. Moallem, R. V. Patel. An Internet-Base Distributed Multiple-Telerobot System. IEEE Transactions on Systems, Man, and Cybernetics-Part A: System and Humans. 2003, 33(5):627-633
24 Reid L. Kress, William R. Hamel, Pamela Murray, Karen Bills. Control Strategies for Teleoperated Internet Assembly. IEEE/ASME Transaction on Mechatronics, 2001, 6(4):410-416
25高胜,赵杰.基于Internet的机器人遥操作虚拟环境的关键问题.哈尔滨工业大学学报[J].2006,38(4):649-653
26祖旭,黄洪钟,张旭.虚拟样机技术及其发展.农业机械学报[J].2004,35(4):168-171
27 Shiroma, N.; Miyauchi, R.; Matsuno, F.; Mobile robot teleoperation through virtual robot ,Robot and Human Interactive Communication,The 17th IEEE International Symposium on Digital Object Identifier, Publication Year: 2008 , Page(s): 477 - 482
28霍孟友.基于的椭球面封头接管自动焊接装置.焊接学报.2005, 26(1):74~78
29闫政,梁君直,陈江.采用DSP控制的高效管道双焊炬全位置自动焊机研究.电焊机.2005,35(4):38-43
30张忠厚,武传松. GLJ-1型自行车架管连接自动焊机.焊接学报.1997,18(4):206-209
31霍孟友.基于的椭球面封头接管自动焊接装置.焊接学报.2005,26(1):74-78
32 Bahrami-Samani, M.; Agahi, M.; Moosavian, S.A.A. Design and Analysis of a Welding Robot.Automation Science and Engineering, 2006.
33 Muramatsu, M.; Namiki, N.; Koyama, R.; Suga, Y. Proceedings. Autonomous mobile robot in pipe for piping operations.International Conference on Intelligent Robots and Systems , p 2166-71 vol.3, 2000
34谢新房;王国栋;多管相贯焊接坡口数控切割研究.工程图学学报, 2007年04期
35刘永,除越兰,王克鸿,余进,杨静宇锅炉焊接机器人离线编程系统,焊接学报,2004 03期
36 Lee, D.M.A.; ElMaraghy, W.H.; ROBOSIM: a CAD-based off-line programming and analysis system for robotic manipulators. Computer-Aided Engineering Journal Volume: 7 , Issue: 5 , Publication Year: 1990 , Page(s): 141– 148
37王克鸿,刘永,余进.弧焊机器人典型工件建模与姿态规划研究.电焊机.2006,33(6):29-32
38陈志翔,卢振洋,殷树言等.焊缝位姿及焊枪位姿的模型.机械工程学报.2003,39(7):59-62
39费仁元、张慧慧.机器人机械设计和分析.北京工业大学出版社1998
40张铁谢存禧.机器人学.华南理工大学出版社2001
41杨振中;周骥平;朱兴龙.基于解耦型球关节的工业机器人控制系统研究初探.制造业自动化2006年07期
42王晓峰;陈焕明;江淑园.焊接位姿参数定义的讨论及典型工件的建模.南昌航空工业学报.2006.6,26(2):24-28
43潘炼东;黄心汉.基于PMAC的机器人控制器设计华中理工大学学报2000年4月vol.28 no4
44 pmac用户手册,北京元茂兴控制设备技术有限责任公司
45刘蕾;唐为义;原所先基于VC++与PMAC的机器人控制软件的开发机器人技术
46祖旭;黄洪钟;张旭;虚拟样机技术及其发展.农业机械学报.2004.3第35卷,第2期
47冷晟;魏孝斌;王宁生;基于Pro/E的虚拟设计与制造环境的研究与开发.机械与电子2003年01期
48 Boud, A.C.; Steiner, S.J.; A new method for off-line robot programming: applications and limitations using a virtual environment, The Technology Exploitation Process, Fifth International Conference on, Publication Year: 1997, Page(s): 450 - 455
49王凯;曹西京.基于Pro/E的机械产品机构运动的仿真设计.轻工机械2006年01期
50刘辛军;汪劲松;高峰;王立平;王启明;李剑锋;并联机器人机构新构型设计的探讨.中国机械工程.2001.12.第12期
51高峰.并联机器人设计理论及其关键应用技术研究.河北工业大学学报. 2004年4月.第2期
52高洪;赵韩.并联机器人机构学理论研究综述.安徽工程科技学院学报. 2006年3月.第1期
53刘阳;冯宝富;蔡光起.并联机器人的研究现状与展望.机床与液压. 2004年.第3期
2唐新化.焊接机器人的现状及发展趋势.电焊机.2006.3
3 Bolmsjo, Gunnar ; Olsson, Magnus; Cederberg, Per ,Robotic arc welding - trends and developments for higher autonomy, Source: Industrial Robot, p 98-104, 2002
4任福深.基于PC+DSP模式的管道插接专用焊接机器人系统研究.北京工业大学博士论文.2009,2-3
5符娅波,边美华,许先果.焊接机器人的应用与发展.焊接.2006,35(11):79-81
6 G.S.Bolmsjo.Robotic Arc Welding-Programming and Control.IFAC Robot Control.1998:541-546
7 World Robot survey sales up 25 percent in 2000. Industrial Robot. 2002, 29(2):7-8
8哈恩晶.焊接机器人的应用现状与发展趋势.机械工人(热加工).2004,(5):16-18
9张柯等.移动焊接机器人的研究现状及发展趋势.2004, 8:5-9
10 Paolo D, Eugenio G, et al. IEEE Robotics and Autamation Magazine ,1996,(9):44
11 Hyosig K. IEEE Engeering in Medicine and Biology,2001,(12):44
12赵匀,武传宇,胡旭东,俞高红.农业机器人的研究进展及存在的问题.农业工程学报.2003,19(1):20-24
13 RyuKH,KimG,HanJS.Developmentofarobotic transplanter forbeding plants.JAgricEngRes.2001,78(2):141-146
14钱善华等.救灾机器人的研究现状与煤矿救灾的应用.机器人.2006,28(3):350-354
15黄政艳.焊接机器人的应用现状与技术展望[J].装备制造技术, 2007,(03)
16 Gunnar Bolmsj?, Magnus Olsson, Per Cederberg ,Robotic arc welding– trends and developments for higher autonomy, Industrial Robot,2002,Volume:29 ,Page:98– 104
17谭一炯;周方明;王江超;黄志杰.焊接机器人技术现状与发展趋势.电焊机.2006.3
18 Coldstein, B. L. M., et al, Technologies for the Integration of Manufacturing Applications, Advanced Technology Program, 1995, 5
19 Wright, Paul K., Principlcs of Open-Architecture Manufacturing, Journal of Manufacturing System, 1995, 14(3)
20陈玮,郑时雄,周学才.基于网络的开放式机器人通用控制系统的研究.华南理工大学学报(自然科学版),2001,29(5):35-37
21 William Rippen, Jim Cilsinn and Lange Flitter. Networking of Welding Applications: A Tutorial. Welding Journal. 79(1), 2000:49-53
22 Jahng-Hyon Park,Joonyoung park. Real Time Bilateral Control for Internet based TeleroboticSystem. Proceedings of the IEEE/RSJ Intl. Conf. On Intelligent Robotics and Systems, Las Vegas, Nevada. 2003:1106-1110
23 Xiao-Gang Wang, M. Moallem, R. V. Patel. An Internet-Base Distributed Multiple-Telerobot System. IEEE Transactions on Systems, Man, and Cybernetics-Part A: System and Humans. 2003, 33(5):627-633
24 Reid L. Kress, William R. Hamel, Pamela Murray, Karen Bills. Control Strategies for Teleoperated Internet Assembly. IEEE/ASME Transaction on Mechatronics, 2001, 6(4):410-416
25高胜,赵杰.基于Internet的机器人遥操作虚拟环境的关键问题.哈尔滨工业大学学报[J].2006,38(4):649-653
26祖旭,黄洪钟,张旭.虚拟样机技术及其发展.农业机械学报[J].2004,35(4):168-171
27 Shiroma, N.; Miyauchi, R.; Matsuno, F.; Mobile robot teleoperation through virtual robot ,Robot and Human Interactive Communication,The 17th IEEE International Symposium on Digital Object Identifier, Publication Year: 2008 , Page(s): 477 - 482
28霍孟友.基于的椭球面封头接管自动焊接装置.焊接学报.2005, 26(1):74~78
29闫政,梁君直,陈江.采用DSP控制的高效管道双焊炬全位置自动焊机研究.电焊机.2005,35(4):38-43
30张忠厚,武传松. GLJ-1型自行车架管连接自动焊机.焊接学报.1997,18(4):206-209
31霍孟友.基于的椭球面封头接管自动焊接装置.焊接学报.2005,26(1):74-78
32 Bahrami-Samani, M.; Agahi, M.; Moosavian, S.A.A. Design and Analysis of a Welding Robot.Automation Science and Engineering, 2006.
33 Muramatsu, M.; Namiki, N.; Koyama, R.; Suga, Y. Proceedings. Autonomous mobile robot in pipe for piping operations.International Conference on Intelligent Robots and Systems , p 2166-71 vol.3, 2000
34谢新房;王国栋;多管相贯焊接坡口数控切割研究.工程图学学报, 2007年04期
35刘永,除越兰,王克鸿,余进,杨静宇锅炉焊接机器人离线编程系统,焊接学报,2004 03期
36 Lee, D.M.A.; ElMaraghy, W.H.; ROBOSIM: a CAD-based off-line programming and analysis system for robotic manipulators. Computer-Aided Engineering Journal Volume: 7 , Issue: 5 , Publication Year: 1990 , Page(s): 141– 148
37王克鸿,刘永,余进.弧焊机器人典型工件建模与姿态规划研究.电焊机.2006,33(6):29-32
38陈志翔,卢振洋,殷树言等.焊缝位姿及焊枪位姿的模型.机械工程学报.2003,39(7):59-62
39费仁元、张慧慧.机器人机械设计和分析.北京工业大学出版社1998
40张铁谢存禧.机器人学.华南理工大学出版社2001
41杨振中;周骥平;朱兴龙.基于解耦型球关节的工业机器人控制系统研究初探.制造业自动化2006年07期
42王晓峰;陈焕明;江淑园.焊接位姿参数定义的讨论及典型工件的建模.南昌航空工业学报.2006.6,26(2):24-28
43潘炼东;黄心汉.基于PMAC的机器人控制器设计华中理工大学学报2000年4月vol.28 no4
44 pmac用户手册,北京元茂兴控制设备技术有限责任公司
45刘蕾;唐为义;原所先基于VC++与PMAC的机器人控制软件的开发机器人技术
46祖旭;黄洪钟;张旭;虚拟样机技术及其发展.农业机械学报.2004.3第35卷,第2期
47冷晟;魏孝斌;王宁生;基于Pro/E的虚拟设计与制造环境的研究与开发.机械与电子2003年01期
48 Boud, A.C.; Steiner, S.J.; A new method for off-line robot programming: applications and limitations using a virtual environment, The Technology Exploitation Process, Fifth International Conference on, Publication Year: 1997, Page(s): 450 - 455
49王凯;曹西京.基于Pro/E的机械产品机构运动的仿真设计.轻工机械2006年01期
50刘辛军;汪劲松;高峰;王立平;王启明;李剑锋;并联机器人机构新构型设计的探讨.中国机械工程.2001.12.第12期
51高峰.并联机器人设计理论及其关键应用技术研究.河北工业大学学报. 2004年4月.第2期
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