海底管道铺设焊接机器人系统研究
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摘要
海底管道铺设全位置焊接机器人是深水管道铺设系统中重要的专用铺管设备，其稳定的工作性能及较高的焊接效率是决定铺管效率即施工经济效益的第一因素。由于海底管道铺设焊接机器人一直由国外专业公司垄断，不仅设备购置费昂贵，后期的设备维护、焊接工艺购置费用也价值不菲，国内又不具备海底管道铺设焊接机器人设计制造能力，这严重制约着南海深水油气田的勘探开发进程。为满足我国深水油气田开发工程的需要，打破国外技术垄断，实现海底管道铺设焊接机器人的国产化，需要对海底管道铺设焊接机器人的机构设计、控制系统体系结构、关键技术及焊接工艺等问题进行深入研究。
本文在充分调研国内外管道焊接机器人研究现状的基础上，根据海底管道铺设全位置焊接的工艺特征，分析了海底管道铺设焊接系统结构，提出了海底管道铺设焊接机器人系统总体设计方案，明确了需要研究的关键技术。主要的研究工作如下：
1、研究了海底管道铺设焊接机器人控制系统的开放式体系结构。针对传统机器人控制系统无法解决多总线异构设备之间的实时数据交换问题。提出了基于EtherCAT的多总线异构网络横向互联的实时控制数据交换模型。采用基于Windows的软PLC过程数据映射技术实现异构系统的数据交换及各功能子系统间的协同控制。以开放式控制网络体系结构研究为理论基础，对海底管道铺设焊接机器人控制系统的总体结构及各功能子系统进行了设计，形成了基于CAN-open的数字化焊接电源控制、运动控制、角度传感、电气辅助、完整的数据管理和在线监控等功能单元与一体的综合控制系统。设计的控制系统开放性和可扩展性好，有利于电弧传感、接触传感、激光跟踪等智能化应用功能的扩展。
2、对海底管道铺设焊接机器人运动控制系统进行了研究。采用正弦波驱动无刷直流电动机的id=0矢量控制策略，有效地抑制直流无刷电机的电磁转矩脉动，提高了驱动电机的控制精度；摆动机构在采用电流内环速度外环控制结构的基础上，加入低通滤波器和陷波滤波器。低通滤波器能抑制系统中的高频干扰，陷波器的使用剔除了摆动机构传动环节中存在弹性变形导致的机械共振点,提高了摆动机构控制精度。采用激光测距传感器测量齿间隙量,并对其进行补偿,保证了摆动机构摆宽的精度。
3、针对行走机构双电机驱动的严格同步要求，采用“分时通信、同步执行”的协议模型实现同步组单轴速度指令的同步执行。由于刚性连接的两行走电机间的耦合关系导致的负载不均衡及两轴实际速度不协调问题,提出了主从速度跟随单轴变增益同步控制算法，测试结果表明该算法保证了两轴同步运动的精度，可保证整个焊接过程的平稳运行。
4、分析了系统中关键设备CAN-open通信模块的接口特性，研究了CAN-open设备模型原理及主站单元与数字化焊接电源、伺服驱动器等从站单元的数据交换过程，利用SDO通信方式配置设备对象词典，通过PDO通信方式确保了多个功能子系统数据透明传输和一体化协同控制的顺利实现。
5、研究了海底管道铺设优质高效的流水生产线式焊接作业模式,依据制定的流水线生产工艺，构建了海底管道铺设生产线多级控制网络平台。研究了焊接工作站双焊接机器人协同操作实现自动焊道覆盖功能的技术手段。采用自动化设备规范通信技术及实时以太网技术能实现双机器人控制系统间的数据交换，利用双机器人协同操作控制策略读取共享变量，按照协同操作控制逻辑能保证起弧与停弧位置一致性，能使焊接接头形成无缺陷对接。
6、针对管道焊接工艺特点，分析了实现电弧传感在管道焊接应用中的技术难点，研制了适宜于管道焊接的高速扫描焊炬，用于较高摆动频率下的电弧传感研究。在搭建的焊接试验平台上进行了电弧传感的初步研究，提出了边界区域电流均值法提取焊缝横向偏差，取得了一定的跟踪效果，为更深入的研究基于电弧传感的管道焊接焊缝跟踪系统打下基础。
7、海管铺设全位置焊接工艺研究。以海底管道铺设焊接机器人为对象，研究主要焊接工艺参数的匹配规律，形成了一套用于指导焊接工艺参数的调节规范。采用双炬焊接工艺及窄间隙坡口和背部铜衬垫内对口器等有效技术手段,进行管道焊接工艺试验，确立了一套海底管道铺设焊接机器人的焊接工艺参数。进行了铺管焊接机器人海上焊接试验，焊接效率高，焊缝成形良好。通过海上试验诸多环节的考验，焊接样机的技术性能完全满足海上应用需要。
以上研究成果为海底管道铺设焊接机器人工程样机的制造提供依据，为深入开展智能化关键技术的研究奠定了基础，将会有效的推进海底管道铺设焊接机器人的实际工程化应用进程。
All-position welding robot which is used to submarine pipeline laying isthe important special equipment of deep-water pipeline laying system. Theproductivity and reliability are most essential features of thesubmarine pipeline laying robot. Because submarine pipeline laying weldingrobot has been monopolized by foreign professional companies, the equipmentis not only expensive, but also its maintenance and welding process cost isexpensive, above all, our country don’t have the ability to design andmanufacture the submarine pipeline laying welding robot, so these seriouslyhamper the exploration and development of South Sea oil and gas fields. Inorder to meet the needs of develop deep-water oil and gas fields, to break themonopoly of foreign technology and to achieve the localization of submarinepipeline laying welding robot, we must furtherly study the mechanical design,control system architecture, key technology and welding process of submarinepipeline laying welding robot.
Based on the domestic and foreign research situation of pipelinewelding robot and the process characteristic of submarine pipeline layingall-position welding, the architecture of submarine pipeline laying welding system was analyzed, the whole design scheme and key technology ofsubmarine pipeline laying welding robot system were proposed. Themain research work follows:
1. The open system structure of submarine pipeline welding robot controlsystem has been studied. The real-time control network data exchange modelbased on EtherCAT and real-time transverse interconnection fieldbus isestablished. Soft PLC process data mapping technology based on Windows isused to achieve data exchange of heterogeneous system and cooperationcontrol between functional subsystems. On the theoretical basis of opencontrol network architecture, the overall structure of the submarine pipelinelaying welding robot control system and functional subsystems are designed.Digital welding power based on CAN-open, motion control, angle sensing,electricity and gas auxiliary unit, a complete data management and on-linemonitoring functional unit is integrated in control system. Opening controlsystem is characterized by strong data processing and expandable ability,which can be extended to a number of intelligent applications, such as arcsensor, contact sensor, laser tracking.
2. For the BLDCM which has a trapezoidal back-EMF，this dissertationproposes a novel id=0vector control method，it can effectively minimize thetorque ripple caused by distortion of the back-EMF and improve the precisionof motor control. Using double closed loops PID controller with velocity andcurrent, low-pass filters, and notch filters. The high frequency interferences in system were suppressed by low-pass filter, the machinery vibration atresonance point in pulling and rotating mechanism are attenuated by digitalnotch filter, so improving the control accuracy of the oscillation mechanism.The accuracy of oscillation width mainly depends on the gear gap measuredby laser displacement sensor and compensation.
3. In allusion to the strict demand of synchronization of dual motordriving the running mechanism, the profile velocity operating mode using forvector group based on CAN-open protocol is presented, a novel protocolmodel named “communication by time-sharing and executing onsynchronization” was adopted for simultaneous executing velocity command.Due to a load imbalance problem and the discordance of two-axis actualvelocity caused by the coupling relationships between two drive motor byrigid joint, The master-slave speed follower arithmetic of dual-motor drivenwelding robot is proposed under the various loads. Experimentation resultindicates that the accuracy of two-axle synchronous movement and theoperation stability of welding robot are ensured by using the algorithm.
4. Analysis of module's interface features of key equipment based onCAN-open communication, CAN-open device model principle and dataexchange process of the master-slave unit have been studied. By means ofSDO communication way to deploy equipmental Objects Dictionary, PDOcommunication is used to achieve process data fast exchange and cooperationcontrol between functional subsystems.
5. The welding operation mode that submarine pipeline laying productionlines has high welding quality and efficiency has been studied. According toproduction technology of assembly line, a multi-level control networkplatform is constructed to realize effective distribution control and cooperativemanagement for the whole assembly line. The technical means that dual-robotare cooperatively controlled to achieve the automatic weld bead overlayfunction in a welding workstations has been studied. The thesis achieves thedata exchange between the dual-robot control system by means of automationequipment specification communications technology and real-time Ethernettechnology, it also reads the shared variability by the dual-robot collaborativecontrol strategy, guarantees the position consistence between arc and stoppingthe arc, and makes the welding joints no defects.
6. In allusion to the characteristics of pipeline welding process, technicaldifficulties achieving arc sensor in pipe welding were analyzed, high speedoscillation torch which is suitable for pipe welding was developed and be usedto study arc sensor in a higher oscillating frequency. The welding test platformwas built to preliminarily evaluate the sensitivity of arc sensor system. Thecurrent average of the border algorithm has been proposed to extract thelateral deviation of welding bead. The result showed that the trackingalgorithm is feasible, it’s lay the foundation for furtherly study pipe weldingbased on arc sensor.
7. The welding parameters matching rule of submarine pipeline laying welding robot was studied. A set of welding parameters adjustmentspecification has been obtained. These technological means which containsdual-torch welding procedure, narrow gap groove, an internal line-up clampwith copper was used in pipe welding test. With the welding proceduredeveloped in the welding laboratory, a series of sound welds have beenobtained efficiently in offshore pipeline laying welding site at Bohai Sea.
These research results would provide the references for submarinepipeline laying welding robot design and manufacturing, and also lays thefoundation of further studies on intelligent key technologies. The content ofthis dissertation will effectively promote the process of practical engineeringapplications for submarine pipeline laying welding robot.
本文在充分调研国内外管道焊接机器人研究现状的基础上，根据海底管道铺设全位置焊接的工艺特征，分析了海底管道铺设焊接系统结构，提出了海底管道铺设焊接机器人系统总体设计方案，明确了需要研究的关键技术。主要的研究工作如下：
1、研究了海底管道铺设焊接机器人控制系统的开放式体系结构。针对传统机器人控制系统无法解决多总线异构设备之间的实时数据交换问题。提出了基于EtherCAT的多总线异构网络横向互联的实时控制数据交换模型。采用基于Windows的软PLC过程数据映射技术实现异构系统的数据交换及各功能子系统间的协同控制。以开放式控制网络体系结构研究为理论基础，对海底管道铺设焊接机器人控制系统的总体结构及各功能子系统进行了设计，形成了基于CAN-open的数字化焊接电源控制、运动控制、角度传感、电气辅助、完整的数据管理和在线监控等功能单元与一体的综合控制系统。设计的控制系统开放性和可扩展性好，有利于电弧传感、接触传感、激光跟踪等智能化应用功能的扩展。
2、对海底管道铺设焊接机器人运动控制系统进行了研究。采用正弦波驱动无刷直流电动机的id=0矢量控制策略，有效地抑制直流无刷电机的电磁转矩脉动，提高了驱动电机的控制精度；摆动机构在采用电流内环速度外环控制结构的基础上，加入低通滤波器和陷波滤波器。低通滤波器能抑制系统中的高频干扰，陷波器的使用剔除了摆动机构传动环节中存在弹性变形导致的机械共振点,提高了摆动机构控制精度。采用激光测距传感器测量齿间隙量,并对其进行补偿,保证了摆动机构摆宽的精度。
3、针对行走机构双电机驱动的严格同步要求，采用“分时通信、同步执行”的协议模型实现同步组单轴速度指令的同步执行。由于刚性连接的两行走电机间的耦合关系导致的负载不均衡及两轴实际速度不协调问题,提出了主从速度跟随单轴变增益同步控制算法，测试结果表明该算法保证了两轴同步运动的精度，可保证整个焊接过程的平稳运行。
4、分析了系统中关键设备CAN-open通信模块的接口特性，研究了CAN-open设备模型原理及主站单元与数字化焊接电源、伺服驱动器等从站单元的数据交换过程，利用SDO通信方式配置设备对象词典，通过PDO通信方式确保了多个功能子系统数据透明传输和一体化协同控制的顺利实现。
5、研究了海底管道铺设优质高效的流水生产线式焊接作业模式,依据制定的流水线生产工艺，构建了海底管道铺设生产线多级控制网络平台。研究了焊接工作站双焊接机器人协同操作实现自动焊道覆盖功能的技术手段。采用自动化设备规范通信技术及实时以太网技术能实现双机器人控制系统间的数据交换，利用双机器人协同操作控制策略读取共享变量，按照协同操作控制逻辑能保证起弧与停弧位置一致性，能使焊接接头形成无缺陷对接。
6、针对管道焊接工艺特点，分析了实现电弧传感在管道焊接应用中的技术难点，研制了适宜于管道焊接的高速扫描焊炬，用于较高摆动频率下的电弧传感研究。在搭建的焊接试验平台上进行了电弧传感的初步研究，提出了边界区域电流均值法提取焊缝横向偏差，取得了一定的跟踪效果，为更深入的研究基于电弧传感的管道焊接焊缝跟踪系统打下基础。
7、海管铺设全位置焊接工艺研究。以海底管道铺设焊接机器人为对象，研究主要焊接工艺参数的匹配规律，形成了一套用于指导焊接工艺参数的调节规范。采用双炬焊接工艺及窄间隙坡口和背部铜衬垫内对口器等有效技术手段,进行管道焊接工艺试验，确立了一套海底管道铺设焊接机器人的焊接工艺参数。进行了铺管焊接机器人海上焊接试验，焊接效率高，焊缝成形良好。通过海上试验诸多环节的考验，焊接样机的技术性能完全满足海上应用需要。
以上研究成果为海底管道铺设焊接机器人工程样机的制造提供依据，为深入开展智能化关键技术的研究奠定了基础，将会有效的推进海底管道铺设焊接机器人的实际工程化应用进程。
All-position welding robot which is used to submarine pipeline laying isthe important special equipment of deep-water pipeline laying system. Theproductivity and reliability are most essential features of thesubmarine pipeline laying robot. Because submarine pipeline laying weldingrobot has been monopolized by foreign professional companies, the equipmentis not only expensive, but also its maintenance and welding process cost isexpensive, above all, our country don’t have the ability to design andmanufacture the submarine pipeline laying welding robot, so these seriouslyhamper the exploration and development of South Sea oil and gas fields. Inorder to meet the needs of develop deep-water oil and gas fields, to break themonopoly of foreign technology and to achieve the localization of submarinepipeline laying welding robot, we must furtherly study the mechanical design,control system architecture, key technology and welding process of submarinepipeline laying welding robot.
Based on the domestic and foreign research situation of pipelinewelding robot and the process characteristic of submarine pipeline layingall-position welding, the architecture of submarine pipeline laying welding system was analyzed, the whole design scheme and key technology ofsubmarine pipeline laying welding robot system were proposed. Themain research work follows:
1. The open system structure of submarine pipeline welding robot controlsystem has been studied. The real-time control network data exchange modelbased on EtherCAT and real-time transverse interconnection fieldbus isestablished. Soft PLC process data mapping technology based on Windows isused to achieve data exchange of heterogeneous system and cooperationcontrol between functional subsystems. On the theoretical basis of opencontrol network architecture, the overall structure of the submarine pipelinelaying welding robot control system and functional subsystems are designed.Digital welding power based on CAN-open, motion control, angle sensing,electricity and gas auxiliary unit, a complete data management and on-linemonitoring functional unit is integrated in control system. Opening controlsystem is characterized by strong data processing and expandable ability,which can be extended to a number of intelligent applications, such as arcsensor, contact sensor, laser tracking.
2. For the BLDCM which has a trapezoidal back-EMF，this dissertationproposes a novel id=0vector control method，it can effectively minimize thetorque ripple caused by distortion of the back-EMF and improve the precisionof motor control. Using double closed loops PID controller with velocity andcurrent, low-pass filters, and notch filters. The high frequency interferences in system were suppressed by low-pass filter, the machinery vibration atresonance point in pulling and rotating mechanism are attenuated by digitalnotch filter, so improving the control accuracy of the oscillation mechanism.The accuracy of oscillation width mainly depends on the gear gap measuredby laser displacement sensor and compensation.
3. In allusion to the strict demand of synchronization of dual motordriving the running mechanism, the profile velocity operating mode using forvector group based on CAN-open protocol is presented, a novel protocolmodel named “communication by time-sharing and executing onsynchronization” was adopted for simultaneous executing velocity command.Due to a load imbalance problem and the discordance of two-axis actualvelocity caused by the coupling relationships between two drive motor byrigid joint, The master-slave speed follower arithmetic of dual-motor drivenwelding robot is proposed under the various loads. Experimentation resultindicates that the accuracy of two-axle synchronous movement and theoperation stability of welding robot are ensured by using the algorithm.
4. Analysis of module's interface features of key equipment based onCAN-open communication, CAN-open device model principle and dataexchange process of the master-slave unit have been studied. By means ofSDO communication way to deploy equipmental Objects Dictionary, PDOcommunication is used to achieve process data fast exchange and cooperationcontrol between functional subsystems.
5. The welding operation mode that submarine pipeline laying productionlines has high welding quality and efficiency has been studied. According toproduction technology of assembly line, a multi-level control networkplatform is constructed to realize effective distribution control and cooperativemanagement for the whole assembly line. The technical means that dual-robotare cooperatively controlled to achieve the automatic weld bead overlayfunction in a welding workstations has been studied. The thesis achieves thedata exchange between the dual-robot control system by means of automationequipment specification communications technology and real-time Ethernettechnology, it also reads the shared variability by the dual-robot collaborativecontrol strategy, guarantees the position consistence between arc and stoppingthe arc, and makes the welding joints no defects.
6. In allusion to the characteristics of pipeline welding process, technicaldifficulties achieving arc sensor in pipe welding were analyzed, high speedoscillation torch which is suitable for pipe welding was developed and be usedto study arc sensor in a higher oscillating frequency. The welding test platformwas built to preliminarily evaluate the sensitivity of arc sensor system. Thecurrent average of the border algorithm has been proposed to extract thelateral deviation of welding bead. The result showed that the trackingalgorithm is feasible, it’s lay the foundation for furtherly study pipe weldingbased on arc sensor.
7. The welding parameters matching rule of submarine pipeline laying welding robot was studied. A set of welding parameters adjustmentspecification has been obtained. These technological means which containsdual-torch welding procedure, narrow gap groove, an internal line-up clampwith copper was used in pipe welding test. With the welding proceduredeveloped in the welding laboratory, a series of sound welds have beenobtained efficiently in offshore pipeline laying welding site at Bohai Sea.
These research results would provide the references for submarinepipeline laying welding robot design and manufacturing, and also lays thefoundation of further studies on intelligent key technologies. The content ofthis dissertation will effectively promote the process of practical engineeringapplications for submarine pipeline laying welding robot.
引文
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