遥控焊接力觉遥示教技术研究
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摘要
在核设施修复、空间站装配和海洋工程建设等需要焊接环境,人类的生存条件十分恶劣,需要有人参与进行遥控焊接,遥控示教是遥控焊接的关键技术之一。传统的焊接机器人示教通常是利用示教盒(或示教棒)进行在线示教,这种在线示教法比较直观,但在遥控焊接环境操作人员无法到达焊接现场,通过立体视觉辅助示教,由于视觉误差,示教精度较低,不能满足遥控焊接工艺要求。激光视觉传感能够获取焊缝轮廓信息,反馈给机器人控制器实时调整焊枪位姿跟踪焊缝。但也无法适应所有遥控焊接环境,如工件表面状态对激光辅助示教有一定影响,不规则焊缝特征点提取困难,所以希望开发新的遥示教方法,以便解决不同遥控焊接条件下遥示教问题。
将力觉引入遥控焊接遥示教中,与立体视觉配合,能够完成遥控焊接遥示教任务,且信息处理不复杂,不受环境(光、烟、气雾、色彩等)的干扰,在激光视觉遥示教看不清场合仍可能“摸”得出,系统结构简单,成本低,反应灵敏度高,力觉传感与焊缝直接接触,示教精度高,为此本文提出了“遥控焊接力觉遥示教技术”的研究,通过力觉遥示教焊缝辨识模型和自适应控制模型,实现遥示教局部自适应控制,通过共享技术和视觉临场感实现人对遥控焊接遥示教宏观全局监控。
通过对激光辅助传感遥示教分析,提出建立力觉遥示教必要性,建立力觉遥示教硬件系统,提出了六维力传感器探针选择原则,分析了六维力传感器解耦原理,通过力传感器空间位置变化六维力值测定,确定六维力传感器空间变化盲区和焊缝辨识六维接触力阈值,完成了六维力传感器标定,为力觉遥示教创造条件。
为解决探针与工件接触力调整稳定性问题,建立了遥示教接触力仿人柔性控制模型。通过对遥示教的探针与焊接环境接触力分析,提出了遥控焊接接触力分段控制策略,异常情况的接触力稳定性监控决策算法,任务自适应仿人智能算法;实现了遥示教接触力仿人智能控制特征辨识、特征记忆、多模态控制和多目标决策,减小接触力振荡幅值,缩短接触力稳定时间,提高了遥示教探针与焊接工件之间力交互作用下的操作稳定性。
为克服由于机器人的振动、焊缝表面粗糙不平和电磁场干扰等因素,造成焊缝辨识力信号不稳,根据焊缝辨识受力信号变化分析,提出了用卡尔曼滤波递推方法对焊缝辨识受力信号进行的滤波处理,建立焊缝受力信号滤波
The remote welding is needed in space station assembly, ocean project construction and nuclear power equipment repairing. The tele-teaching is the key of remote welding. The teaching box is used to teach on line in traditional teaching. Because the operator can’t arrive the remote welding site, the vision sensing is used to teach robot assistantly. Owing to the error of vision, the teaching precision is too lower to meet the remote welding process. The robot controller can adjust real-time the position and pose of welding torch to track welding seam by its outline information obtained by laser vision in structured environment. But the method is not used in all remote welding environment. For example, it is difficult to extract the feature points based on laser vision in irregular or bright welding seam . So a new tele-teaching method is developed to be used in different remote welding environment.
The force sensing is introduced into tele-teaching. Cooperating with stereoscopic vision, it overcomes the difficult problem of the feature point extraction of welding seam. The force sensing information is easily processed. It is not disturbed by light, smoke, inhalator and color. The force sensing can touch the welding seam that can not be identified by the laser vision. The tele-teaching system based on force sensing has simple structure, low cost, high sensitivity and teaching precision.The tele-teaching base on force sensing is brought forward to improve the efficiency and precision of tele-teaching in remote welding. It includes two projects developed, such as using welding seam identifying model (WSIM) and adaptive control model to carry out local autonomous tele-teaching, and using sharing technology and vision telepresence to fulfill whole tele-teaching.
By analyzing tele-teaching based on laser vision, there is need to found tele-teaching system based on force sensing. It includes the hardware system, the probe select principle , the decoupling principle, and the calibration of threshold and blind section of 6 dimensional (6D) force in different space position.
The soft control model of human-simulation intelligent control (HSIC) is founded to solve the adjusting stability of touch force between probe and
将力觉引入遥控焊接遥示教中,与立体视觉配合,能够完成遥控焊接遥示教任务,且信息处理不复杂,不受环境(光、烟、气雾、色彩等)的干扰,在激光视觉遥示教看不清场合仍可能“摸”得出,系统结构简单,成本低,反应灵敏度高,力觉传感与焊缝直接接触,示教精度高,为此本文提出了“遥控焊接力觉遥示教技术”的研究,通过力觉遥示教焊缝辨识模型和自适应控制模型,实现遥示教局部自适应控制,通过共享技术和视觉临场感实现人对遥控焊接遥示教宏观全局监控。
通过对激光辅助传感遥示教分析,提出建立力觉遥示教必要性,建立力觉遥示教硬件系统,提出了六维力传感器探针选择原则,分析了六维力传感器解耦原理,通过力传感器空间位置变化六维力值测定,确定六维力传感器空间变化盲区和焊缝辨识六维接触力阈值,完成了六维力传感器标定,为力觉遥示教创造条件。
为解决探针与工件接触力调整稳定性问题,建立了遥示教接触力仿人柔性控制模型。通过对遥示教的探针与焊接环境接触力分析,提出了遥控焊接接触力分段控制策略,异常情况的接触力稳定性监控决策算法,任务自适应仿人智能算法;实现了遥示教接触力仿人智能控制特征辨识、特征记忆、多模态控制和多目标决策,减小接触力振荡幅值,缩短接触力稳定时间,提高了遥示教探针与焊接工件之间力交互作用下的操作稳定性。
为克服由于机器人的振动、焊缝表面粗糙不平和电磁场干扰等因素,造成焊缝辨识力信号不稳,根据焊缝辨识受力信号变化分析,提出了用卡尔曼滤波递推方法对焊缝辨识受力信号进行的滤波处理,建立焊缝受力信号滤波
The remote welding is needed in space station assembly, ocean project construction and nuclear power equipment repairing. The tele-teaching is the key of remote welding. The teaching box is used to teach on line in traditional teaching. Because the operator can’t arrive the remote welding site, the vision sensing is used to teach robot assistantly. Owing to the error of vision, the teaching precision is too lower to meet the remote welding process. The robot controller can adjust real-time the position and pose of welding torch to track welding seam by its outline information obtained by laser vision in structured environment. But the method is not used in all remote welding environment. For example, it is difficult to extract the feature points based on laser vision in irregular or bright welding seam . So a new tele-teaching method is developed to be used in different remote welding environment.
The force sensing is introduced into tele-teaching. Cooperating with stereoscopic vision, it overcomes the difficult problem of the feature point extraction of welding seam. The force sensing information is easily processed. It is not disturbed by light, smoke, inhalator and color. The force sensing can touch the welding seam that can not be identified by the laser vision. The tele-teaching system based on force sensing has simple structure, low cost, high sensitivity and teaching precision.The tele-teaching base on force sensing is brought forward to improve the efficiency and precision of tele-teaching in remote welding. It includes two projects developed, such as using welding seam identifying model (WSIM) and adaptive control model to carry out local autonomous tele-teaching, and using sharing technology and vision telepresence to fulfill whole tele-teaching.
By analyzing tele-teaching based on laser vision, there is need to found tele-teaching system based on force sensing. It includes the hardware system, the probe select principle , the decoupling principle, and the calibration of threshold and blind section of 6 dimensional (6D) force in different space position.
The soft control model of human-simulation intelligent control (HSIC) is founded to solve the adjusting stability of touch force between probe and
引文
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