城轨客车车顶点焊焊接规划及仿真
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摘要
本文介绍了不锈钢城轨车车体结构及制造工艺特点,分析了城轨车车顶点焊机器人工位的制造资源(点焊机器人、焊钳等)及点焊工艺特点等各方面因素对焊接规划的影响,并完成了该工位的焊接规划和仿真。论文主要研究内容包括:对车顶焊接工位进行设计,确定了机器人的数量、点焊机器人的放置方式及放置位置等;分析了车顶工位焊接规划的特点、任务和实现途径,以提高车顶工位生产效率、减少生产时间为目的,建立了抽象为旅行商问题的焊接规划问题的数学模型,对比了各种算法的优劣,结合本文的实际情况采用遗传算法求解焊接规划问题,给出了遗传算法的各步操作,并用VC++程序得到计算结果;选用Delmia做为虚拟仿真平台,完成了城轨车车顶工位在虚拟环境下的建模、布局和仿真,实现了机器人工作过程中的防碰撞、干涉检测,机器人位姿的调整和轨迹的优化等仿真试验,并对仿真结果进行了离线编程。通过实践证明了采用数学算法和仿真相结的方法进行焊接规划效率高、用时少、可以避免因计算失误而带来的损失,有较大的实用价值。
With the continuous development of our national economy, the urbanization of our country is put on agenda, as an inevitable process of urbanized, the urban railway carriage product will have a new period of rapid development. For its low cost, low energy consumption, friendly to the environment, in line with sustainable development and so on, stainless steel urban railway carriage became the best choice of urban rail vehicle. Because the roof is a very important part of the urban railway carriage, a reasonable plan to this station will not only increase the product efficiency but also will save time and so on, it’s very meaningful to shorten the entire product cycle, and also a good guidance to the design and plan of other station.
With the continuous development of science and technology, globalized and intensified competition, in order to reduce costs, improve productivity and save time, virtual manufacturing technology is being increasingly used in automobile, aviation, aerospace and other fields of actual production, and put forward the concept of“Digital factory”. Stainless steel roof station is a typical spot welding robot station, in order to design and plan rationally, we fully study the characteristics of stainless steel roof production, learn the experience of automobile industry, use the virtual manufacturing technology to design and plan the roof of the urban subway carriage in virtual environment..
Weld planning involves many factors, such as the workplace structure, welding technologies, welding clamp, robot and so on. So before planning, we should know the roof of the urban railway station very well, we study the roof component and the welding spot on it to make out the influence of the technology characteristics, the number of welding spot, the location of welding spot, the property of welding spot to the weld planning. We analyze the affection of the spot-welding technologies to this station, such as the influence of the welding sequence to the shunting current and welding deformation. We learn the manufacturing resources, such as the robot’s position, posture, movement, clash and interference and so on.
We design the station of carriage roof, determine the reasonable amount of welding robot, the placement of robot and the placement location., discuss the task and realization of weld planning, in order to improve the rationality of welding robot station and reduce the production cycle to increase the welding productivity, we have to find a good welding sequence. The mathematical model of the welding sequence optimization is travelling salesman problem, we compare the advantages and disadvantages of various algorithms, considering the actual situation of the research, we choose genetic algorithm as the solution of the question, determine the steps, then use the VC++ to implement the program, find the optimal solution of welding sequence.
We use Delmia software as a virtual simulation platform, draw on the experience of automobile industry, try to plan and simulate the station of urban railway carriage. First, we finish the physical modeling, create the 3D modeling of the part, fixtures, robots, welding guns and so on, put them into the simulation environment, and make the layout. We simulate the welding process, create the welding path, detect the clash and interfere, adjust the gesture of robot, optimize the robot’s trace to obtain a reasonable weld process planning, and do the off-line programming.
In this paper, we use mathematical algorithms and visual simulation to plan the station of urban railway carriage roof, this method save planning time and working time, reduce manufacturing costs, improve the robot’s capacity, create a considerable economic benefits, it is also a good guidance for the further study.
With the continuous development of our national economy, the urbanization of our country is put on agenda, as an inevitable process of urbanized, the urban railway carriage product will have a new period of rapid development. For its low cost, low energy consumption, friendly to the environment, in line with sustainable development and so on, stainless steel urban railway carriage became the best choice of urban rail vehicle. Because the roof is a very important part of the urban railway carriage, a reasonable plan to this station will not only increase the product efficiency but also will save time and so on, it’s very meaningful to shorten the entire product cycle, and also a good guidance to the design and plan of other station.
With the continuous development of science and technology, globalized and intensified competition, in order to reduce costs, improve productivity and save time, virtual manufacturing technology is being increasingly used in automobile, aviation, aerospace and other fields of actual production, and put forward the concept of“Digital factory”. Stainless steel roof station is a typical spot welding robot station, in order to design and plan rationally, we fully study the characteristics of stainless steel roof production, learn the experience of automobile industry, use the virtual manufacturing technology to design and plan the roof of the urban subway carriage in virtual environment..
Weld planning involves many factors, such as the workplace structure, welding technologies, welding clamp, robot and so on. So before planning, we should know the roof of the urban railway station very well, we study the roof component and the welding spot on it to make out the influence of the technology characteristics, the number of welding spot, the location of welding spot, the property of welding spot to the weld planning. We analyze the affection of the spot-welding technologies to this station, such as the influence of the welding sequence to the shunting current and welding deformation. We learn the manufacturing resources, such as the robot’s position, posture, movement, clash and interference and so on.
We design the station of carriage roof, determine the reasonable amount of welding robot, the placement of robot and the placement location., discuss the task and realization of weld planning, in order to improve the rationality of welding robot station and reduce the production cycle to increase the welding productivity, we have to find a good welding sequence. The mathematical model of the welding sequence optimization is travelling salesman problem, we compare the advantages and disadvantages of various algorithms, considering the actual situation of the research, we choose genetic algorithm as the solution of the question, determine the steps, then use the VC++ to implement the program, find the optimal solution of welding sequence.
We use Delmia software as a virtual simulation platform, draw on the experience of automobile industry, try to plan and simulate the station of urban railway carriage. First, we finish the physical modeling, create the 3D modeling of the part, fixtures, robots, welding guns and so on, put them into the simulation environment, and make the layout. We simulate the welding process, create the welding path, detect the clash and interfere, adjust the gesture of robot, optimize the robot’s trace to obtain a reasonable weld process planning, and do the off-line programming.
In this paper, we use mathematical algorithms and visual simulation to plan the station of urban railway carriage roof, this method save planning time and working time, reduce manufacturing costs, improve the robot’s capacity, create a considerable economic benefits, it is also a good guidance for the further study.
引文
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[3]肖田元,郑会永等.虚拟制造体系结构研究[J].计算机集成制造系统-CIMS,1992(2):34-38.
[4] WORNH,FREY D,KEITEL J.Digital factory planning and running enterprises of the future [A].Industrial Electronics Society,IECON 2000.26th Annual Conference of the IEEE[C].IEEE,2000:1286-1291.
[5]王金庆.数字化工厂及其关键技术研究[D].南京:南京航空航天大学,2001.
[6]郑顺水.生产线仿真技术研究.先进制造技术,2004,23(4):22-24.
[7]李玮.关于旅行商问题的改进遗传算法[D].重庆:重庆大学,2004.
[8]柴仁民.白车身侧围外板总成机器人工位的建模、规划及仿真[D].成都:电子科技大学,2008.
[9] HIFI , MHAND . Dynamic Programming and Hill-Climbing Techniques for Constrained Two-Dimensional Cutting Stock Problems.Kluwer Academic Publishers,Dordrecht ,Netherlands,March 2004,8(1):65～84.
[10]宋翔,聂义勇,储诚斌.无限制背包问题的爬山算法.小型微型计算机系统,2004(7):1352～1355.
[11]李艳萍,刘海江.基于改进爬山法的白车身生产线焊点规划方法.汽车技术.2008,8:55-59.
[12] COLORNI A , DORIGO M , MANIEZZO V . Ant system for job-shop scheduling[J].Belgian Journal of Operations Research,Statistics and ComputerScience,1994,34(1):39-54.
[13] DORIGO M,MANIEZZO V, COLORNI A..The ant system: optimization by a colony of cooperating agents[J].IEEE Transactions on Systems,Man,and Cybernetics-Part B,1996,26(1):28-41.
[14] DORIGO M, GAMBARDELLA L M .Ant colony system:A cooperative learning approach to the traveling salesman problem[J] . IEEE Transactions on Evolutionary Computation,1997,1(1):53-66.
[15]陈佑健.蚁群算法的改进及在TSP问题上的仿真验证.计算机工程与设计,2006,27(14):52-56.
[16] HOLLAND.Adaptation in Natural and Artificial Systems.Ann Arbor: University of Michigan press,1975,100-103.
[17] J.D.BAGLEY.The behavior of adaptive systems which employ genetic and correlation algorithms.University of Michigan..1967.
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[19] HOPFIELD J J,TANK D W.Neural computation of decisions in optimization problems[J].Biological Cybernetics,,1985,52(3):141~152.
[20] HOPFIELD J J,TANK D W.Computing with neural circuits:a model[J].Science,1986,233:625~633.
[21]雷建平,沈成武,闻冀骏.货郎担问题与单亲遗传算法.武汉理工大学学报,2003 11(20):81-83.
[22]胡守仁,于少波,戴葵等.神经网络导论.北京:国防大学出版社.
[23]焦李成.神经网络的应用与实现[M] .西安:西安电子科技大学出版社, 1993.
[24]穆文全,廖晓峰,虞厥邦.基于遗传算法和BP算法的多层感知机杂交训练算法[J].电子科学学刊,1997(2)19:190-194.
[25]李伟.先进制造技术.北京:机械工业出版社,2005.
[26]肖田元,韩向利,王新龙.虚拟制造的定义与关键技术.清华大学学报(自然科学版).1998,38:102-106.
[27]朱名铨,张树生.虚拟制造系统与实现.西北工业大学出版社,2001.
[28] WIENS.G.J.An overview of virtual manufacturing.Virtual manufacturing proceeding of 2nd agile manufacturing conference(AMC’95) , Albuquerque , New Mexico ,USA1995.ERI Press.233-243.
[29] KIMURA F.Product and Process modeling as a kernel for virtual manufacturing environment [J].Annual of The CIRP,1993,42(I):85-93.
[30] MASAHIKO ONOSATO,KAZUAKI IWATA.Development of a Virtual Manufacturing System by Integrating Product Models and Factory Models[J].Annals of the CIRP,1993,42(1):475-478.
[31]庄剑波,于洋,朱盛镭.虚拟现实技术在汽车工业中的应用.上海汽车,1998(9):23-28.
[32]贾广飞,葛敬霞,印建平.虚拟制造技术及其在我国的发展策略[J].现代制造工程,2005(7)47:116-118.
[33]陆平,张浩,马玉敏.数字化工厂及其与企业信息系统的集成.成组技术与生产现代化.2005,22(2):22-25.
[34] YONGKANG MA , ZEMING Wang , HUI LI . Simulation and Optimizing of Work-station of Body-in-white Welding Based on ROBCAD . Harbin : International conference on Mechatronics and Automation[C].2007,5:2276-2281.
[35] WAN DONG,XIAO TING TENG.Off-line programming of Spot-weld Robot for Car-body in White Based on Robcad.Harbin:International conference on Mechatronics and Automation[C].2007.5:763-768.
[36]尚校. DELMIA在汽车白车身焊装领域的应用.http://articles.e-Work.net.cn/CAE/Anicle49280.htm,2007-11-27.
[37]张小江,高秀华.机器人仿真研究及运动学动力学分析[D].长春:吉林大学机械学院.2006.
[38]王家海,庞旭旻.基于DELMIA/Robotics的白车身焊接机器人路径仿真研究[J].机电产品开发与创新.2009,3(1):1-4.
[39]刘海江,茆凡.白车身侧围工位仿真技术研究[J].机械与电子.2006,2:53-55.
[40]赵小宁.谈不锈钢车辆制造技术[J].制造工程设计.2004,7:50-51.
[41]茆凡.白车身侧围焊点任务组合优化研究[D].上海:同济大学,2006,3.
[42]赵熹华.压力焊[M].机械工业出版社,2003.
[43]张家菊,张玉萍.汽车车身电阻点焊焊点强度影响因素的分析.焊接技术,1995(5):8-11.
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