球罐全位置焊接机器人智能控制系统

Intelligent Control System of All-position Welding Robot

关键词:  焊接机器人  智能控制  自动焊接  视觉伺服系统

Key words:  welding robot  intelligent control  automatic welding  vision servo system

摘要:

研制了一种用于球罐全位置焊接机器人的智能控制系统。采用两点式视觉伺服反馈系统,以预先画出的坡口平行线为机器人的目标运动轨迹,实现机器人在多层多道焊接时的重复自动跟踪。系统选用工业控制级可编程控制器作为核心控制器件,外加自制的电机驱动等辅助电路,实现了对五自由度球罐焊接机器人的柔性磁轮的控制、跟踪机构的控制和摆动机构的控制,并使之协调联动,满足焊接过程的要求。此系统控制下的球罐焊接机器人的主要创新点是,实现了无导轨自动焊接全位置焊缝与多层多道焊接的自动跟踪。焊接工艺评定试验结果表明,此焊接机器人自动跟踪精度高,焊缝质量好,工作稳定可靠,已实现小批量试生产,产品也已用于实际焊接生产。

Abstract:

An intelligent control system for the all-position and multi-layer welding robot of spherical tanks was developed. In this system a 2-point vision servo system was sued to guide the welding robot following a line parallel to the groove repeatedly. An industrial controller PLC was used as the CPU. In addition several auxiliar processing and driving circuits had been used to control the robot's 5 freedom parts such as the flexible magnetic wheel, the tracking mechanism and the swing mechanism to work coordinately. The welding robot under the control of this intelligent system can realize all-position and multi-layer welding of a ball tank or a cylinder tank. There are two patented innovation points in the all-position welding robot controlled by this system. The first is the flexible magnetic wheel used to make it possible for the robot to attach to and roll free on the tank surface without any rail. The second is the two-stage vision servo system, the mainfunction of which is to guide the welding robot and the torch to go along the welding line. The welding tests show that the welding robot can make the all-position and multi-layer welds with high tracking accuracy, excellent quality and reliable behavior.