基于焊缝激光跟踪技术的波纹板焊接机器人控制系统研发

发布时间：2019-06-22 12:19

【摘要】：随着我国工业化自动化水平的不断提高,以及“中国制造2025”的不断推进,作为自动化设备的主要力量,工业机器人得到越来越多的关注。近些年随着波纹板在货车车厢、集装箱等行业的广泛应用,波纹板焊接机器人的需求越来越大。因此开发一款波纹板焊接机器人系统即满足了市场的需求,也符合“中国制造2025”指南中所支持高端装备制造与机器人重点支持的领域。在系统开发之前,首先对波纹板的制造工艺、类型、焊缝特点进行了分析;在此基础上确定了以二氧化碳保护焊作为波纹板的焊接方式;分析了不同板厚下焊丝直径、焊接电压、焊接电流、气体压力等参数的选择原则;确立了控制电压和给定电压、给定电流的关系式,使得可以通过上位机软件实现对电压和电流的调节。在研究焊接工艺的基础上,分析了波纹板焊接机器人的机械结构,并对其控制系统整体方案和硬件进行了设计。波纹板焊接机器人的机械结构主要包括:机器人本体结构和输送夹紧结构。机器人本体采用直角坐标结构,主要包括X轴、Y轴、Z轴、C轴,各个运动轴在焊接过程中具有不同作用,这也是各个运动轴的设计来源,而输送夹紧结构则是根据上料、夹紧、下料等工艺过程进行的设计;在机器人机械结构分析的基础上,建立了以固高运动控制器为核心的波纹板焊接机器人的控制系统,并对其硬件接口电路进行了设计。作为机器人的“眼睛”,激光跟踪器的选用及检测状况的分析是系统运行的重要前提。本系统选用日本基恩士公司的LK-G型激光跟踪器,并确立了交叉的安装方式来获取横向和竖向的位置信息;为了得到实际的位置信息,确定了采用两点标定的方法标定激光跟踪器;并通过对比确定采用RS-232作为运动控制器与激光跟踪器的通讯方式。在焊接工艺和硬件结构的研究基础上,开发了波纹板焊接机器人软件系统。主要包括:人机界面设计和功能模块设计。人机界面包括:主界面、手动界面、自动界面、I/O诊断界面、系统参数界面、加工参数界面;功能模块设计主要包括:回零模块、通讯模块、焊接加工模块、加工暂停模块、加工继续模块、I/O诊断模块、参数设置模块以及摆枪模块设计。为了验证系统的稳定性并检验焊接效果,对多块波纹板进行了焊接实验,从最后的焊接效果可以得出:本系统能焊接出比较美观完整的焊缝。
[Abstract]:With the continuous improvement of the level of industrialization automation in China and the continuous promotion of "made in China 2025", as the main force of automation equipment, industrial robots have received more and more attention. In recent years, with the wide application of wavy plate in freight car, container and other industries, the demand of wavy plate welding robot is increasing. Therefore, the development of a wavy plate welding robot system not only meets the needs of the market, but also meets the key areas of high-end equipment manufacturing and robot support in the "made in China 2025" guide. Before the development of the system, the manufacturing process, type and weld characteristics of the corrugated plate are analyzed, on the basis of which the carbon dioxide shielded welding is determined as the welding mode of the wavy plate, and the selection principles of welding wire diameter, welding voltage, welding current, gas pressure and other parameters under different plate thickness are analyzed. The relationship between the control voltage and the given current is established, so that the voltage and current can be adjusted by the upper computer software. On the basis of studying the welding technology, the mechanical structure of the wavy plate welding robot is analyzed, and the overall scheme and hardware of the control system are designed. The mechanical structure of wavy plate welding robot mainly includes robot body structure and conveying clamping structure. The robot body adopts rectangular coordinate structure, which mainly includes X axis, Y axis, Z axis and C axis. Each moving shaft plays different roles in the welding process, which is also the design source of each moving shaft, while the conveying clamping structure is designed according to the process of feeding, clamping and cutting. Based on the analysis of the mechanical structure of the robot, the control system of the wavy plate welding robot based on the fixed height motion controller is established, and its hardware interface circuit is designed. As the "eye" of robot, the selection of laser tracker and the analysis of detection condition are important prerequisites for the operation of the system. In this system, the LK- G laser tracker of Keenz Company of Japan is selected, and the cross installation mode is established to obtain the transverse and vertical position information. In order to obtain the actual position information, the two-point calibration method is used to calibrate the laser tracker, and the communication mode between the motion controller and the laser tracker is determined by comparison. Based on the research of welding technology and hardware structure, the software system of wavy plate welding robot is developed. Mainly includes: man-machine interface design and functional module design. The man-machine interface includes: main interface, manual interface, automatic interface, I / O diagnostic interface, system parameter interface, machining parameter interface; functional module design mainly includes: zero return module, communication module, welding processing module, machining pause module, machining continuation module, I / O diagnosis module, parameter setting module and swing gun module design. In order to verify the stability of the system and test the welding effect, the welding experiments of multiple wavy plates are carried out. From the final welding effect, it can be concluded that the system can weld a more beautiful and complete weld.
【学位授予单位】：济南大学
【学位级别】：硕士
【学位授予年份】：2017
【分类号】：TG409

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