基于激光视觉传感的弧焊机器人系统开发

发布时间：2018-04-15 20:53

本文选题：自动化焊接 + 激光视觉　；参考：《深圳大学》2017年硕士论文

【摘要】：基于激光视觉传感的弧焊机器人系统具有定位快、精度高、抗干扰能力强等优势,在批量化、个性化生产中具有广泛的应用前景。国内对基于激光视觉传感的弧焊机器人研究虽然取得了一些成果,但在系统集成度、柔性化、自主性等方面与国外先进技术仍有一定差距,能满足企业生产要求的产品较少。因此,研发一种柔性强、自主性强的基于激光视觉传感的弧焊机器人系统具有重要意义。本文针对国内某集装箱制造企业的实际需求,自主开发了一套基于激光视觉传感的弧焊机器人系统,该系统由工控机、PLC、6自由度机器人、自动化焊接电源、基于结构光的激光视觉传感系统等组成。针对本文使用的6自由度机器人,建立了其运动学模型、求解了其坐标变换矩阵、推导出了逆运动学解析解。根据机器人的运动学模型,提出了一种焊枪姿态保持的方法。根据相机在机器人末端坐标系中的标定参数计算焊缝特征点在机器人末端工具坐标系中的位置坐标,结合机器人的坐标变换矩阵,最终求出焊缝特征点在机器人基坐标系中的坐标位置。提出了一种系统集成控制架构,以工控机和PLC为控制核心,分别对机器人和焊接电源系统进行控制和管理。由工控机将图像处理得到的焊缝特征点位置信息发送给机器人,机器人按照给定位置沿焊缝运动。提出了一种由PLC控制自动化焊接电源的控制方法,由PLC控制焊机的参数调节并监测电弧状态。设计实现了工控机与机器人之间基于TCP/IP协议的网络通信、工控机与PLC之间基于PLC编程专用通信协议的串口通信。设计了系统的软件架构和控制界面。针对T型接口焊接过程中可能产生的焊接热变形进行了理论分析,结合焊接工件尺寸提出了抑制热变形的措施、计算了拘束力和临界拘束长度的理论值,并在此基础上设计了焊接工装。论文搭建、调试了所设计的基于激光视觉传感的弧焊机器人系统,并进行了实验研究。分别进行了示教方式仿形走、基于视觉传感的自主跟踪焊缝实验,最后进行了自动化焊接实验。实验表明,本文设计的基于激光视觉传感的弧焊机器人系统对焊缝的跟踪误差小于0.96mm,焊接速度达到24cm/min,实现了T型316L不锈钢材料的机器人自动化焊接。
[Abstract]:The arc welding robot system based on laser vision sensor has the advantages of fast positioning, high precision and strong anti-interference ability, so it has a wide application prospect in mass and individualized production.Although some achievements have been made in the research of arc welding robot based on laser vision sensor, there is still a certain gap between domestic and foreign advanced technologies in system integration, flexibility and autonomy, and few products can meet the production requirements of enterprises.Therefore, it is of great significance to develop a flexible and autonomous arc welding robot system based on laser vision sensor.Aiming at the actual demand of a container manufacturing enterprise in China, this paper develops an arc welding robot system based on laser vision sensor. The system is composed of a 6-DOF robot and an automatic welding power source.Laser vision sensing system based on structured light, etc.The kinematics model of the 6-DOF robot used in this paper is established, its coordinate transformation matrix is solved, and the inverse kinematics analytical solution is derived.According to the kinematics model of robot, a method of welding torch attitude maintenance is proposed.According to the calibration parameters of the camera in the robot terminal coordinate system, the position coordinates of the weld seam feature points in the robot terminal tool coordinate system are calculated, and the coordinate transformation matrix of the robot is combined.Finally, the coordinate position of the weld seam feature point in the robot base coordinate system is obtained.A system integrated control architecture is proposed, which controls and manages the robot and the welding power supply system with the industrial control computer and PLC as the control core, respectively.The position information of the weld seam characteristic points obtained by image processing is sent to the robot by the industrial computer. The robot moves along the weld according to the given position.A control method of automatic welding power supply controlled by PLC is proposed. The parameters of the welding machine are controlled by PLC and the arc state is monitored.The network communication between IPC and robot based on TCP/IP protocol and the serial communication between IPC and PLC based on PLC programming protocol are designed and realized.The software architecture and control interface of the system are designed.Based on the theoretical analysis of the possible thermal deformation in the welding process of T-type interface, the measures to suppress the thermal deformation are put forward in combination with the size of the welded workpiece, and the theoretical values of the restraint force and the critical restraint length are calculated.On this basis, the welding tooling is designed.The design of arc welding robot system based on laser vision sensor is built and debugged in this paper.The experiment of self-tracking welding seam based on visual sensor was carried out, and the automatic welding experiment was carried out.The experiments show that the tracking error of arc welding robot system based on laser vision sensor is less than 0.96mm and the welding speed is 24cm / min. The robot automatic welding of T-type 316L stainless steel is realized.
【学位授予单位】：深圳大学
【学位级别】：硕士
【学位授予年份】：2017
【分类号】：TP242

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