CN113199175A - Auxiliary welding device of crawling welding robot, control method and welding method thereof - Google Patents
Auxiliary welding device of crawling welding robot, control method and welding method thereof Download PDFInfo
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- CN113199175A CN113199175A CN202110404894.0A CN202110404894A CN113199175A CN 113199175 A CN113199175 A CN 113199175A CN 202110404894 A CN202110404894 A CN 202110404894A CN 113199175 A CN113199175 A CN 113199175A
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B60—VEHICLES IN GENERAL
- B60P—VEHICLES ADAPTED FOR LOAD TRANSPORTATION OR TO TRANSPORT, TO CARRY, OR TO COMPRISE SPECIAL LOADS OR OBJECTS
- B60P3/00—Vehicles adapted to transport, to carry or to comprise special loads or objects
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K37/00—Auxiliary devices or processes, not specially adapted to a procedure covered by only one of the preceding main groups
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K37/00—Auxiliary devices or processes, not specially adapted to a procedure covered by only one of the preceding main groups
- B23K37/02—Carriages for supporting the welding or cutting element
- B23K37/0211—Carriages for supporting the welding or cutting element travelling on a guide member, e.g. rail, track
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B25—HAND TOOLS; PORTABLE POWER-DRIVEN TOOLS; MANIPULATORS
- B25J—MANIPULATORS; CHAMBERS PROVIDED WITH MANIPULATION DEVICES
- B25J11/00—Manipulators not otherwise provided for
- B25J11/005—Manipulators for mechanical processing tasks
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B25—HAND TOOLS; PORTABLE POWER-DRIVEN TOOLS; MANIPULATORS
- B25J—MANIPULATORS; CHAMBERS PROVIDED WITH MANIPULATION DEVICES
- B25J5/00—Manipulators mounted on wheels or on carriages
- B25J5/007—Manipulators mounted on wheels or on carriages mounted on wheels
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B25—HAND TOOLS; PORTABLE POWER-DRIVEN TOOLS; MANIPULATORS
- B25J—MANIPULATORS; CHAMBERS PROVIDED WITH MANIPULATION DEVICES
- B25J9/00—Programme-controlled manipulators
- B25J9/16—Programme controls
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B25—HAND TOOLS; PORTABLE POWER-DRIVEN TOOLS; MANIPULATORS
- B25J—MANIPULATORS; CHAMBERS PROVIDED WITH MANIPULATION DEVICES
- B25J9/00—Programme-controlled manipulators
- B25J9/16—Programme controls
- B25J9/1656—Programme controls characterised by programming, planning systems for manipulators
- B25J9/1664—Programme controls characterised by programming, planning systems for manipulators characterised by motion, path, trajectory planning
- B25J9/1666—Avoiding collision or forbidden zones
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B25—HAND TOOLS; PORTABLE POWER-DRIVEN TOOLS; MANIPULATORS
- B25J—MANIPULATORS; CHAMBERS PROVIDED WITH MANIPULATION DEVICES
- B25J9/00—Programme-controlled manipulators
- B25J9/16—Programme controls
- B25J9/1679—Programme controls characterised by the tasks executed
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B25—HAND TOOLS; PORTABLE POWER-DRIVEN TOOLS; MANIPULATORS
- B25J—MANIPULATORS; CHAMBERS PROVIDED WITH MANIPULATION DEVICES
- B25J9/00—Programme-controlled manipulators
- B25J9/16—Programme controls
- B25J9/1694—Programme controls characterised by use of sensors other than normal servo-feedback from position, speed or acceleration sensors, perception control, multi-sensor controlled systems, sensor fusion
- B25J9/1697—Vision controlled systems
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B62—LAND VEHICLES FOR TRAVELLING OTHERWISE THAN ON RAILS
- B62D—MOTOR VEHICLES; TRAILERS
- B62D57/00—Vehicles characterised by having other propulsion or other ground- engaging means than wheels or endless track, alone or in addition to wheels or endless track
- B62D57/02—Vehicles characterised by having other propulsion or other ground- engaging means than wheels or endless track, alone or in addition to wheels or endless track with ground-engaging propulsion means, e.g. walking members
- B62D57/024—Vehicles characterised by having other propulsion or other ground- engaging means than wheels or endless track, alone or in addition to wheels or endless track with ground-engaging propulsion means, e.g. walking members specially adapted for moving on inclined or vertical surfaces
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B66—HOISTING; LIFTING; HAULING
- B66F—HOISTING, LIFTING, HAULING OR PUSHING, NOT OTHERWISE PROVIDED FOR, e.g. DEVICES WHICH APPLY A LIFTING OR PUSHING FORCE DIRECTLY TO THE SURFACE OF A LOAD
- B66F11/00—Lifting devices specially adapted for particular uses not otherwise provided for
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B66—HOISTING; LIFTING; HAULING
- B66F—HOISTING, LIFTING, HAULING OR PUSHING, NOT OTHERWISE PROVIDED FOR, e.g. DEVICES WHICH APPLY A LIFTING OR PUSHING FORCE DIRECTLY TO THE SURFACE OF A LOAD
- B66F11/00—Lifting devices specially adapted for particular uses not otherwise provided for
- B66F11/04—Lifting devices specially adapted for particular uses not otherwise provided for for movable platforms or cabins, e.g. on vehicles, permitting workmen to place themselves in any desired position for carrying out required operations
- B66F11/044—Working platforms suspended from booms
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- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P90/00—Enabling technologies with a potential contribution to greenhouse gas [GHG] emissions mitigation
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Abstract
The invention relates to an auxiliary welding device, a control method and a welding method for a crawling welding robot. The welding device comprises a crank arm type lifting mechanism assembly, a welding device and a welding device, wherein the crank arm type lifting mechanism assembly controls an operation room to flexibly move to the surface and the periphery of any operation position of a large-sized component, and a crawling welding robot, an electric control device of a whole machine and a peripheral device are arranged in the operation room; the crank arm type lifting mechanism assembly consists of a combined general control operation platform and a crank arm lifting mechanism which are arranged on a carrying tool; the crank arm lifting mechanism adopts three sections of hydraulic folding working arms to be rigidly connected with a tail end operation room; the crank arm lifting mechanism consists of a welding operation arm which is pivoted on the combined master control operation table through a first pivot and a first crank arm which is pivoted at the end part of one end of the welding operation arm through a second pivot; each crank arm is driven by a cylinder.
Description
Technical Field
The invention belongs to the technical field of intelligent welding robots, and particularly relates to an auxiliary welding device, a control method and a welding method for an all-position crawling welding robot. The invention is special engineering operation equipment which is specially used for realizing rapid deployment and implementation operation on large curved surfaces of large components (such as energy chemical storage tanks, ships and marine platform manufacturing), and the system integrates all-position crawling welding robot equipment with path planning, automatic visual recognition, tracking and control functions of welding seams and a crank-type lifting device which can cross obstacles and flexibly move in a large range.
Background
Marine and petrochemical equipment of ships is characterized by being heavy, large and complex in structure, a plurality of manufacturing links are manual operation, and sometimes the manufacturing links need to be operated on site, wherein welding operation is the most typical, and the parts are the bottleneck for realizing manufacturing automation. Taking large spherical tanks and large cylindrical storage tanks of typical petrochemical equipment as examples, the welding work at present mainly depends on two ways: firstly, bridging is matched with manual welding; secondly, laying a welding track and welding by adopting a welding trolley. The first mode has low welding efficiency, poor consistency of welding seams, low welding quality, extremely high labor intensity of welders, low safety of workers working aloft and high labor cost; the second mode is aimed at certain specific welding seams, can improve welding efficiency and welding quality to a certain extent more effectively, replaces the welder, lets the welder liberate, but also needs to lay the track in advance, loads and hangs a series of welding auxiliary work such as welding special plane, and a large amount of manufacturing time are spent on welding auxiliary work to the pertinence of welding seam is stronger, and the application scope is restricted. Therefore, aiming at the problems in the manufacturing and welding of petrochemical equipment, the intelligent trackless all-position mobile welding robot which can be widely applied to most of seam welding work in the manufacturing of the large structural member is urgently needed, welding seams and path planning can be autonomously navigated and identified under the condition that tracks do not need to be laid or scaffolds are built and only a small amount of manual assistance is needed, and the welding work of transverse seams and longitudinal seams in the outer surfaces of spherical tanks and cylindrical storage tanks is completed.
In order to improve the manufacturing level and the production efficiency and quality, the automation of operations such as welding large structural members is urgently required to be realized. However, the conventional industrial robot or dedicated automation equipment is limited in mobility and flexibility (intelligence) and is difficult to be applied to such occasions, so that a new solution is urgently needed. One of the ideas to solve this problem is to use a larger automated system than the workpiece, but such automated system is very costly and has limited variety of applicable products, and thus, such large automated system is less competitive. The crawling robot can move on the surface of the workpiece at all positions and can adapt to different types of workpieces, has great advantages in the aspects of operation flexibility, flexibility and the like, and is relatively low in cost, so that the crawling robot has wide application prospects in operations such as welding (including grinding), spraying and nondestructive inspection of energy petrochemical large-scale steel structural members.
On the other hand, energy chemical equipment is often an important infrastructure and generally needs to be overhauled regularly. Use large-scale power generating equipment to overhaul as the example, the maintenance of these facilities or need to take the scaffold frame, or need tear down the maintenance object and overhaul in the workshop, this causes the maintenance cycle length. If can avoid taking, tearing down the scaffold frame or dismantle the process of installation maintenance object, can accomplish the maintenance at the scene, this can reduce unnecessary supplementary process time (dismantlement, installation, debugging etc.), can produce huge economic benefits. In addition, in some cases, due to environmental restrictions (such as radioactive places), there is a great potential safety hazard for workers to perform maintenance work. And the wall climbing robots of various types carry out the maintenance operation, so that the maintenance period can be shortened, the maintenance operation efficiency can be improved, the operation quality can be improved, and the operation safety can be guaranteed. Therefore, from the above point of view, the crawling robot has a wide application prospect in such maintenance operations.
In conclusion, the crawling robot has great market potential in the aspects of manufacturing (or building) and in-service maintenance of facilities such as offshore oil platforms, ships, storage tanks and large power generation equipment involved in energy conversion. At present, a few enterprises and research institutes of colleges and universities in international and domestic markets have made certain breakthrough in this respect, products have come out from laboratories, and particularly, a certain number of detection crawling (wall climbing) robot products are applied to specific products of energy pipelines and power generation equipment, but the application of the products in the aspects of welding, grinding and spraying of large-scale structural members such as energy storage tanks, ships, maritime workers and the like is started, and a lot of challenges are faced. For these trades actual demands, current product kind and function are still more single, and the popularization degree of application and popularization is also far from not enough, and the main reason is these operation occasions still have a great deal of realistic problems: for example, the self-load problem of the crawling robot (the load is 1:2 in comparison with the current better model machine in the industry, and the increase of the load means that the self-weight needs to be increased, so that the self-platform of the crawling robot is large and heavy, the arrangement and implementation are not flexible, and the crawling robot is limited by space in an actual use scene); how to quickly transit and deploy the crawling robot with the surface of a working area; the crawling robot works with peripheral equipment and material placement problems (such as a controller, a welding power supply for welding, a wire feeder, a wire reel and a wire barrel, a paint delivery and supply system for spraying, a matched instrument for detection and the like); the crawling robot can cross obstacles and cross-region operation; how the device is abnormal to handle the problem in time, etc.
Disclosure of Invention
The invention aims to overcome a series of problems that the existing crawling robot is insufficient in load, limited in carrying equipment space, difficult to realize batch industrial application, low in implementation efficiency and the like, and solves the problems that the crawling welding robot is rapidly deployed on site, limited in robot load, limited in operation range and the like, but the problem of arrangement of safety cables of the crawling welding robot is not determined at all, the crawling welding robot is preferably set to be connected with an operation room, and then is connected with a construction workpiece, so that the device and the method are used for auxiliary welding of the all-position crawling welding robot. Aiming at the welding manufacture of large components in the manufacture (construction) of energy chemical storage tanks, ships and marine platforms, a special engineering operation device and a welding method for rapidly deploying and implementing operation on site by a large curved surface crawling welding operation robot are provided. The device mainly comprises a crank arm type lifting mechanism assembly and two modules of a tail end operation room, wherein the tail end operation room is integrated with a full-position crawling robot with the functions of path planning, automatic visual recognition, tracking and control of welding seams, a crawling welding robot controller, a welding power supply, a wire feeder, a protective gas tank, a welding wire barrel and the like. The crank arm type lifting mechanism assembly can flexibly move an operation room (operation room) with a crawling welding robot to the surface and the periphery of any operation position of a large component, the crawling robot climbs to a starting operation position through the movable connecting bridge on one side of the operation room and withdraws the movable connecting bridge, the tail end operation room can move along with a working movement route of the crawling robot or move in a clearance mode, the whole tail end operation room can move flexibly in a large range beyond obstacles under the control of a combined master control operation platform, and the operation of flexibly welding the complex surface of the large component, spraying, polishing, flaw detection and the like can be realized by combining the all-position crawling robot. Terminal operation is equipment and is passed through ethernet with the total accuse operation panel of combination and is connected, can easily confirm the position and the height that the operation room will reach through remote video image at the total accuse operation panel of combination to through techniques such as visual tracking sensor, carry out real time monitoring and adjustment parameter to welding seam orbit, welding seam appearance and the postweld quality in the welding process, with the required accurate movement orbit of operations such as accomplishing welding, improve robot welding efficiency and welding quality of crawling. The invention can realize the system device that the auxiliary equipment can follow and walk while the crawling robot works by lifting the working operation room carrying the all-position crawling robot and the auxiliary equipment such as the controller, the welding power supply, the wire feeder, the protective gas mixing tank and the like to the vicinity of any working position through the hydraulic and electric integrated system of the all-in-one machine.
The first technical scheme of the invention is that the auxiliary welding device for the all-position crawling welding robot is characterized by comprising a 360-degree rotary hydraulic crank arm type lifting mechanism assembly, a crawling welding robot, an electric control device and a peripheral device of a whole machine, wherein the hydraulic crank arm type lifting mechanism assembly controls an operation room to flexibly move to the surface and the periphery of any operation position of a large member, and the crawling welding robot is arranged in the operation room.
Preferably, the method comprises the following steps: the crank arm type lifting mechanism assembly consists of a combined general control operation table and a crank arm lifting mechanism which are arranged on a carrying tool; the crank arm lifting mechanism adopts three sections of hydraulic folding working arms to be rigidly connected with a tail end operation room; the crank arm lifting mechanism consists of a welding operation arm which is pivoted on the combined master control operation table through a first pivot, and a first crank arm which is pivoted at the end part of one end of the welding operation arm through a second pivot; the crank arms are driven by cylinders.
Preferably, the method comprises the following steps: the operation room is rigidly connected with the second crank arm, a movable connecting bridge is arranged on the outer side of the operation room, the movable connecting bridge bears and bears the stable transition between the crawling welding robot and the workpiece, the movable connecting bridge is connected with a pair of hydraulic cylinder systems through a group of hinges, the required angle for the surface transition of the crawling welding robot and the workpiece is ensured, a camera is mounted on the second crank arm right below the movable connecting bridge, peripheral equipment for the welding robot is arranged on the operation room, and the peripheral equipment is connected to a relay box on a lower chassis and a combined general control operation platform from a lifting mechanism through a special cable for power supply and communication; the peripheral equipment comprises a welding power supply, a wire feeder and a welding wire barrel, a protective gas mixture, a crawling robot controller and a cable winding mechanism.
Preferably, the method comprises the following steps: the crawling welding robot consists of a permanent magnet type four-wheel drive moving platform, a six-degree-of-freedom welding mechanical arm borne on the moving platform, a supporting frame fixedly arranged on a welding mechanical arm, a second crank arm pivoted with the supporting frame through a third pivot, a third crank arm pivoted with the other end of the second crank arm through a fourth pivot, a first connecting arm pivoted with the other end of the third crank arm through a fifth pivot, a second connecting arm pivoted with the first connecting arm through a sixth pivot, a welding gun fixedly arranged on the second connecting arm, a welding seam tracker fixedly arranged at the end part of the second connecting arm and a molten pool monitoring camera; the welding seam tracker for welding is arranged on the tail end shaft of the second connecting arm, the central line of the welding seam tracker and the central line of a welding gun on the tail end shaft of the second connecting arm are positioned on the same horizontal plane in space, and the relative displacement is fixed; the welding line tracker automatically seeks the start point and the stop point of the welding line, the three-dimensional track data and the width data of the welding line are transmitted to the crawling welding robot controller in real time, and the crawling welding robot controller performs cooperative control, operation task path planning, welding gun posture generation and real-time deviation correction on a welding machine system, the welding line tracker and a crawling robot control system which are composed of a welding power supply.
Preferably, the method comprises the following steps: the electric control equipment comprises a combined general control operation platform, a crawling robot system controller and a mobile walking crank arm lifting platform controller, wherein the crawling robot system controller is respectively communicated with the crawling robot controller, the welding seam tracker controller and the welding machine system controller through EtherCat, GigE and CANopen to realize control signal transmission and operation data feedback; the crawling robot controller realizes control signal transmission and operation data feedback through EtherCat, a crawling robot trolley and servo of each joint, and the welding seam tracker controller realizes control signal transmission and operation data feedback through GigE and a welding seam detection visual sensor; the mobile walking crank arm lifting platform controller is interconnected with the mobile walking mechanism controller, the crank arm lifting mechanism controller and the operation room controller through CANopen and RS485 serial ports, so that the mobile walking self-locking, crank arm rotation, crank arm lifting, operation room opening and closing and the operation room following crawling robot gap movement of the platform trolley are realized; the mobile walking mechanism controller realizes control signal transmission and operation data feedback through the WIFI/5G, CANopen, the monitoring camera and the inter-operation opening and closing oil cylinder; the crank arm lifting mechanism controller realizes control signal transmission and operation data feedback through CANopen and crank arm rotation and a crank arm lifting oil cylinder and a support oil cylinder; the mobile walking controller realizes control signal transmission and operation data feedback through the CANopen, the mobile walking mechanism and the driving mechanism.
Preferably, the method comprises the following steps: the crawling welding robot, the mobile walking device, the chassis, the crank arm lifting mechanism and the operation room are electrically connected; the crawling operation robot is used for simultaneously tracking a molten pool and detecting the quality of a welded weld bead, a required molten pool monitoring camera and weld bead detection equipment are arranged on a mechanical arm at the tail end of the crawling robot and are electrically connected with a crawling robot controller, and collected images and detection data are transmitted to a display screen of a main control operation platform on a chassis through Ethernet communication to display shot images and analysis data; the following movement is controlled by combining a working room monitoring camera according to the walking distance and the direction of the crawling robot through a combined and combined master control operation platform on a wireless remote control terminal or a chassis.
The second technical solution of the present invention is a control method for an all-position crawling welding robot, characterized by comprising the steps of:
firstly, calibrating a teaching track, and inputting a welding gun and measuring deviation; (ii) a
Secondly, sending welding gun measurement deviation to a sensor;
turning on the laser, and sending a calibration task number;
fourth, executing a calibration teaching track;
sending the TCP user coordinate to the sensor;
sixthly, judging whether teaching tracks are finished? If not, returning to the fourth step, and if yes, entering a next step;
the laser is shut down and calibration is complete.
The third technical solution of the present invention is a welding control method for a full-position crawling welding robot, which is characterized by comprising the steps of:
the method comprises the steps of searching for a bit and teaching; welding demonstration;
secondly, inputting a welding seam type task number;
turning on the laser, and sending a calibration task number;
fourth, executing a calibration teaching track;
judging whether the welding line is found stably: if not, returning to the fourth step, and if yes, entering a next step;
sixthly, turning off the laser and returning to the starting point of the welding seam;
turn on the laser, perform welding teaching and compensate according to the sensor;
and judging whether to end: if not, returning to step-quietness; if yes, entering the next step;
the laser is turned off to complete the welding.
The fourth technical solution of the present invention is the welding control method for the all-position crawling welding robot, which is characterized by comprising the steps of:
the method includes the steps that firstly, a welding robot moves to an initial position of a path planning point on the surface of a workpiece, and scanning track teaching is executed;
secondly, inputting a welding seam type task number;
turning on the laser, and executing scanning teaching;
fourth, the TCP user coordinates are sent to the sensor;
judge whether teaching track is completed? If not, returning to the fourth step, and if yes, entering a next step;
sixthly, requesting to weld track points;
executing a welding trajectory;
judging whether the welding track is finished, if not, returning to the step of quieting, and if so, entering the next step; (ii) a
A self-sustaining off laser;
the welding is finished.
The fifth technical solution of the present invention is a welding method for an all-position crawling welding robot, characterized by comprising the steps of:
the method comprises the steps that an operation room is quickly moved to the position near the initial operation position of a workpiece through a combined and combined general control operation table, a monitoring display and a wireless remote control terminal, and a movable connecting bridge is controlled to be in place through a tail end monitoring camera and an operation room opening and closing oil cylinder;
the crawling operation robot starts crawling operation according to a planned collision-free path, the cable winding mechanism automatically releases wires, and the tail end operation room moves or moves intermittently along with the crawling welding robot according to the operation condition;
the welding seam tracking sensor automatically locates the start and stop points of the welding seam, three-dimensional trajectory data and width data of the welding seam are transmitted to the crawling welding robot controller in real time, and the crawling welding robot controller performs cooperative control, operation task path planning, welding gun posture generation and real-time deviation correction on a welding machine system, a welding seam tracker and a crawling robot control system which are formed by a welding power supply;
the crawling robot system controller, the crawling robot body controller, the welding seam tracker controller and the welding machine system controller respectively adopt EtherCat, GigE and CANopen to achieve control signal transmission and operation data feedback; the mobile walking crank arm lifting platform controller is interconnected with the mobile walking mechanism controller, the crank arm lifting mechanism controller and the tail end operation room controller through CANopen and RS485 serial ports, so that the mobile walking self-locking, crank arm rotation, crank arm lifting, operation room opening and closing and the operation room following crawling robot gap movement of the platform trolley are realized;
at this moment, if the system has an abnormal audible and visual alarm, or the system automatically interrupts welding operation when the system needs to cross a large obstacle or move for a large distance according to task requirements, the crawling robot returns to the tail end operation room according to a set path, and the operator operates the wireless remote control terminal to quickly move the tail end operation room to a new operation position or interrupt the operation position to restart the operation.
Compared with the prior art, the invention has the beneficial effects that:
the auxiliary welding device and the welding method provided by the invention solve the series of problems that the conventional crawling robot has insufficient load, cannot carry peripheral equipment, has low implementation efficiency of operation field deployment and the like and affects the batch industrial application of products. The crawling robot can be designed to be small, exquisite and specific, so that the manufacturing cost of the crawling robot is reduced, the field arrangement is fast and flexible, the time from the crawling robot to the surface of an operation area is shortened, the problem of safe placement of peripheral equipment and materials matched with operation of the crawling robot is solved with low cost, the problems of obstacle crossing and cross-area operation of the crawling robot, abnormal rapid processing of the equipment and the like are solved. The integrated operation, the integrated transportation and the like of the crawling robot and the peripheral equipment are realized.
The auxiliary welding device disclosed by the invention has the advantages of smaller occupied space, lower cost and convenience in operation. The novel full-hydraulic self-propelled special chassis is adopted, the technologies of electromechanical-hydraulic integration, reliability design, computer aided design and the like are adopted between the crank arm lifting mechanism and the tail end operation room, the chassis is a full-hydraulic drive and self-propelled special chassis, and the limitation that the traditional domestic high-altitude operation lifting platform vehicle can only adopt the refitting design of a chassis of an automobile or a crane is broken through. The device is very suitable for rapid deployment and moving operation in limited space of storage tanks, ships and marine platform construction sites, the crank arm lifting mechanism can rotate by 360 degrees, the folding arm type working arm is adopted, the barrier can be spanned for working, and compared with a vertical lifting platform on the market, the device has larger operation range and unlimited space.
The auxiliary welding device and the welding method provided by the invention are multifunctional and multipurpose, and the operation stability is good. Through the terminal operation of crank arm elevating system and big arm between, can be fast with crawling robot lifting to work piece initial work position surface, crawling robot controller and peripheral equipment provide the interface for expanding quick switch-over of operation device and various equipment simultaneously in the terminal operation room, can realize multiple operation functions such as welding, spraying, polishing, the detection of robot of crawling. The operation room can follow the movement according to the movement track of the crawling robot, simultaneously bears a large amount of peripheral equipment, lightens the working load of the crawling robot, greatly improves the operation efficiency of the crawling robot and reduces the system cost. The chassis structure breaks through the traditional design theory and method, and the center of gravity shift is reduced by optimizing the overall layout and load distribution of the boarding platform. A unique large-angle back-up type hinge point structure is adopted, various counterweight modules are reasonably arranged, and the working torque is effectively balanced. The rigid frame of the H-shaped variable cross-section composite box girder and the high-load solid rubber tire are adopted, so that the overall rigidity of the chassis is increased, and the stability of the whole machine in the running and operating processes is ensured.
The operation height of the system of the device can reach 18 meters at most, rated load of a tail end operation room is designed to be 200-400 kg, a crank arm can rotate around the chassis for 360 degrees, and the required position and posture of each working arm and the operation room can be adjusted through operation. The invention has simple operation structure, convenient operation, safety and reliability, and is the crawling operation auxiliary equipment with optimized safety and working efficiency. Four hydraulic support legs are assembled on the vehicle, and the support legs are H-shaped, so that the stability and the safety of the whole vehicle during operation are ensured.
Fifthly, the whole device is provided with diesel engine power, bus intelligent control, proportion control, an emergency pump, a loudspeaker, a work timing meter, an inclination alarm, 360-degree discontinuous rotation of a crank arm, an automatic leveling platform, circuit fault code display, platform hydraulic swing, engine restart protection, an engine glow plug preheating device, a rotary strobe light, 4 x 2 driving, a platform weighing limiting function, a platform work light and a foot switch in a standard mode. Alternative configurations include: direct current, alternating current and direct current, dual-purpose of diesel and electric, a cab and the like.
Sixthly, the crawling operation auxiliary equipment is simple in operation structure, convenient to operate, safe and reliable, and is optimal in safety and working efficiency. The system has compact structure and flexible steering, the width of the chassis of the system can ensure that equipment enters a narrow passage and a crowded working area, and the system can be combined with an all-position crawling robot to realize the flexible welding, spraying, polishing, flaw detection and other operations on the complex surface of a large component.
Drawings
FIG. 1 is a schematic structural diagram of an auxiliary welding device of a full-position crawling welding robot in the invention;
FIG. 2 is a schematic structural view of the crawling welding robot of the present invention;
FIG. 3 is a schematic block diagram of the cooperative control of the system of the present invention;
FIG. 4 is a control flow diagram of the calibration of the welding robot in the system of the present invention;
FIG. 5 is a flowchart of the welding control of the full position crawling welding robot in the first embodiment of the present invention;
FIG. 6 is a flowchart of the welding control of the full position crawling welding robot in the second embodiment of the present invention;
FIG. 7 is a flow chart of the control communication of the weld tracking sensor of the present invention with a crawling welding robot.
Description of the main component symbols:
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Combined general control console 11 | Crank |
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First crank |
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Movable connecting |
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Robot controller 244 | Cable winding mechanism 245 | |
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Second crank |
Third crank 352 |
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Lift platform controller 42 | Weld tracking controller 43 |
| Welder system controller 44 | Weld visual sensor 45 | Running gear controller 46 | Lifting mechanism controller 47 |
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Detailed Description
The invention will be described in more detail below with reference to the accompanying drawings:
referring to fig. 1 and 2, the auxiliary welding device for the all-position crawling welding robot includes a 360-degree rotation hydraulic type crank arm lifting mechanism assembly 1, an operation room 2 controlled by the crank arm lifting mechanism assembly 1 to move, a crawling welding robot 3 arranged in the operation room 2, and an electric control device 4 of the whole machine.
Referring to fig. 1, the crank arm type lifting mechanism assembly 1 is composed of a combined general control operation platform 11 and a crank arm lifting mechanism 12 which are arranged on a vehicle; the crank arm lifting mechanism adopts three sections of hydraulic folding working arms, and a tail end operation room is rigidly connected with the three sections of arms; the crank arm lifting mechanism 12 consists of a welding operation arm 121 which is pivoted on the combined general control operation table 11 through a first pivot 1211, and a first crank arm 122 which is pivoted at one end of the welding operation arm 121 through a second pivot 1221; the crank arms are driven by cylinders to flexibly move the operation room 2 with the crawling welding robot 3 to the surface and the periphery of any operation position of a large member.
Referring to fig. 2, the crawling welding robot 3 is composed of a moving platform 31, a permanent magnet four-wheel drive six-degree-of-freedom welding mechanical arm 32 carried on the moving platform 31, a support frame 33 fixedly mounted on the welding mechanical arm 32, a second crank arm 351 pivotally connected to the support frame 33 through a third pivot 341, a third crank arm 352 pivotally connected to the other end of the second crank arm 351 through a fourth pivot 342, a first connecting arm 36 pivotally connected to the other end of the third crank arm 352 through a fifth pivot 343, a second connecting arm 39 pivotally connected to the first connecting arm 36 through a sixth pivot (not shown), a welding gun 37 fixedly mounted on the second connecting arm 39, a weld tracker 38 fixedly mounted on the end of the second connecting arm 39, and a bath monitoring camera (not shown); the welding seam tracker 38 is arranged on the tail end shaft of the second connecting arm 39, the central line of the welding seam tracker 38 and the central line of the welding gun 37 on the tail end shaft of the second connecting arm 39 are positioned on the same spatial horizontal plane, and the relative displacement is fixed; the seam tracker 38 automatically locates the seam start and stop point, transmits the seam three-dimensional trajectory data and the seam width data to the crawling welding robot controller 244 in real time, and the crawling welding robot controller 244 performs cooperative control, operation task path planning, welding gun posture generation and real-time deviation correction on a welding machine system, the seam tracker 38 and a crawling robot control system which are composed of the welding power source 241.
The operation room 2 is rigidly connected with the second crank arm 123, a movable connecting bridge 21 is arranged outside the operation room 2, the movable connecting bridge 21 bears and undertakes smooth transition between the crawling welding robot 3 and the workpiece, the movable connecting bridge 21 is connected with a pair of hydraulic cylinders 22 by a group of hinges in a systematic way to ensure the angle required by the transition of the crawling welding robot 3 and the surface of a workpiece, a camera 23 is arranged on a second crank arm 123 right below the movable connecting bridge 21, peripheral equipment 24 for the welding robot is arranged on the operation room 2, the peripheral devices 24 include a welding power source 241, a wire feeder & wire barrel 242, a shielding mixture 243, a crawling robot controller 244, and a cable hoist mechanism 245, the peripheral devices 24 are powered and communicate through dedicated cables from the lifting mechanism to the relay box on the chassis below and to the combined console 11. The operation room 2 integrates a full-position crawling robot 3 with the functions of path planning, automatic visual recognition, tracking and control of welding seams and peripheral equipment 24 of the crawling welding robot. Crank arm formula elevating system assembly 1 can be with the operation 2 nimble removal of operation room of taking crawling welding robot 3 to the arbitrary operation position surface of large-scale component and periphery, and the swing joint bridge 21 of crawling robot 3 one side through the operation room climbs behind the position of beginning the operation, and swing joint bridge 21 withdraws, operation room 2 can follow the removal or clearance formula removal according to 3 work movement routes of crawling robot, whole operation room 2 can be under the control of combination total control operation panel 11, can cross the obstacle and nimble removal on a large scale, can combine full position crawling robot 3 to realize operations such as the nimble welding of large-scale component complex surface, spraying, polishing, flaw detection. 2 equipment of operation room and combination are always controlled the operation panel 11 and are passed through the ethernet and are connected, can easily confirm position and height that 2 will reach of operation room in combination always controlling the operation panel 11 through remote video image to through techniques such as visual tracking sensor, carry out real time monitoring and adjustment parameter to welding seam orbit, welding seam looks and the postweld quality in the welding process, with the required accurate movement track of operations such as accomplishing welding, improve 3 welding efficiency and the welding quality of robot of crawling.
The auxiliary welding device for the all-position crawling welding robot comprises a movable platform capable of being operated movably, a 360-degree rotary hydraulic type crank arm lifting mechanism 1, a combined general control operation table 11, a tail end operation room 2, the all-position crawling welding robot 3, a crawling robot controller 244, a welding power source 241, a wire feeder 242, a welding wire barrel 242, a protective mixed gas 243, a remote control operation box and the like.
The welding method of the crawling robot auxiliary device comprises the following steps:
the special engineering operation device and the welding method are suitable for quick deployment and implementation of large-scale component curved surface crawling welding operation sites in energy chemical storage tanks, ships and marine platforms manufacturing, and comprise a mobile walking mechanism 5 and a rotary chassis 6, wherein the walking mechanism 5 comprises a walking mechanism and a driving mechanism for driving the walking mechanism to walk, the walking mechanism and the chassis utilize Jiangling and Dongbaowang automobile chassis, the special engineering operation device further comprises a hydraulic crank arm lifting mechanism 1 and a tail end operation workshop 2, the hydraulic crank arm lifting mechanism 1 adopts folding working arms 122, 123 and 124 (two-section arm and three-section arm), the tail end operation workshop 2 adopts a semi-open type, a movable connecting bridge 21 can be opened and closed on one side, and the movable connecting bridge 21 ensures that the crawling operation robot 3 and a large-scale curved surface can crawl at a required angle through a hinge and a pair of hydraulic cylinders 22. Peripheral devices such as a welding power source 241 and a wire feeder, a welding wire barrel 242, a shielding gas mixture 243, a crawling robot controller 244, a cable winding mechanism 245 and the like for the operation of the all-position crawling welding robot 3 are fixed in the end operation room 2, and the peripheral devices 24 are connected to the lower chassis 6 and the combined general control console 11 on the chassis through dedicated cables for power supply and communication.
The automobile master control operating platform is used for controlling the traveling device 5, the crank arm lifting mechanism 12 and the combined master control operating platform 11 to be arranged on an automobile chassis, a diesel engine power system and a power supply system capable of being externally connected with alternating current are arranged on the chassis, a power supply conversion and voltage stabilization device is arranged on the chassis and can provide required alternating current and direct current power supplies for the combined master control operating platform 11, and a 380V power supply cable and a 220V power supply cable and an Ethernet communication cable are arranged between the combined master control operating platform 11 and an operation operating room 2 at the tail end of the crank arm lifting mechanism 12.
Referring to fig. 7, the electric control device 4 includes a combined general control console 11, a crawling robot system controller 41, and a mobile walking crank arm lifting platform controller 42, where the crawling robot system controller 41 respectively implements control signal transmission and operation data feedback with a crawling robot controller 244, a weld tracker controller 43, and a welding machine system controller 44 through EtherCat, GigE, and CANopen; the crawling robot controller 244 realizes control signal transmission and operation data feedback through EtherCat, the crawling robot trolley 32 and each joint servo, and the welding seam tracker controller 43 realizes control signal transmission and operation data feedback through GigE and a welding seam detection visual sensor 45; the mobile walking crank arm lifting platform controller 42 is interconnected with the mobile walking controller 46, the crank arm lifting mechanism controller 47 and the operation room controller 48 through CANopen and RS485 serial ports, so that the mobile walking self-locking of the platform trolley, the rotation of the crank arm, the lifting of the crank arm, the opening and closing of the operation room and the gap movement of the operation room 2 along with the crawling robot 3 are realized; the mobile walking controller 46 realizes control signal transmission and operation data feedback through WIFI/5G, CANopen, the monitoring camera 23 and the inter-working opening and closing oil cylinder 22; the crank arm lifting mechanism controller 47 realizes control signal transmission and operation data feedback through CANopen and crank arm rotation and a crank arm lifting oil cylinder and a support oil cylinder; the mobile traveling controller 46 realizes control signal transmission and operation data feedback through the CANopen, the mobile traveling mechanism 5 and the driving mechanism.
The crawling robot controller 244 cooperatively and integrally controls a crawling robot system, a welding machine system (including a welding power supply, a wire feeder, a welding wire barrel and a protective gas mixture), a welding seam tracker and the like, and adopts RT-Linux as a real-time operating system platform for intelligent cooperative control. Based on the hardware characteristics of each subsystem, control signal transmission and running data feedback of the upper computer, the crawling robot 3, the welding seam tracker 126 and the welding machine are respectively realized below by respectively adopting EtherCat, GigE, CANopen and the like, and the wireless WIFI technology is used for remote video monitoring of the field operation condition. The cable and the air pipe connected with the crawling welding robot 3 are collected and released through a cable winding mechanism 245 on the operation room 2, the remote control operation box is electrically connected with the combined master control operation platform 11 on the chassis, and the combined master control operation platform 11 is provided with a common centralized operation button, a human-computer interaction interface and a monitoring interface to replace direct operation on the crawling robot controller 244. When abnormal faults need to be detected and maintained in a shutdown mode or a welding wire barrel 242 and a welding gun need to be replaced, the crawling robot 3 stops working, returns to the combined master control operation platform 11 according to a planned path to automatically clear or return, retracts the crank arm lifting platform, and manually ascends an operation room to repair and replace materials and parts.
This crawling operation robot 3 still can be used to trail the molten bath simultaneously and weld the postweld welding bead quality testing, required molten bath monitoring camera and welding bead check out test set install on crawling robot terminal arm and with crawl robot controller 244 electricity and be connected to through ethernet communication with the image of gathering and detect data transmission to make up the display screen of the total control operation panel 11 on chassis 6 and show and shoot image and analysis data.
The camera 23 is further installed in the terminal operation room 2 of the crank arm lifting mechanism 12 and is used for enabling the operators of the combined master control operation table 11 to observe the distance between the operation room 2 and the surface of a workpiece and the shape of the contact surface of the workpiece, and the operators of the combined master control operation table 11 can conveniently adjust the angle of the movable connecting bridge 21 and observe the reciprocating transition process from the crawling robot 3 to the surface of the workpiece.
The hydraulic system of the crank arm lifting mechanism 1 is provided with a valve which can not lead the oil pipe of the main arm oil cylinder to burst, and the hydraulic supporting leg 51 is provided with a hydraulic locking device which can not lead the oil cylinder of the hydraulic supporting leg 51 to retract. And the hydraulic system is provided with a platform overload automatic protection device so as to protect the safety of operators under normal work or special conditions of peripheral equipment in a work operation room at the tail end of the large arm, and each section of the working arm 122, 123 and 124 of the crank arm lifting mechanism 1 is provided with a limiting device.
The working height of the device system can reach 18 meters at most, the rated load of the tail end working operation room 2 is designed to be 200-400 kg, the crank arm can rotate around the chassis for 360 degrees, and the required position and posture can be adjusted by operating the working arms and the working operation room 2 at two positions. Four hydraulic support legs 51 are assembled on the vehicle, and the support leg type is H-shaped, so that the stability and the safety of the whole vehicle during operation are ensured.
The whole device is provided with diesel engine power in a standard configuration mode, bus intelligent control, proportional control, an emergency pump, a loudspeaker, a work timing meter, an inclination alarm, crank arm 360-degree discontinuous rotation, an automatic leveling platform, circuit fault code display, platform hydraulic swing, engine restart protection, an engine glow plug preheating device, a rotary strobe light, 4 x 2 driving, a platform weighing limiting function, a platform work light and a foot switch. Alternative configurations include: direct current, alternating current and direct current, dual-purpose of diesel and electric, a cab and the like.
Referring to fig. 4, the control method for calibrating the all-position crawling welding robot includes the following steps:
firstly, calibrating a teaching track, and inputting a welding gun and measurement;
sending a welding gun and a measurement deviation to a sensor;
turning on the laser, and sending a calibration task number;
fourth, executing a calibration teaching track;
sending the TCP user coordinate to the sensor;
sixthly, judging whether teaching tracks are finished? If not, returning to the fourth step, and if yes, entering a next step;
the laser is shut down and calibration is complete.
Referring to fig. 5, a welding control method for a full-position crawling welding robot includes the following steps:
the method comprises the steps of searching for a bit and teaching; welding demonstration;
secondly, inputting a welding seam type task number;
turning on the laser, and sending a calibration task number;
fourth, executing a calibration teaching track;
judging whether the welding line is found stably: if not, returning to the fourth step, and if yes, entering a next step;
sixthly, turning off the laser and returning to the starting point of the welding seam;
turn on the laser, perform welding teaching and compensate according to the sensor;
and judging whether to end: if not, returning to step-quietness; if yes, entering the next step;
the laser is turned off to complete the welding.
Referring to fig. 6, the control method for calibrating the all-position crawling welding robot includes the following steps:
the method comprises the steps of firstly, teaching a scanning track;
secondly, inputting a welding seam type task number;
turning on the laser, and executing scanning teaching;
fourth, the TCP user coordinates are sent to the sensor;
judge whether teaching track is completed? If not, returning to the fourth step, and if yes, entering a next step;
sixthly, turning off the laser;
request welding track points;
and executing a welding trajectory;
the self-john judges whether the welding track is finished, if not, the step is returned to, and if so, the step is carried out;
the welding is finished.
Referring to fig. 3 to 7, the welding method for calibrating the full-position crawling welding robot includes the following steps:
firstly, the operation room 2 is quickly moved to the position near the initial operation position of a workpiece by combining a master control operation table 11, a monitoring display 13 and a wireless remote control terminal 14, and a movable connection bridge 21 is controlled to be in place by a tail end monitoring camera 23 and an opening and closing oil cylinder of the operation room 2;
the crawling operation is started by the crawling operation robot 3 according to the planned collision-free path, the cable winding mechanism 245 automatically releases the cable, and the tail end operation room 2 moves or moves intermittently along with the crawling welding robot 3 according to the operation condition;
the sensors automatically find positions of start and stop points of the welding seam, three-dimensional trajectory data and width data of the welding seam are transmitted to the crawling welding robot controller 244 in real time, and the crawling welding robot controller 244 performs cooperative control, operation task path planning, posture generation of the welding gun and real-time deviation correction on a welding machine system, a welding seam tracker 126 and the crawling welding robot controller 244 which are formed by a welding power supply;
the crawling robot system controller, the crawling robot body controller 244, the welding seam tracker controller 43 and the welding machine system controller 44 respectively adopt EtherCat, GigE and CANopen to achieve control signal transmission and operation data feedback; the mobile walking crank arm lifting platform controller 42 is interconnected with the mobile walking mechanism controller 46, the crank arm lifting mechanism controller 47 and the tail end operation room controller 48 through CANopen and RS485 serial ports, so that the mobile walking self-locking of the platform trolley, the rotation of the crank arm, the lifting of the crank arm, the opening and closing of the operation room 2 and the movement of the operation room 2 along with the clearance of the crawling robot are realized;
at this moment, if the system has an abnormal audible and visual alarm, or the system automatically interrupts welding operation when the system needs to cross a large obstacle or move for a large distance according to the task, the crawling robot 3 returns to the tail end operation room according to a set path, and the operator operates the wireless remote control terminal to quickly move the tail end operation room 2 to a new operation position or interrupt the operation position to restart the operation.
The above-mentioned embodiments are only preferred embodiments of the present invention, and all equivalent changes and modifications made within the scope of the claims of the present invention should be covered by the claims of the present invention.
Claims (10)
1. The auxiliary welding device for the all-position crawling welding robot is characterized by comprising a 360-degree rotary hydraulic crank arm type lifting mechanism assembly, a crawling welding robot, an electric control device of a whole machine and a peripheral device, wherein the operation room is controlled by the hydraulic crank arm type lifting mechanism assembly to flexibly move to the surface and the periphery of any operation position of a large member, and the crawling welding robot is arranged in the operation room.
2. The auxiliary welding device for the all-position crawling welding robot of claim 1, wherein the crank arm type lifting mechanism assembly consists of a combined general control operation platform and a crank arm lifting mechanism which are arranged on a carrier; the crank arm lifting mechanism adopts three sections of hydraulic folding working arms to be rigidly connected with a tail end operation room; the crank arm lifting mechanism consists of a welding operation arm which is pivoted on the combined master control operation table through a first pivot, and a first crank arm which is pivoted at the end part of one end of the welding operation arm through a second pivot; the crank arms are driven by cylinders.
3. The auxiliary welding device for the all-position crawling welding robot of the claim 1, it is characterized in that the operation room is rigidly connected with the second crank arm, a movable connecting bridge is arranged outside the operation room, the movable connecting bridge bears and bears the stable transition between the crawling welding robot and the workpiece, the movable connecting bridge is connected with a pair of hydraulic cylinder systems through a group of hinges to ensure the angle required by the transition between the crawling welding robot and the surface of the workpiece, a camera is arranged on a second crank arm right below the movable connecting bridge, peripheral equipment for the welding robot is arranged on the operation room, the peripheral equipment comprises a welding power supply, a wire feeder and a welding wire barrel, a protective gas mixture, a crawling robot controller and a cable winding mechanism, the peripheral equipment is connected with the relay box and the combined general control operation table on the lower chassis from the lifting mechanism through a special cable for power supply and communication.
4. The auxiliary welding device for the all-position and all-position crawling welding robot as claimed in claim 3, wherein the crawling welding robot comprises a permanent magnet type four-wheel drive moving platform, a six-degree-of-freedom welding mechanical arm borne on the moving platform, a supporting frame fixedly arranged on the welding mechanical arm, a second crank arm pivoted to the supporting frame through a third pivot, a third crank arm pivoted to the other end of the second crank arm through a fourth pivot, a first connecting arm pivoted to the other end of the third crank arm through a fifth pivot, a second connecting arm pivoted to the first connecting arm through a sixth pivot, a welding gun fixedly arranged on the second connecting arm, a welding seam tracker fixedly arranged on the end part of the second connecting arm, and a molten pool monitoring camera; the welding seam tracker for welding is arranged on the tail end shaft of the second connecting arm, the central line of the welding seam tracker and the central line of a welding gun on the tail end shaft of the second connecting arm are positioned on the same horizontal plane in space, and the relative displacement is fixed; the welding line tracker automatically seeks the start point and the stop point of the welding line, the three-dimensional track data and the width data of the welding line are transmitted to the crawling welding robot controller in real time, and the crawling welding robot controller performs cooperative control, operation task path planning, welding gun posture generation and real-time deviation correction on a welding machine system, the welding line tracker and a crawling robot control system which are composed of a welding power supply.
5. The auxiliary welding device for the all-position crawling welding robot as claimed in claim 1 or 2, wherein the electric control equipment comprises a combined general control operation table, a crawling robot system controller and a moving walking crank lifting platform controller, and the crawling robot system controller respectively realizes control signal transmission and operation data feedback with the crawling robot controller, the welding seam tracker controller and the welding machine system controller through EtherCat, GigE and CANopen; the crawling robot controller realizes control signal transmission and operation data feedback through EtherCat, a crawling robot trolley and servo of each joint, and the welding seam tracker controller realizes control signal transmission and operation data feedback through GigE and a welding seam detection visual sensor; the mobile walking crank arm lifting platform controller is interconnected with the mobile walking mechanism controller, the crank arm lifting mechanism controller and the operation room controller through CANopen and RS485 serial ports, so that the mobile walking self-locking, crank arm rotation, crank arm lifting, operation room opening and closing and the operation room following crawling robot gap movement of the platform trolley are realized; the mobile walking mechanism controller realizes control signal transmission and operation data feedback through the WIFI/5G, CANopen, the monitoring camera and the inter-operation opening and closing oil cylinder; the crank arm lifting mechanism controller realizes control signal transmission and operation data feedback through CANopen and crank arm rotation and a crank arm lifting oil cylinder and a support oil cylinder; the mobile walking controller realizes control signal transmission and operation data feedback through the CANopen, the mobile walking mechanism and the driving mechanism.
6. The auxiliary welding device for the all-position crawling welding robot as claimed in claim 5, wherein the crawling welding robot, the mobile walking device, the chassis, the crank arm lifting mechanism and the operation room are electrically connected; the crawling operation robot is used for simultaneously tracking a molten pool and detecting the quality of a welded weld bead, a required molten pool monitoring camera and weld bead detection equipment are arranged on a mechanical arm at the tail end of the crawling robot and are electrically connected with a crawling robot controller, and collected images and detection data are transmitted to a display screen of a main control operation platform on a chassis through Ethernet communication to display shot images and analysis data; the following movement is controlled by combining a working room monitoring camera according to the walking distance and the direction of the crawling robot through a combined and combined master control operation platform on a wireless remote control terminal or a chassis.
7. A control method for calibrating a full-position and full-position crawling welding robot is characterized by comprising the following steps:
firstly, calibrating a teaching track, and inputting a welding gun and measuring deviation;
secondly, sending welding gun measurement deviation to a sensor;
turning on the laser, and sending a calibration task number;
fourth, executing a calibration teaching track;
sending the TCP user coordinate to the sensor;
sixthly, judging whether teaching tracks are finished? If not, returning to the fourth step, and if yes, entering a next step;
the laser is shut down and calibration is complete.
8. A welding control method for a full-position and full-position crawling welding robot is characterized by comprising the following steps:
the method comprises the steps of searching for a bit and teaching; welding demonstration;
secondly, inputting a welding seam type task number;
turning on the laser, and sending a calibration task number;
fourth, executing a calibration teaching track;
judging whether the welding line is found stably: if not, returning to the fourth step, and if yes, entering a next step;
sixthly, turning off the laser and returning to the starting point of the welding seam;
turn on the laser, perform welding teaching and compensate according to the sensor;
and judging whether to end: if not, returning to step-quietness; if yes, entering the next step;
the laser is turned off to complete the welding.
9. A control method for calibration of a full-position crawling welding robot is characterized by comprising the following steps:
the method includes the steps that firstly, a welding robot moves to an initial position of a path planning point on the surface of a workpiece, and scanning track teaching is executed;
secondly, inputting a welding seam type task number;
turning on the laser, and executing scanning teaching;
fourth, the TCP user coordinates are sent to the sensor;
judge whether teaching track is completed? If not, returning to the fourth step, and if yes, entering a next step;
sixthly, requesting to weld track points;
executing a welding trajectory;
judging whether the welding track is finished, if not, returning to the step of quieting, and if so, entering the next step;
laser device with self-closing function
The welding is finished.
10. A welding method for an all-position crawling welding robot is characterized by comprising the following steps:
the method comprises the steps that an operation room is quickly moved to the position near the initial operation position of a workpiece through a combined and combined general control operation table, a monitoring display and a wireless remote control terminal, and a movable connecting bridge is controlled to be in place through a tail end monitoring camera and an operation room opening and closing oil cylinder;
the crawling operation robot starts crawling operation according to a planned collision-free path, the cable winding mechanism automatically releases wires, and the tail end operation room moves or moves intermittently along with the crawling welding robot according to the operation condition;
the welding seam tracking sensor automatically locates the start and stop points of the welding seam, three-dimensional trajectory data and width data of the welding seam are transmitted to the crawling welding robot controller in real time, and the crawling welding robot controller performs cooperative control, operation task path planning, welding gun posture generation and real-time deviation correction on a welding machine system, a welding seam tracker and a crawling robot control system which are formed by a welding power supply;
the crawling robot system controller, the crawling robot body controller, the welding seam tracker controller and the welding machine system controller respectively adopt EtherCat, GigE and CANopen to achieve control signal transmission and operation data feedback; the mobile walking crank arm lifting platform controller is interconnected with the mobile walking mechanism controller, the crank arm lifting mechanism controller and the tail end operation room controller through CANopen and RS485 serial ports, so that the mobile walking self-locking, crank arm rotation, crank arm lifting, operation room opening and closing and the operation room following crawling robot gap movement of the platform trolley are realized;
at this moment, if the system has an abnormal audible and visual alarm, or the system automatically interrupts welding operation when the system needs to cross a large obstacle or move for a large distance according to task requirements, the crawling robot returns to the tail end operation room according to a set path, and the operator operates the wireless remote control terminal to quickly move the tail end operation room to a new operation position or interrupt the operation position to restart the operation.
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| CN116921955A (en) * | 2023-09-01 | 2023-10-24 | 新蔚来智能科技(山东)有限公司 | Steel member welding method and welding equipment thereof |
| CN117245303A (en) * | 2023-11-03 | 2023-12-19 | 杭萧钢构（山东）有限公司 | Welding robot suitable for large-sized steel member and welding method thereof |
| CN118342172A (en) * | 2024-06-17 | 2024-07-16 | 中建安装集团有限公司 | Mechanical arm special for welding petroleum storage tank pontoon board and use method thereof |
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