引水压力钢管现场组焊主从式爬壁机器人设计

Design of a master-slave wall climbing robot system for field assembly welding of penstock

为改善作业环境、提升焊接效率,设计研制了一种主从式爬壁焊接机器人系统。主机器人搭载焊枪并跟踪焊缝运动;从机器人负载送丝机等焊接相关设备并承载线缆拖曳力,跟随主机器人运动;主机器人与从机器人合作完成现场组焊作业。主机器人负载相对较低,运动灵活,可快速到达预焊位置并调节焊枪位置;从机器人负载能力较强,吸附稳定。主机器人与从机器人均采用永磁间隙吸附及轮式运动机构。为保证机器人全位置全姿态的焊接作业,通过静力学与动力学分析优化了吸附机构设计。焊接机构采用深度相机视觉跟踪模块,对焊缝坡口的识别精度可达1 mm。在此基础上,设计开发了基于ROS的控制系统,并试制了一套机器人样机,综合试验结果表明,机器人样机的运动性能和坡口识别跟踪精度满足工程应用需求。

In order to improve the working environment and raise the welding efficiency,a master-slave wall-climbing robot system was designed and developed.The master robot carried the welding torch and followed the weld.The slave robot loaded the related welding equipment such as wire feeder,and the force from the cable.The slave robot followed the master robot in motion.The master robot cooperated with the slave robot to complete the field assembling welding.The master robot’s overall weight was relatively light and its motion was flexible,so it could reach the target position quickly and adjust the position of welding gun.The slave robot had strong load capacity and adhesion stability.Both the master robot and the slave robot adopted the non-contact permanent magnetic adhesion and the wheeled motion mechanism.In order to ensure the all-position and all-attitude welding,the design of the adsorption mechanism was optimized through static and dynamic analysis of the robot.The welding mechanism employed depth camera as visual tracking module and its recognition accuracy of weld seam reached 1 mm.On this basis,the software and hardware platform of the control system based on ROS was designed and developed,and a set of robot prototype was developed.The comprehensive experiment results showed that the motion performance and weld recognition and track accuracy of the robot prototype met the requirements of engineering applications.