船舱格子型角焊缝移动焊接机器人系统设计

Design of Mobile Welding Robot System for Lattice Fillet Welds in Base Ship

针对大型船舱格子型角焊缝空间狭小,大型自动化设备与工人难以高质量完成焊接作业的现状,设计了一种可进行连贯直角角焊缝焊接的移动焊接机器人系统。该机器人由机械结构与电路控制系统组成,其中机械结构包括双轴后驱车体、可伸缩接触式传感器、机器人升降旋转复合机构、焊枪位姿调整机构;电控系统硬件包括PLC控制器、行程限位开关、步进电机与配套驱动器、直流减速电机和配套的运动状态调控板。另外,还建立了机器人在直角段角焊缝焊接过程的运动学模型,获取了该段焊缝在均分为10段后每段焊枪的伸缩速度与机器人旋转角速度的数值,为直角型角焊缝焊接的跟踪控制过程提供了PLC编程的数据基础;并基于可伸缩接触式传感器,实现了直线型角焊缝的路径跟踪。实验证明,该机器人能实现小空间直角型角焊缝与直线型角焊缝的连贯焊接,焊缝成型质量好,无焊穿、气孔、焊瘤、咬边、裂纹等不良状况。

Aiming at the current situation that the grid fillet welds'space in large cabins is small and it is difficult for large-scale automation equipment and workers to complete the welding operation with high quality,a mobile welding robot system that can perform continuous right-angle fillet weld welding was designed.The robot was composed of a mechanical structure and a circuit control system.The mechanical structure includes a biaxial rear driving body,a telescopic contact sensor,a robot lifting and rotating composite mechanism and a welding torch pose adjustment mechanism.The hardware of the electronic control system includes PLC controller,travel limit switch,stepper motor and supporting driver,DC deceleration motor and supporting motion state control board.In addition,the kinematic model of the robot in the welding process of right-angle fillet weld was established,and the values of the extension and contract speeds of the welding torch and the rotational angular speed of the robot in each weld section were obtained for the weld divided into 10 sections,which provided the data basis of PLC programming for the tracking control process of the right-angle fillet weld.Based on the retractable contact sensor,the path tracking of the straight fillet weld was realized.The experiments show that the robot can realize the continuous welding of right-angle fillet welds and straight fillet welds in small space,and the welding seam forming quality is good,and there are no bad conditions such as weld penetration,blowhole,weld flash,undercut and crack.