A measuring and correcting method about locus errors in robot welding

When tubules regularly arranged are welded onto a bobbin by robot, the position and orientation of some tubules may be changed by such factors as thermal deformations and positioning errors etc. Which make it very difficult to weld automatically and continuously by the method of teaching and playing. In this paper, a kind of error measuring system is presented. By which the position and orientation errors of tubules relative to the teaching one can be measured. And, a method to correct the locus errors is also proposed, by which the moving locus planned via teaching points can be corrected in real time according to measured error parameters. So that, just by teaching one, all tubules on a bobbin could be welded automatically.

An Automatic Test System in Robot Welding Station

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Off-line simulation of robot welding of radar pedestal

A study of the interference simulation based on robot welding of the radar pedestal was carried out by using the KUKA Sim Pro simulation software and off-line program technology. Compared with the actual robot welding process, it was found that the trajectory of the simulated robot welding process in line with that recorded in the actual welding process, and the actual limit and interference appeared at the same place as the simulation process. There was no interference phenomenon on the outside weld-seam; on the internal weld-seam, especially on the weld-joint of support plate connected to the cylinder, a phenomenon of interference appeared. It was helpful to use the simulation method to guide the actual robot welding so as to protect robot from impacting and reduce the weld defects.

基于博途和RobotStudio的焊接机器人应用研究

采用RobotStudio进行机器人运动轨迹规划、碰撞检测以及离线编程,通过S7通信协议实现与PLC的数据交互,利用博途进行PLC编程和监控,最后通过人机界面实现用户与仿真系统的直观交互。整个系统形成闭环,从机器人编程到实时数据监控,再到用户操作反馈,实现了焊接过程的全面仿真与优化。该焊接工业机器人仿真系统旨在通过集成先进的仿真技术和实时通信功能,为焊接工艺提供高度集成的仿真环境、智能化的数据分析与监控、直观的人机交互体验、安全可靠的虚拟测试与验证平台。其成果可广泛应用于教育培训、科研实验等领域,降低成本和安全风险。

A vision tracking system of robot CO_2 short transfer welding

This paper expounds the necessity of applying real-time control in vision sensing and tracking system of welding robot and analyses the difficulty of welding image processing. Through experiments, a practical robot CO2 arc adaptive feedback tracking system is established. According to the analysing of current and voltage signals between welding torch and base metal, the image freezing time for TMS-32020 processor is determined, and the defect of dark image and serious splashes in CO, welding image are avoided. Thus welding image becomes clear, and digitalization of video signal is stability. Then, with adaptive threshold control the welding image binaryzation, 3×3 mean level filtration and 3×3 weighting mean level filtration in welding seam are processed.Furthermore, the deviation between the centre of welding torch and the seam welded is found out, even though there are much spatter in the welding image.At last, the end effector of the robot is controlled and a welding torch is carried to track the seam welded during arc welding.

FLEXIBLE MAGNETIC WHEEL TYPE INTELLIGENT WELDING ROBOT FOR SPHERICAL TANK

An intelligent welding robot for spherical tank's all-position multi-layerwelds is developed. Based on the dynamics analyzing and simulation testing, a flexible magneticwheel mechanism is created as the robot's walking carriage. It makes the robot directly attracted tothe surface of the spherical tank so as to realize the all-position walking and welding withoutrail. At the same time, a CCD real-time tracing system is developed for the robot to repeatedlytrace the all-position and multi-layer seams. The welding tests show that the welding robot can makethe all-position and multi-layer welds with high tracing accuracy, excellent quality and reliablebehavior, and it can be applied for practical production.

Constant Speed Control for Complex Cross-section Welding Using Robot Based on Angle Self-Test

Expandable profile liner（EPL） is a promising new oil well casing cementing technique, and welding is a major EPLs connection technology. Connection of EPL is still in the stage of manual welding so far, automatic welding technology is a hotspot of EPL which is one of the key technologies to be solved. A robot for automatic welding of＂8＂ type EPL is studied. Four quadrants of mathematical equations of the 8-shaped cross-section track of EPL, consisting of multiple arcs, are established. Mechanism program for complex cross-section welding of EPL based on angle detection is proposed according to characteristics of small size, small valleys, and large forming errors, etc. A welding velocity vector control model is established by linkage control of a welding vehicle, a small driven actuator, and a height tracking mechanism. A constant speed control model based on an angle and symmetrical analysis model of rectangular coordinate system for EPL is built. Constraint conditions of constant speed control between each section are analyzed with 4 sections in first quadrant as an example, and cooperation work mechanism of the welding vehicle and the small tracking actuator is established based on pressure detection. The constant speed control model using angle self-test can be used to avoid the need for a precise mathematical model for tracking control and to adapt manufacture and installation deviation of EPL workpiece. The model is able to solve constant speed and trajectory tracking problems of EPL cross-section welding. EPL seams welded by the studied robot are good in appearance, and non-destructive testing（NDT） shows the seams are good in quality with no welding defects. Bulge tests show that the maximum pressure of welded EPL is 35 MPa, which can fulfill expansion performance requirements.

Seam Tracking and Visual Control for Robotic Arc Welding Based on Structured Light Stereovision

A real-time arc welding robot visual control system based on a local network with a multi-level hierarchy is developed in this paper. It consists of an intelligence and human-machine interface level, a motion planning level, a motion control level and a servo control level. The last three levels form a local real-time open robot controller, which realizes motion planning and motion control of a robot. A camera calibration method based on the relative movement of the end-effector connected to a robot is proposed and a method for tracking weld seam based on the structured light stereovision is provided. Combining the parameters of the cameras and laser plane, three groups of position values in Cartesian space are obtained for each feature point in a stripe projected on the weld seam. The accurate three-dimensional position of the edge points in the weld seam can be calculated from the obtained parameters with an information fusion algorithm. By calculating the weld seam parameter from position and image data, the movement parameters of the robot used for tracking can be determined. A swing welding experiment of type V groove weld is successfully conducted, the results of which show that the system has high resolution seam tracking in real-time, and works stably and efficiently.

Discerning Weld Seam Pro les from Strong Arc Background for the Robotic Automated Welding Process via Visual Attention Features

In the robotic welding process with thick steel plates,laser vision sensors are widely used to profile the weld seam to implement automatic seam tracking.The weld seam profile extraction(WSPE)result is a crucial step for identifying the feature points of the extracted profile to guide the welding torch in real time.The visual information processing system may collapse when interference data points in the image survive during the phase of feature point identification,which results in low tracking accuracy and poor welding quality.This paper presents a visual attention featurebased method to extract the weld seam profile(WSP)from the strong arc background using clustering results.First,a binary image is obtained through the preprocessing stage.Second,all data points with a gray value 255 are clustered with the nearest neighborhood clustering algorithm.Third,a strategy is developed to discern one cluster belonging to the WSP from the appointed candidate clusters in each loop,and a scheme is proposed to extract the entire WSP using visual continuity.Compared with the previous methods the proposed method in this paper can extract more useful details of the WSP and has better stability in terms of removing the interference data.Considerable WSPE tests with butt joints and T-joints show the anti-interference ability of the proposed method,which contributes to smoothing the welding process and shows its practical value in robotic automated welding with thick steel plates.

3D reconstruction of worn parts for flexible remanufacture based on robotic arc welding

3D reconstruction of worn parts is the foundation for remanufacturing system based on robotic arc welding, because it can provide 3D geometric information for robot task plan. In this investigation, a novel 3D reconstruction system based on linear structured light vision sensing is developed. This system hardware consists of a MTC368-CB CCD camera, a MLH-645 laser projector and a DH-CG300 image grabbing card. This system software is developed to control the image data capture. In order to reconstruct the 3D geometric information from the captured image, a two steps rapid calibration algorithm is proposed. The 3D reconstruction experiment shows a satisfactory result.

ALGORITHM AND IMPLEMENTATION OF AUTO-SEARCHING WELD LINE FOR WELDING MOBILE ROBOT

An algorithm of auto-searching weld line for welding mobile robot is presented. Auto-searching weld line is that the robot can automatically recognize a weld groove according to the characteristics of the weld groove before welding, and then adjust itself posture to the desired status preparing for welding, namely, it is a process that the robot autonomously aligns itself to the center of welding seam. Firstly, the configuration of welding mobile robot with the function of auto-searching weld line is introduced, then the algorithm and implementation of auto-searching weld line are presented on the basis of kinematics model of the robot, at last trajectory planning among auto-searching weld line is investigated in detail. The experiment result shows that the developed welding mobile robot can successfully implement the task of auto-searching weld line before welding, tracking error precision can be controlled to approximate ±1.5 mm, and satisfy the requirement of practical welding project.

Control algorithm based on trajectory and orientation of oblique intersection line welding-cutting robot

Working principle for a four-axis oblique intersection line welding robot is analyzed. A mathematical model for welding torch orientation angle is established, and an interpolation algorithm based on time division is proposed. The algorithm makes all interpolation points fall on a required curve in theory with no accumulated errors and a direct interpolation control on the saddle-shaped curve trajectory and space orientation angle can be achieved. It is shown by MATLAB simulation that the algorithm is real-time and fully meets the precision requirement. The algorithm has been applied to real robots.

Guiding the welding robot to the initial welding position with visual method

Using step pattern match technology with variational resolution can recognize the position and orientation of the weld seam in the image. According to using the image segmentation method based on pattern match, not only advanced the speed and anti-jamming capability, but also captured the edge information of the weld seam and the edge of the workpiece, and the image coordinate of the initial welding position can be obtained. The matrix for hand-eye relationship of the robot can be calculated by adopting the rapid calculation method. According to the depth calculating principle with the special point matching using binocular stereovision, the initial welding position can be confirmed by calculating the middle point of the perpendicular line of two radials in the space, and the function to guide the welding robot to the initial welding position can be realized.

Study on general inverse kinematics of rotating/tilting positioner for robotic arc welding off-line programming

Off line programming provides an essential link between CAD and CAM, whose development will result in greater use of robotic arc welding. An arc welding system with a robot and a rotating/tilting positioner is one of the most typical workcells. The inverse kinematics of robot and positioner is the foundation of the off line programming system. The previous researchers only focused on a special solution of the positioner inverse kinematics, which is the solution at down hand welding position. In this paper, we introduce a method for representing welding position. Then a general algorithm of rotating/tilting positioner inverse kinematics is presented, and an approach to find the unique solution of the inverse kinematics is discussed. The simulation experiment results show that the general algorithm can improve the ability of robotic arc welding off line programming system to program all types of welding positions.

Seam tracking control for mobile welding robot based on vision sensor

To solve the seam tracking problem of mobile welding robot,a new controller based on the dynamics of mobile welding robot was designed using the method of backstepping kinematics into dynamics.A self-turning fuzzy controller and a fuzzy-Gaussian neural network(FGNN) controller were designed to complete coordinately controlling of cross-slider and wheels.The fuzzy-neural control algorithm was described by applying the Gaussian function and back propagation(BP) learning rule was used to tune the membership function in real time by applying the FGNN controller.To make the tracking more quickly and smoothly,the neural network controller based on dynamic model was designed,which utilized self-learning and self-adaptive ability of the neural network to deal with the partial uncertainty and the disturbances of the parameters of the robot dynamic model and real-time compensate the dynamics coupling.The results show that the selected control input torques make the system globally and asymptotically stable based on the Lyapunov function selected out;the accuracy of the proposed controller tracing is within ±0.4 mm and can satisfy the requirements of practical welding project.

Study on motion simulation of arc welding robot based on UG

The motion simulation of arc welding robot is the basis of the system of robot off-line programming, and it has been one of the important research directions. The UGNX 4. 0 is adopted to establish 3D simulating model of MOTOMAN-HP6 arc welding robot. The kinematic model under link-pole coordinate system is established by the second development function offered by UG/OPEN API and the method of programming using VC ＋＋ 6. 0. The methods of founding model and operational procedures are introduced, which provides a good basis for off-line programming technique under Unigraphies condition.

Dynamic modeling and simulation for nonholonomic welding mobile robot

Based on the Newton-Euler method, the dynamic behaviors of the left and right driving wheels and the robot body for the welding mobile robot were derived. In order to realize the combination control of body turning and slider adjustment, the dynamic behaviors of sliders were also investigated. As a result, a systematic and complete dynamic model for the welding mobile robot was constructed. In order to verify the effectiveness of the above model, a sliding mode tracking control method was proposed and simulated, the lateral error stabilizes between -0.2 mm and ＋0.2 mm, and the total distance of travel for the slider is consistently within 4-2 ram. The simulation results verify the effectiveness of the established dynamic model and also show that the seam tracking controller based on the dynamic model has excellent performance in terms of stability and robustness. Furthermore, the model is found to be very suitable for practical applications of the welding mobile robot.

Dynamic and control system analysis of two-wheeled robot for welding application

Aiming at the welding condition of space complex seam is uncertain and the intelligence of welding robot is unideal, a two-wheeled mobile robot is developed. It not only has the capacity of autonomous decision and avoiding obstacles, but also can flexibly move and strongly adapt variable environment. The composition of the welding robot is described and the dynamic model is established. The feasible control strategy and control algorithm is put forward. The simulation experiments of real world are conducted, the results are satisfying.

Inverse kinematics and welding experiments of the intersecting pipe welding robot

A robot used for multi-pass welding of the piping branch junctions and nozzle attachments to main pressure vessels is 4-DOF serial mechanism, two mobile joints and two rotary joints are adopted in design. The kinematic model was established with DH parameters, the inverse kinematics was solved. According to the forward and inverse kinematics equations, the robot kinematics was simulated in Matlab, the simulations indicate that the solution for inverse kinematics can satisfy the welding requirements well. As there are size errors, processing errors and welding deformation, the path of welding is forecasted according to the previous welding situation, and then, the path is taught at desired via-points, which plays an important role in submerged-arc welding. The submerged-arc welding experiments indicate that the robot and the welding methods are preferable to ensure welding quality.

An approach to measure the pose of RHJD4-1 arc welding robot for calibration

A measurement setup used for robot calibration was designed to meet the requirement of off line programming technique. The robot end effector pose (position and orientation) can be calculated indirectly by using this setup. The setup has been applied to RHJD4 1 arc welding robot. The experimental results show the method of pose measuring using the measurement setup is simple and reliable to finish pose measuring for robot calibration. In addition, the setup can measure the position repeatability of robot.