焊接机器人方案_PLC_类别分类_产品

焊接机器人方案

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将机器人通过磁吸直接固定在甲板任意位置（磁吸底座如图5所示，通过拨动开关控制磁力的通断），有几种焊缝在机器人中编入几种焊接模式，如横焊还是立焊。这种方案机器人体重轻，工作半径626mm的机器人重量为12kg，一人即可搬运，使用过程中因臂展较短，焊接一个大方格需搬运2-4次，但因其重量轻、易固定，操作简单快捷，能够快速改变机器人位置，提高焊接效率；工作半径1327mm的机器人重量为41kg，两人即可搬运，臂展长，固定一次焊接范围大，焊接一个大方格需至多搬运两次，减少了机器人的搬动次数。

识别焊缝。安装好机器人并进行定位后，第一次对甲板进行焊接时，首先进行人工示教，确定机器人的焊接路线，后续焊接相同形状位置无需重新示教。示教过程采用将激光线条直接打在焊缝位置，而不是采用激光点对焊缝上下扫描的方式，极大地提高了焊缝识别的速度和精度。

相机标定。确保机器人TCP端口的精度；将焊枪尖端放在外部尖端上旋转X，Y，Z轴，确保TCP始终饶外部尖端旋转，精度误差超过1mm需重校TCP。

将一个标定物放在设计的坐标原点处，将激光照射到标定物上，获得标定信息后，软件自动设置该点为坐标原点。标定完成后，在对相同结构的焊接位置进行焊接时，只需识别标定物，确定原点，即可焊接，无需重复人工示教。

激光焊缝跟踪器。完整的焊接跟踪过程分为四段，第一段为搜索寻位阶段，第二阶段为跟踪焊接阶段，第三阶段为保持焊接阶段，最后为结束段。坐标系分为：世界坐标（基坐标），法兰坐标，工具坐标，用户坐标。

焊缝跟踪实际上调整的是工具坐标。工具坐标以法兰为中心，分为三个方向x，y，z符合右手定则。为了使焊缝跟踪器能够正确的调整机器人的轨迹，需要对焊缝跟踪器的坐标系与机器人的工具坐标进行校准。

解决干扰问题。为避免在焊接车间中，大功率设备和焊接本身产生的电磁干扰对焊接机器人的通讯和测量补偿造成影响，采取以下措施：

（1）选择具有抗干扰性的传感器，以减小焊接过程中产生的电磁干扰对测量精度的影响；考虑使用自适应控制算法，可以实时调整参数以应对电磁干扰引起的测量误差；定期进行校准和检测，确保测量系统的准确性。

（2）选择抗干扰能力强的通讯方式，例如使用具有抗干扰特性的工业以太网协议，如Profinet或EtherCAT；采用差分信号传输，以减少对电磁干扰的敏感性；使用屏蔽电缆来减少外部电磁干扰对通讯线路的影响。

（3）在通讯线路上添加滤波器，以滤除来自大功率设备的电磁噪声；采用隔离技术，确保通讯信号不受其他电气设备的影响。

（4）对焊接机器人的控制系统和传感器进行电磁屏蔽，防止外部电磁干扰影响其正常运行；将关键部件放置在金属屏蔽盒内，以防止电磁辐射和感应。

（5）确保焊接机器人系统和其他设备的良好接地，以减少地回路引起的电磁干扰；使用专门的接地系统，确保电流通过合适的路径流回地。

Fix the robot directly at any position on the deck through magnetic suction (the magnetic suction base is shown in Figure 5, and the magnetic force is controlled by toggle switches). There are several welding modes in the robot, such as horizontal welding or vertical welding. This solution has a lightweight human body, and a robot with a working radius of 626mm weighs 12kg, which can be transported by one person. During use, due to the short arm span, welding a large grid requires 2-4 times of transportation. However, due to its lightweight, easy fixation, and simple and fast operation, it can quickly change the position of the robot and improve welding efficiency; The weight of the robot with a working radius of 1327mm is 41kg, which can be carried by two people. The arm is extended, and the welding range is large when fixed once. Welding a large grid requires at most two moves, reducing the number of moves for the robot.

Identify welds. After installing the robot and positioning it, when welding the deck for the first time, manual teaching is carried out to determine the welding route of the robot. Subsequent welding of the same shape position does not require re teaching. The teaching process adopts the method of directly hitting laser lines at the weld seam position, instead of using laser points to scan up and down the weld seam, greatly improving the speed and accuracy of weld seam recognition.

Camera calibration. Ensure the accuracy of the robot's TCP port; Place the welding gun tip on the external tip and rotate the X, Y, and Z axes to ensure that the TCP always rotates around the external tip. If the accuracy error exceeds 1mm, recalibrate the TCP.

Place a calibration object at the designed coordinate origin, irradiate the laser onto the calibration object, obtain calibration information, and the software automatically sets the point as the coordinate origin. After calibration is completed, when welding positions of the same structure, only the calibration object needs to be identified and the origin determined to weld, without the need for repeated manual teaching.

Laser weld seam tracker. The complete welding tracking process is divided into four stages. The first stage is the search and positioning stage, the second stage is the tracking welding stage, the third stage is the holding welding stage, and the last stage is the ending stage. The coordinate system is divided into world coordinates (base coordinates), flange coordinates, tool coordinates, and user coordinates.

Weld seam tracking actually adjusts the tool coordinates. The tool coordinates are centered on the flange and divided into three directions x, y, and z, which comply with the right-hand rule. In order to enable the weld seam tracker to adjust the trajectory of the robot correctly, it is necessary to calibrate the coordinate system of the weld seam tracker with the tool coordinates of the robot.

Resolve interference issues. To avoid the impact of electromagnetic interference generated by high-power equipment and welding itself on the communication and measurement compensation of welding robots in the welding workshop, the following measures are taken:

(1) Select sensors with anti-interference capabilities to reduce the impact of electromagnetic interference generated during the welding process on measurement accuracy; Consider using adaptive control algorithms that can adjust parameters in real-time to cope with measurement errors caused by electromagnetic interference; Regularly calibrate and test to ensure the accuracy of the measurement system.

(2) Choose communication methods with strong anti-interference capabilities, such as using industrial Ethernet protocols with anti-interference characteristics, such as ProfNet or Ether CAT; Using differential signal transmission to reduce sensitivity to electromagnetic interference; Use shielded cables to reduce the impact of external electromagnetic interference on communication lines

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