阅读说明：本技术 焊接系统、控制装置、控制程序及焊接方法 (Welding system, control device, control program, and welding method ) 是由 竹村义也 斋藤康之 焦有卓 于 2020-02-14 设计创作，主要内容包括：能够自动地计算把持工件时的定位器的位置,使定位器的定位作业自动化而实现作业效率的提高。使用焊接装置(30)及定位器(40)对工件(W)进行焊接的焊接系统(1)具有对焊接装置(30)及定位器(40)进行控制的控制装置(50)。定位器(40)具备：工件位置设定机构(41),其具有基准位置信息；以及至少一个把持机构(10),其把持工件(W)。控制装置(50)具有定位器位置计算单元(51a),所述定位器位置计算单元(51a)基于从工件位置设定机构(41)提供的基准位置信息和预先输入到控制装置(50)的工件信息,来计算把持工件(W)时的把持机构(10)的位置。(The position of the positioner when holding the workpiece can be automatically calculated, and the positioning operation of the positioner can be automated to improve the operation efficiency. A welding system (1) for welding a workpiece (W) by using a welding device (30) and a positioner (40) is provided with a control device (50) for controlling the welding device (30) and the positioner (40). The positioner (40) is provided with: a workpiece position setting mechanism (41) having reference position information; and at least one gripping mechanism (10) which grips the workpiece (W). The control device (50) is provided with a positioner position calculation unit (51a), and the positioner position calculation unit (51a) calculates the position of the gripping mechanism (10) when gripping the workpiece (W) based on reference position information supplied from the workpiece position setting mechanism (41) and workpiece information input to the control device (50) in advance.)

1. A welding system for welding a workpiece using a welding device and a positioner,

the welding system has a control device that controls the welding device and the positioner,

the positioner is provided with: a workpiece position setting mechanism having reference position information; and at least one holding mechanism for holding the workpiece,

the control device includes a positioner position calculation unit that calculates a position of the gripping mechanism when gripping the workpiece, based on the reference position information supplied from the workpiece position setting mechanism and workpiece information input to the control device in advance.

2. The welding system of claim 1,

the control device has a database in which a position of the gripping mechanism when gripping the workpiece is stored for each piece of the workpiece information,

the positioner position calculating unit calculates the position of the gripping mechanism when gripping the workpiece with reference to the database.

3. The welding system of claim 1 or 2,

the workpiece information includes at least one of dimensional data and welding position data of the workpiece.

4. The welding system of claim 1 or 2,

the control device includes a synchronization control unit that controls the welding device to synchronize with the positioner.

5. The welding system of claim 1 or 2,

the welding device is a welding robot,

the welding robot and the positioner each have a movement axis that can move in parallel.

6. The welding system of claim 5,

the positioner has more than two holding mechanisms,

when one of the gripping mechanisms is a driving side gripping mechanism and the remaining gripping mechanisms are driven side gripping mechanisms,

the driving side gripping mechanism and the driven side gripping mechanism are respectively provided with a servo motor positioned at a predetermined position,

the control device controls the position of the driven-side gripping mechanism based on the position located by the driving-side gripping mechanism with respect to the position of the gripping mechanism when gripping the workpiece, which is calculated by the positioner position calculation unit.

7. The welding system of claim 1 or 2,

the control device includes an automatic program generation unit that automatically generates an operation program for moving the gripping mechanism and the welding device to the position of the gripping mechanism when gripping the workpiece, which is calculated by the positioner position calculation unit.

8. The welding system of claim 1 or 2,

the workpiece information includes center-of-gravity data of the workpiece,

the positioner position calculating unit calculates the position of the gripping mechanism when gripping the workpiece with reference to the center of gravity data.

9. A control device for a welding system for welding a workpiece by using a welding device and a positioner,

the control device controls the welding device and the positioner,

the control device includes a positioner position calculation unit that calculates a position of a gripping mechanism of the positioner when gripping the workpiece, based on reference position information supplied from a workpiece position setting mechanism of the positioner and workpiece information input to the control device in advance.

10. A control program for a welding system for welding a workpiece by using a welding device and a positioner,

the control program controls the welding device and the positioner,

the control program includes a positioner position calculating step of calculating a position of a gripping mechanism of the positioner when gripping the workpiece, based on reference position information supplied from a workpiece position setting mechanism of the positioner and workpiece information input in advance to the control program.

11. A welding method for welding a workpiece by using a welding device and a positioner,

the welding method comprises the following steps: controlling the welding device and the positioner by a control device that controls the welding device and the positioner,

the positioner is provided with: a workpiece position setting mechanism having reference position information; and at least one holding mechanism for holding the workpiece,

the welding method comprises the following steps: the position of the gripping mechanism when gripping the workpiece is calculated based on the reference position information supplied from the workpiece position setting mechanism and workpiece information input to the control device in advance.

Technical Field

The present invention relates to a welding system, a control device, a control program, and a welding method, and more particularly, to a welding system, a control device, a control program, and a welding method capable of automatically welding a large-sized welding workpiece by a welding robot.

Background

Conventionally, a welding apparatus for automatically welding a large-sized welding workpiece such as a steel frame structure by a welding robot has been disclosed. For example, a welding device described in patent document 1 includes: a welding robot, a welding control device for controlling the welding robot, and a rotary positioner for holding a workpiece automatically generate an operation trajectory and welding conditions of the welding robot in accordance with a welding robot trajectory and welding conditions prepared in advance, based on workpiece information such as a size of a steel frame structure and a shape of a welded joint input to an input unit of the welding control device.

Prior art documents

Patent document

Patent document 1: japanese patent No. 5883700 publication

Disclosure of Invention

Problems to be solved by the invention

In welding a workpiece, first, an operation of positioning the workpiece and a positioner holding the workpiece at an appropriate position is required. The positioning operation of the positioner requires a very time-consuming and complicated operation, and conventionally, the positioning operation is performed by trial and error based on the long-term experience of the operator, which has a problem of low efficiency.

The welding apparatus disclosed in patent document 1 aims to automate a welding operation after positioning a workpiece and a rotary positioner, and the positioning operation of the rotary positioner is not particularly studied.

The present invention has been made in view of the above-described problems, and an object thereof is to provide a welding system, a control device, a control program, and a welding method capable of automatically calculating the position of a positioner when gripping a workpiece, and automating the positioning operation of the positioner to improve the work efficiency.

Means for solving the problems

The above object of the present invention is achieved by the following configuration (1) of the welding system.

(1) A welding system for welding a workpiece by using a welding device and a positioner,

the welding system has a control device that controls the welding device and the positioner,

the positioner is provided with: a workpiece position setting mechanism having reference position information; and at least one holding mechanism for holding the workpiece,

the control device includes a positioner position calculation unit that calculates a position of the gripping mechanism when gripping the workpiece, based on the reference position information supplied from the workpiece position setting mechanism and workpiece information input to the control device in advance.

Preferred embodiments of the present invention relating to the welding system relate to the following (2) to (8).

(2) The welding system according to the above (1),

the control device has a database in which a position of the gripping mechanism when gripping the workpiece is stored for each piece of the workpiece information,

the positioner position calculating unit calculates the position of the gripping mechanism when gripping the workpiece with reference to the database.

(3) The welding system according to the above (1) or (2),

the workpiece information includes at least one of dimensional data and welding position data of the workpiece.

(4) The welding system according to any one of the above (1) to (3),

the control device includes a synchronization control unit that controls the welding device to synchronize with the positioner.

(5) The welding system according to any one of the above (1) to (4),

the welding device is a welding robot,

the welding robot and the positioner each have a movement axis that can move in parallel.

(6) The welding system according to the above (5),

the positioner has more than two holding mechanisms,

when one of the gripping mechanisms is a driving side gripping mechanism and the remaining gripping mechanisms are driven side gripping mechanisms,

the driving side gripping mechanism and the driven side gripping mechanism are respectively provided with a servo motor positioned at a predetermined position,

the control device controls the position of the driven-side gripping mechanism based on the position located by the driving-side gripping mechanism with respect to the position of the gripping mechanism when gripping the workpiece, which is calculated by the positioner position calculation unit.

(7) The welding system according to any one of the above (1) to (6),

the control device includes an automatic program generation unit that automatically generates an operation program for moving the gripping mechanism and the welding device to the position of the gripping mechanism when gripping the workpiece, which is calculated by the positioner position calculation unit.

(8) The welding system according to any one of the above (1) to (7),

the workpiece information includes center-of-gravity data of the workpiece,

the positioner position calculating unit calculates the position of the gripping mechanism when gripping the workpiece with reference to the center of gravity data.

The above object of the present invention is achieved by the following configuration (9) of a control device of a welding system.

(9) A control device for a welding system for welding a workpiece by using a welding device and a positioner,

the control device controls the welding device and the positioner,

the control device includes a positioner position calculation unit that calculates a position of a gripping mechanism of the positioner when gripping the workpiece, based on reference position information supplied from a workpiece position setting mechanism of the positioner and workpiece information input to the control device in advance.

The above object of the present invention is achieved by the following configuration (10) of a control program of a welding system.

(10) A control program for a welding system for welding a workpiece by using a welding device and a positioner,

the control program controls the welding device and the positioner,

the control program includes a positioner position calculating step of calculating a position of a gripping mechanism of the positioner when gripping the workpiece, based on reference position information supplied from a workpiece position setting mechanism of the positioner and workpiece information input in advance to the control program.

The above object of the present invention is achieved by the following structure (11) of the welding method.

(11) A welding method for welding a workpiece by using a welding device and a positioner,

the welding method comprises the following steps: controlling the welding device and the positioner by a control device that controls the welding device and the positioner,

the positioner is provided with: a workpiece position setting mechanism having reference position information; and at least one holding mechanism for holding the workpiece,

the welding method comprises the following steps: the position of the gripping mechanism when gripping the workpiece is calculated based on the reference position information supplied from the workpiece position setting mechanism and workpiece information input to the control device in advance.

Effects of the invention

According to the welding system, the control device, the control program, and the welding method of the present invention, the position of the positioner when gripping the workpiece can be automatically calculated, and the positioning operation of the positioner can be automated to improve the operation efficiency.

Drawings

Fig. 1 is a schematic diagram showing an overall configuration of a welding system according to an embodiment of the present invention.

Fig. 2A is a schematic diagram for explaining the structure and operation of the rotary positioner provided in the welding system according to the embodiment of the present invention, and is a diagram showing a state in which the circular arc portion of the annular holding portion is opened.

Fig. 2B is a schematic diagram for explaining the structure and operation of the rotary positioner provided in the welding system according to the embodiment of the present invention, and is a diagram showing a state in which a steel frame structure is accommodated in the annular holding portion.

Fig. 2C is a schematic diagram for explaining the structure and operation of the rotary positioner provided in the welding system according to the embodiment of the present invention, and is a diagram showing a state in which the circular arc portion of the annular holding portion is closed.

Fig. 3 is a schematic configuration diagram of the welding system shown in fig. 1 as viewed from above.

Fig. 4 is a schematic block diagram of the welding system shown in fig. 1.

Fig. 5 is a flow chart illustrating a welding sequence performed by the welding system shown in fig. 1.

Detailed Description

< 1. welding System >

A welding system according to an embodiment of the present invention will be described with reference to fig. 1 to 4.

The welding system 1 welds a steel frame structure W as a welding workpiece by gas shielded arc welding, for example.

As shown in fig. 1, a welding system 1 includes: the welding apparatus and control apparatus carriage 20, a welding robot 30 as a welding apparatus, a positioner 40 for holding the steel frame structure W at a predetermined position, and a control apparatus 50 for controlling the welding robot 30 and the positioner 40.

Further, as described with reference to fig. 4, the welding robot 30 includes: a slide mechanism 22 for moving the welding robot 30 mounted thereon in a direction to approach or separate from the steel-frame structure W, and a manipulator 32 having six-axis joints.

The positioner 40 includes: a pair of rotary positioners 10 as gripping means for the steel frame structure W, and a workpiece position setting means 41.

The control device 50 includes: a pc (personal computer)51 for controlling the overall operation of the welding system 1, a positioner controller 52, and a welding robot controller 53. The PC51 also has a database DB that stores the optimum position of the gripping mechanism 10 when gripping the workpiece W, for each piece of workpiece information such as dimensional data, welding position data, and center of gravity data of the steel frame structure W, which will be described later.

[ 1-1. locator ]

As described above, the positioner 40 includes: a pair of rotary positioners 10 as gripping means for the steel frame structure W, and a workpiece position setting means 41.

(1-1-1. rotary positioner)

The rotary positioner 10 holds the steel-frame structure W and rotates it during welding. As shown in fig. 1, the rotary positioner 10 according to the present embodiment is configured by a pair of a driving side rotary positioner 10A as a driving side gripping mechanism and a driven side rotary positioner 10B as a driven side gripping mechanism, and holds a columnar steel-frame structure W at least two positions in the longitudinal direction of the steel-frame structure W.

For example, when the welding robot 30 welds a straight portion of the steel frame structure W, the rotary positioner 10 does not rotate the steel frame structure W and welds the straight portion, and when the welding robot 30 welds an arc portion of the steel frame structure W, the rotary positioner rotates the steel frame structure W. Thus, the welding system 1 can continuously perform welding not only in the straight portion of the steel-frame structure W but also in the arc portion without breaking the arc. As shown in fig. 1, the rotational positioner 10 of the present embodiment includes: an annular holding portion 11, a lift arm mechanism 12, a bracket 13, and a turning positioner cart 14. In the steel-frame structure W, the arc portion is formed at the corner.

The annular holding portion 11 accommodates and holds the steel frame structure W therein. As shown in fig. 1, a plurality of fixing jigs 16 for holding the steel frame structure W from the periphery are provided inside the annular holding portion 11 so as to be extendable and retractable. The annular holding portion 11 clamps and fixes the steel-frame structure W from the periphery by the plurality of fixing jigs 16. As shown in fig. 2A, a gear 11a is formed on the outer periphery of the annular holding portion 11, and the gear 11a is configured to mesh with a pinion gear, not shown, provided inside the carrier 13. In fig. 1, a part of the gear 11a is omitted.

The lift arm mechanism 12 opens and closes the annular holding portion 11. As shown in fig. 2A, the lift arm mechanism 12 is provided on the side of the annular holding portion 11 and the holder 13, and has one end connected to the upper portion of the annular holding portion 11 and the other end connected to the side surface of the holder 13.

Specifically, as shown in fig. 2A, the lift arm mechanism 12 is opened to disconnect the annular holding portion 11 at a predetermined position, and the circular arc portion 11b, which is a part of the annular holding portion 11, is rotated clockwise to be separated from the remaining portion of the annular holding portion 11, so that the steel frame structure W can be accommodated therein. Then, after the steel-frame structure W is housed, as shown in fig. 2B, the arc portion 11B is rotated counterclockwise as shown in fig. 2C, the arc portion 11B is closed again, and the steel-frame structure W is clamped and held by four fixing jigs 16 provided inside the annular holding portion 11.

The holder 13 accommodates the annular holding portion 11. As shown in fig. 2A, the holder 13 has a shape in which a lower half of the annular holding portion 11 is housed and an upper half of the annular holding portion 11 is exposed. Further, inside the carrier 13, a pinion gear, not shown, disposed so as to mesh with the gear 11a of the annular holding portion 11 and a driving portion M for driving the pinion gear are provided. The driving unit M may be provided in at least one of the pair of rotary positioners 10, and the other rotary positioner 10 may be driven by the rotation of the one rotary positioner 10. In fig. 1, reference numeral 10A denotes a driving side rotational positioner, and reference numeral 10B denotes a driven side rotational positioner.

The rotary positioner carriage 14 can move each rotary positioner 10 along the positioner movement rail R1. As shown in fig. 1, the pair of rotary positioner carriages 14 are provided below the rotary positioner 10, and the rotary positioner 10 is independently movable in the longitudinal direction of the steel frame structure W by a servo motor, not shown.

As described above, the rotational positioner 10 is configured such that the gear 11a formed on the outer periphery of the annular holding portion 11 meshes with the pinion gear provided inside the carrier 13. Therefore, the rotary positioner 10 can rotate the steel frame structure W during the welding operation by rotating the annular holding portion 11 by driving the driving portion M.

(1-1-2. workpiece position setting mechanism)

As shown in fig. 1, the workpiece position setting mechanism 41 is disposed along a positioner movement rail R1 on a workpiece position setting mechanism carriage 43 that is movable in the longitudinal direction of the steel frame structure W. As shown in fig. 1 and 3, the workpiece position setting means 41 has, on its side surface, a reference surface 42 for setting a reference position S in the longitudinal direction of the steel frame structure W by, for example, bringing one end of the steel frame structure W into contact with the workpiece. That is, as will be described later, the workpiece position setting means 41 includes reference position information of the steel frame structure W for calculating an optimum position of the gripping means 10 when gripping the workpiece W.

When the reference position S in the longitudinal direction of the steel frame structure W is set, the reference surface 42 does not necessarily have to be in contact with one end of the steel frame structure W, and some gap may be provided between the reference surface 42 and one end of the steel frame structure W. The gap at this time is preferably 10mm or less.

The reference surface 42 does not need to be a side surface of the workpiece position setting means 41, i.e., a physical wall surface, as in the present embodiment, as long as the reference position S in the longitudinal direction of the steel frame structure W can be set, and includes setting the reference position S in the longitudinal direction of the steel frame structure W using a non-contact means such as a laser sensor, for example.

[ 1-2. carriage for welding device and control device ]

The welding mechanism constituting the welding system 1 is mounted on the carriage 20 for the welding apparatus and the control apparatus. As shown in fig. 1, the carriage 20 for the welding apparatus and the control apparatus is formed in a flat plate shape. Wheels 21 are provided on the lower portion of the welding-apparatus carriage 20, and the welding-apparatus carriage 20 is configured to be movable along a welding-apparatus carriage travel rail R2 by the wheels 21 driven by a motor, not shown. That is, the welding-apparatus and control-apparatus carriage 20 is provided so as to be movable in the longitudinal direction of the steel-frame structure W in parallel with the movement direction of the rotary positioner 10.

A slide mechanism 22 driven by a motor, not shown, is provided on the upper portion of the welding device and control device carriage 20, and a welding robot 30 and a control device 50 are placed on the upper portion of the slide mechanism 22. The slide mechanism 22 is configured to be movable on the carriage 20 for the welding apparatus and the control apparatus in a direction orthogonal to the moving direction of the rotary positioner 10, that is, the longitudinal direction of the steel frame structure W. Therefore, the welding robot 30 placed on the upper portion of the slide mechanism 22 is configured to be movable in a direction orthogonal to the moving direction of the rotary positioner 10 during welding. A wire supply container for accommodating a welding wire to be supplied to welding torch 31, a nozzle replacement device for replacing a nozzle provided at the tip of welding torch 31, a nozzle cleaning device for cleaning the nozzle, a wire cutting device for cutting the welding wire, a slag removal device for removing slag generated in the welded portion, and the like, all of which are not shown, may be placed on the upper portion of slide mechanism 22.

[ 1-3. welding robot ]

The welding robot 30 is used to weld the steel-frame structure W. As shown in fig. 1, the welding robot 30 includes a welding torch 31 that supplies a welding wire to a tip portion of a manipulator 32. The welding torch 31 is connected to a welding power supply, not shown, and configured to supply power to the welding wire through the welding torch 31.

The welding robot 30 is mounted on the welding apparatus and control apparatus carriage 20 via the slide mechanism 22, and is provided so as to be movable in the moving direction of the rotary positioner 10 and in the direction orthogonal to the moving direction of the rotary positioner 10 as described above. In fig. 1, the welding robot 30 is disposed between the pair of rotary positioners 10, and welds a weld joint between the pair of rotary positioners 10. The moving direction of the rotary positioner 10 corresponds to the longitudinal direction of the steel frame structure W, and the direction orthogonal to the moving direction of the rotary positioner 10 corresponds to the width direction of the steel frame structure W.

[ 1-4. control device ]

The control device 50 controls the operations of the rotary positioner 10, the rotary positioner carriage 14, the welding device and control device carriage 20, the slide mechanism 22, the welding robot 30, the workpiece position setting mechanism carriage 43, and the like.

Here, as shown in fig. 4, the control device 50 includes: a PC51 that controls the overall operation of the welding system 1, a positioner controller 52 that controls the operation of the positioner 40, and a welding robot controller 53 that controls the welding operation of the welding robot 30.

(1－4－1.PC)

The PC51 includes the positioner position calculating unit 51a and the program automatic generation unit 51b, and has a database DB that stores the optimum position of the rotary positioner 10 when gripping the steel-frame structure W for each piece of workpiece information such as the dimension data, the welding position data, and the center of gravity data of the steel-frame structure W.

The database is an aggregate of information and the like stored so as to keep a predetermined distance so that the welding robot 30 does not interfere with the rotary positioner 10 when welding a steel frame structure W having predetermined workpiece information, for example. That is, the "optimum position of the rotary positioner 10 when gripping the steel-frame structure W" calculated by the positioner position calculating unit 51a is a position of the rotary positioner 10 at which the steel-frame structure W can be welded without causing a problem and the steel-frame structure W can be reliably gripped.

However, the database DB of the present embodiment has been described as a database storing the optimal position of the rotary positioner 10 when gripping the steel-frame structure W, but this is merely an example, and a configuration may be adopted in which a database other than the optimal position of the rotary positioner 10 when gripping the steel-frame structure W is stored. That is, the position of the rotary positioner 10 is not necessarily the optimum position as long as the rotary positioner 10 can weld the steel frame structure W without causing a problem and can grip the steel frame structure W, and therefore, the rotary positioner 10 may be configured to store the positions of the rotary positioner 10 when gripping the steel frame structure W other than the optimum position as the database DB.

The positioner position calculating means 51a calculates the position of the rotary positioner 10 capable of gripping the steel frame structure W at the optimum position, based on the reference position S, which is the reference position information supplied from the workpiece position setting mechanism 41, and the workpiece information input to the PC51 of the control device 50 in advance.

The program automatic generation unit 51b automatically generates an operation program for moving the rotary positioner 10 and the welding robot 30 to the optimum position of the rotary positioner 10 when gripping the steel frame structure W, which is calculated by the positioner position calculation unit 51 a. The database DB may be data accumulated by the learning apparatus, or may use ai (intellectual intelligence) technology.

(1-4-2. positioner control part)

The positioner controller 52 controls the rotary positioner 10 and the welding robot 30 to move to the position of the rotary positioner 10 calculated by the positioner position calculating unit 51a, in accordance with an operation program automatically generated by the PC 51.

(1-4-3. welding robot control section)

The welding robot control unit 53 controls the welding operation of the welding robot 30, and includes a synchronization control unit 53 a. The welding robot control unit 53 controls the operation of the robot hand 32, the power supplied to the welding torch 31, the supply of the welding wire, and the like, based on an operation program generated by the PC51 based on workpiece information such as size data, welding position data, and center of gravity data of the steel frame structure W, or an operation program stored in the welding robot control unit in advance, and performs welding on the welded portion of the steel frame structure W.

At this time, the synchronization control unit 53a controls the operation of the manipulator 32 of the welding robot 30 to be synchronized with the operation of the rotary positioner 10. Specifically, when the arc portion of the steel frame structure W is welded by the welding robot 30, the welding is performed in synchronization with the rotation of the steel frame structure W and the operation of the welding robot 30. Further, the welding robot 30 is moved in synchronization with the operation of the rotary positioner 10 that moves in the longitudinal direction of the steel frame structure W in accordance with a command from the PC51 as necessary.

< 2. welding sequence >

Next, the welding sequence of the steel frame structure W by the welding system 1 will be described in order with reference to fig. 1, 3, and 5. Fig. 3 is a schematic configuration diagram of the welding system shown in fig. 1 as viewed from above, and fig. 5 is a flowchart showing a welding procedure performed by the welding system shown in fig. 1.

First, the workpiece position setting mechanism carriage 43 is moved along the positioner movement rail R1 to position the workpiece position setting mechanism 41 at an arbitrary position. Thus, the reference surface 42 of the workpiece position setting means 41 is set as the reference position S of the steel frame structure W. The position of the workpiece position setting means 41 is arbitrarily determined, and may be set to a position where the welding work area of the steel frame structure W does not overlap with other work areas, for example.

Then, as shown in step S1 of fig. 5, workpiece information such as dimension data, welding position data, and center of gravity data of the steel frame structure W is input in advance to the PC51 by manual input by an operator, input of CAD (Computer-Aided Design) data from the steel frame structure W, or the like. The method of inputting the workpiece information is not particularly limited, but it is preferable to use three-dimensional CAD data from the viewpoint of improving the work efficiency.

Next, as shown in step S2 of fig. 5, the positioner position calculating unit 51a calculates the position of the rotary positioner 10 capable of holding the steel frame structure W at the optimum position for the PC51, based on the reference position information supplied from the workpiece position setting mechanism 41 and the workpiece information of the PC51 input to the pre-control device 50 in advance. That is, the positioner position calculating unit 51a assumes a virtual steel frame structure W showing a state in which one end thereof is in contact with the reference surface 42 of the workpiece position setting mechanism 41, determines an optimal gripping position with respect to the virtual steel frame structure W from the database DB in which the optimal position of the rotary positioner 10 when gripping the steel frame structure W is stored for each piece of workpiece information, and calculates the position of the rotary positioner 10.

In this case, when the center of gravity data of the steel frame structure W is included as the workpiece information, the optimum gripping position is calculated in consideration of the center of gravity data, so that the steel frame structure W can be held in a stable state, and the welding work with high accuracy can be realized.

Further, as shown in step S3 of fig. 5, the PC51 automatically generates an operation program for moving the rotary positioner 10 to the position of the rotary positioner 10 calculated by the positioner position calculating unit 51a by the program automatic generating unit 51b, and sends the operation program to the positioner controller 52.

As shown in step S4 of fig. 5, the positioner controller 52 moves the rotary positioner carriage 14 along the positioner moving rail R1 in accordance with the operation program generated by the program automatic generation unit 51b, and moves the rotary positioner 10 to the position of the rotary positioner 10 calculated by the positioner position calculation unit 51 a.

The movement to the calculated position of the rotational positioner 10 can control the position of the driven-side rotational positioner 10B in accordance with the position of the driving-side rotational positioner 10A. This improves the positional accuracy of the driving rotary positioner 10A and the driven rotary positioner 10B.

Next, as shown in step S5 in fig. 5, after the lift arm mechanism 12 is operated to open the upper portion of the annular holding portion 11 (see fig. 2A), the steel frame structure W is transported by a crane or the like and mounted on the fixing jig 16. When the steel frame structure W is mounted on the fixing jig 16, one end of the steel frame structure W serving as a reference surface is brought into contact with the reference surface 42 of the workpiece position setting mechanism 41 to position the steel frame structure W in the longitudinal direction, and thereafter, the steel frame structure W is clamped and fixed from the periphery by the plurality of fixing jigs 16. After the annular holding portion 11 is closed, the workpiece position setting mechanism 41 is moved in a direction away from the steel frame structure W and retracted. This enables the rotation of the steel-frame structure W by the rotational positioner 10.

Next, as shown in step S6 of fig. 5, the PC5 checks that the respective sections are not in interference with each other, and transmits teaching data such as a welding position, a welding procedure, and a welding method to the welding robot control unit 53 as shown in step S7.

Further, based on the start command from the external input switch as shown in step S8 of fig. 5, the welding robot control unit 53 starts the welding operation of the steel frame structure W by the welding robot 30 as shown in step S9. Specifically, for example, based on an operation program stored in the PC51 or the welding robot control unit 53 itself, the welding operation of the steel frame structure W is performed while the welding robot 30 is moved. In addition, the welding is performed while the carriage 20 for the welding apparatus and the control apparatus, specifically, the welding robot 30 is moved in the longitudinal direction of the steel frame structure W along the movement rail R2 for the welding apparatus and the control apparatus, without rotating the steel frame structure W, with respect to the linear portion in the longitudinal direction of the steel frame structure W; or welding may be performed while moving the slide mechanism 22 in a direction orthogonal to the longitudinal direction of the steel-frame structure W. Further, the robot hand 32 of the welding robot 30 having the six-axis joint may be operated to perform welding without moving the main body of the welding robot 30.

The arc portion of the steel frame structure W rotates the annular holding portion 11 by driving the driving portion M, rotates the steel frame structure W held by the fixing jig 16, and controls the welding robot 30 to perform welding in synchronization with the rotation of the fixing jig 16 by the synchronization control portion 53 a.

After the welding of the steel frame structure W is completed, the upper portion of the ring-shaped holding portion 11 is opened by the lift arm mechanism 12, and the steel frame structure W is carried out to end the welding operation as shown in step S10 in fig. 5.

As described above, according to the welding system of the present embodiment, the optimum position of the rotary positioner 10 when holding the steel-frame structure W, which has conventionally been dependent on the experience of the operator, can be automatically calculated and positioned. That is, the positioning operation of the rotary positioner 10 can be automated and performed efficiently.

The present invention is not limited to the above-described embodiments, and modifications, improvements, and the like can be appropriately made. For example, in the above embodiment, the pair of rotary positioners 10 has been described as the gripping mechanism for the steel-frame structure W, but one or three may be used as long as the steel-frame structure W can be gripped.

As described above, the following matters are disclosed in the present specification.

(1) A welding system for welding a workpiece using a welding device and a positioner,

the welding system has a control device that controls the welding device and the positioner,

the positioner is provided with: a workpiece position setting mechanism having reference position information; and at least one holding mechanism for holding the workpiece,

the control device includes a positioner position calculation unit that calculates a position of the gripping mechanism when gripping the workpiece, based on the reference position information supplied from the workpiece position setting mechanism and workpiece information input to the control device in advance.

According to this configuration, the position of the positioner when gripping the workpiece can be automatically calculated and positioned, and the positioning operation of the positioner can be automated and efficiently performed.

(2) The welding system according to the above (1),

the control device has a database in which a position of the gripping mechanism when gripping the workpiece is stored for each piece of the workpiece information,

the positioner position calculating unit calculates the position of the gripping mechanism when gripping the workpiece with reference to the database.

With this configuration, the gripping position can be calculated for a variety of workpieces.

(3) The welding system according to (1) or (2) above, wherein,

the workpiece information includes at least one of dimensional data and welding position data of the workpiece.

According to this structure, the size of the workpiece and the position to be welded can be accurately obtained.

(4) The welding system according to any one of the above (1) to (3),

the control device includes a synchronization control unit that controls the welding device to synchronize with the positioner.

According to this configuration, by synchronizing the welding device with the operation of the positioner, even in the welding of the arc portion of the workpiece, the welding can be continuously performed without cutting the arc.

(5) The welding system according to any one of the above (1) to (4),

the welding device is a welding robot,

the welding robot and the positioner each have a movement axis that can move in parallel.

According to this configuration, even if the welding robot and the gripping mechanism move, the relative position of the welding robot and the gripping mechanism can be maintained constant.

(6) The welding system according to the above (5),

the positioner has more than two holding mechanisms,

when one of the gripping mechanisms is a driving side gripping mechanism and the remaining gripping mechanisms are driven side gripping mechanisms,

the driving side gripping mechanism and the driven side gripping mechanism are respectively provided with a servo motor positioned at a predetermined position,

the control device controls the position of the driven-side gripping mechanism based on the position located by the driving-side gripping mechanism with respect to the position of the gripping mechanism when gripping the workpiece, which is calculated by the positioner position calculation unit.

According to this configuration, the positional accuracy with respect to the relative position of the driving side gripping mechanism and the driven side gripping mechanism is improved.

(7) The welding system according to any one of the above (1) to (6),

the control device includes an automatic program generation unit that automatically generates an operation program for moving the gripping mechanism and the welding device to the position of the gripping mechanism when gripping the workpiece, which is calculated by the positioner position calculation unit.

According to this configuration, the operation program can be automatically generated, and the work efficiency can be improved.

(8) The welding system according to any one of the above (1) to (7),

the workpiece information includes center-of-gravity data of the workpiece,

the positioner position calculating unit calculates the position of the gripping mechanism when gripping the workpiece with reference to the center of gravity data.

According to this configuration, the gripping mechanism can grip the workpiece in a stable state.

(9) A control device for a welding system for welding a workpiece by using a welding device and a positioner,

the control device controls the welding device and the positioner,

the control device includes a positioner position calculation unit that calculates a position of a gripping mechanism of the positioner when gripping the workpiece, based on reference position information supplied from a workpiece position setting mechanism of the positioner and workpiece information input to the control device in advance.

According to this configuration, the position of the positioner when gripping the workpiece can be automatically calculated and positioned, and the positioning operation of the positioner can be automated and efficiently performed.

(10) A control program for a welding system for welding a workpiece by using a welding device and a positioner,

the control program controls the welding device and the positioner,

the control program includes a positioner position calculating step of calculating a position of a gripping mechanism of the positioner when gripping the workpiece, based on reference position information supplied from a workpiece position setting mechanism of the positioner and workpiece information input to the control program in advance.

According to this configuration, the position of the positioner when gripping the workpiece can be automatically calculated and positioned, and the positioning operation of the positioner can be automated and efficiently performed.

(11) A welding method for welding a workpiece by using a welding device and a positioner,

the welding method comprises the following steps: controlling the welding device and the positioner by a control device that controls the welding device and the positioner,

the positioner is provided with: a workpiece position setting mechanism having reference position information; and at least one holding mechanism for holding the workpiece,

the welding method comprises the following steps: the position of the gripping mechanism when gripping the workpiece is calculated based on the reference position information supplied from the workpiece position setting mechanism and workpiece information input to the control device in advance.

According to this configuration, the position of the positioner when gripping the workpiece can be automatically calculated and positioned, and the positioning operation of the positioner can be automated and efficiently performed.

While various embodiments have been described above with reference to the drawings, it is needless to say that the present invention is not limited to these examples. It is obvious to those skilled in the art that various modifications and variations can be made within the scope described in the claims, and it is needless to say that these modifications and variations also fall within the technical scope of the present invention. In addition, the respective components in the above embodiments may be arbitrarily combined without departing from the scope of the invention.

The present application is based on japanese patent application No. 3/29/2019 (japanese patent application No. 2019-067011), the contents of which are incorporated by reference in the present application.

Description of reference numerals:

1 welding system

10 rotating localizer (holding mechanism)

10A initiative side rotary positioner (initiative side holding mechanism)

10B driven side rotary positioner (driven side holding mechanism)

11 annular holding part

11a gear

11b arc portion

12 lifting arm mechanism

13 support

14 Trolley for rotary positioner

16 fixing clamp

20 carriage for welding device and control device

21 wheel

22 sliding mechanism

30 welding robot (welding device)

31 welding torch

32 mechanical arm

40 locator

41 workpiece position setting mechanism

42 reference plane

43 Trolley for workpiece position setting mechanism

50 control device

51 PC

51a locator position calculation unit

51b program automatic generation unit

52 positioner control part

53 control part of welding robot

53a synchronization control unit

DB database

M drive part

Moving rail (moving shaft) for R1 positioner

Moving rail (moving shaft) for R2 welding device and control device

S reference position (reference position information)

A W steel frame structure (workpiece).