阅读说明：本技术 用于船舶中组立的机器人自适应智能焊接系统及焊接方法 (Robot self-adaptive intelligent welding system and welding method for assembly in ship ) 是由 甘露 沈鹏 刘鹏 于津伟 秦左铭 王正强 喻天祥 王浩 于 2020-11-30 设计创作，主要内容包括：用于船舶中组立的机器人自适应智能焊接系统,包括上位机、门架、轨道、行走小车、焊接机器人、激光位移传感器、传感器挡板、点激光扫描器、3D线激光扫描器、智能焊接控制系统；门架和轨道上分别安装有激光位移传感器和传感器挡板,焊接机器人和3D线激光扫描器安装于行走小车的Z轴移动机构上,点激光扫描器安装于焊接机器人上；智能焊接控制系统包括离线编程模块、焊缝自适应寻位模块、焊接工艺数据库模块、电弧跟踪模块。本发明可以适应船舶生产的特点,实现焊接机器人无需示教,自动寻找焊缝,而且在焊接过程中,能根据焊缝实际情况自动纠偏,保证焊接轨迹的精准,极大程度地节省了时间,提高了焊接的稳定性。(The robot self-adaptive intelligent welding system for assembly in the ship comprises an upper computer, a portal frame, a track, a walking trolley, a welding robot, a laser displacement sensor, a sensor baffle, a point laser scanner, a 3D line laser scanner and an intelligent welding control system; a laser displacement sensor and a sensor baffle are respectively arranged on the portal frame and the track, the welding robot and the 3D line laser scanner are arranged on a Z-axis moving mechanism of the walking trolley, and the point laser scanner is arranged on the welding robot; the intelligent welding control system comprises an offline programming module, a welding seam self-adaptive locating module, a welding process database module and an arc tracking module. The invention can adapt to the characteristics of ship production, realizes that the welding robot does not need teaching, automatically searches for welding seams, can automatically correct the deviation according to the actual conditions of the welding seams in the welding process, ensures the accuracy of welding tracks, greatly saves time and improves the welding stability.)

1. A robot self-adaptive intelligent welding system for assembly in a ship is characterized by comprising an upper computer, a gantry, a track, a walking trolley, a welding robot, a laser displacement sensor, a sensor baffle, a point laser scanner, a 3D line laser scanner and an intelligent welding control system;

the gantry is arranged on the track, and the gantry and the track are respectively provided with a laser displacement sensor and a sensor baffle which are matched with each other;

the walking trolley comprises an X-axis moving mechanism, a Y-axis moving mechanism and a Z-axis moving mechanism, wherein the Y-axis moving mechanism is installed on the gantry, the X-axis moving mechanism is installed on the Y-axis moving mechanism, and the Z-axis moving mechanism is installed on the X-axis moving mechanism;

the welding robot and the 3D line laser scanner are installed on the Z-axis moving mechanism, and the point laser scanner is installed on the welding robot;

the upper computer controls the gantry to move along the rail according to a feedback signal of the laser displacement sensor, the upper computer controls the X-axis moving mechanism, the Y-axis moving mechanism and the Z-axis moving mechanism to move the welding robot according to a scanning feedback of the 3D line laser scanner, and the welding robot determines a working position according to the scanning feedback of the point laser scanner;

the intelligent welding control system comprises an offline programming module, a welding seam self-adaptive locating module, a welding process database module and an electric arc tracking module, wherein the offline programming module, the welding seam self-adaptive locating module and the welding process database module are uniformly regulated and controlled by an upper computer to realize respective functions, and the electric arc tracking module is used for correcting the welding seam track of the welding robot in the welding operation process in real time.

2. The robot-adaptive intelligent welding system for the assembly in the ship of claim 1, wherein the portal is of a double-beam structure and comprises cross beams, upright columns, bottom beams, end beams, wheel set mechanisms, rail clamping devices and synchronous driving motors, one ends of the two cross beams are installed on the two upright columns, the lower ends of the two upright columns are installed on the bottom beams, the end beams are installed at the other ends of the two cross beams, the wheel set mechanisms and the rail clamping devices are installed on the bottom beams and the end beams, the synchronous driving motors for driving the upper wheel set mechanisms are installed on the bottom beams, and the synchronous driving motors are connected with an upper computer.

3. The robotic adaptive intelligent welding system for marine assemblages according to claim 2, wherein the tracks comprise a sill rail, an end beam rail, the sill rail cooperating with a wheelset mechanism and a rail clamp on the sill, the end beam rail cooperating with a wheelset mechanism and a rail clamp on the end beam.

4. The robotic adaptive intelligent welding system for ship assembly according to claim 3, wherein the laser displacement sensor and the sensor baffle are mounted on a sill of the gantry and a sill rail, respectively.

5. The robot-adaptive intelligent welding system for the ship middle assemblage according to claim 1, wherein the X-axis moving mechanism, the Y-axis moving mechanism and the Z-axis moving mechanism of the walking trolley are all driven by precise gears and racks to realize precise motion.

6. The robotic adaptive intelligent welding system for ship erection according to claim 1, wherein the number of the walking trolleys and the number of the welding robots are both two.

7. A robot adaptive intelligent welding method for ship assembly, which is characterized in that the robot adaptive intelligent welding system for ship assembly according to any one of claims 1-6 is adopted, and comprises the following steps:

s1, extracting model information of a workpiece to be welded, combing weld joint information and carrying out integral planning by an offline programming module, generating a welding track according to the weld joint information, extracting corresponding welding parameter information from a welding process database module for matching, generating an offline operation program and then sending the offline operation program to an upper computer;

s2, controlling the movement of the gantry by the upper computer according to the welding seam self-adaptive locating module and by combining gantry position information provided by an off-line operation program, the on-site workpiece placing position and the distance from the laser displacement sensor to the sensor baffle plate;

s3, the upper computer controls the 3D line laser scanner to automatically scan the workpiece according to the welding seam self-adaptive locating module, the information of the characteristic point position of the workpiece is obtained, the actual gantry position information and the information of the characteristic point position of the workpiece are integrated, the data deviation of the corresponding information in the off-line operation program is completed, and a new off-line operation program is generated and then is issued to the welding robot;

s4, the upper computer controls the welding robot and the walking trolley to work cooperatively, the welding robot carries out track operation according to a new off-line operation program,

before the welding robot reaches the starting point of the welding seam, the welding robot automatically searches and scans the workpiece according to the laser scanner of the control point of the welding seam self-adaptive searching module to finish the fine detection of the starting point position and the end point position of the welding seam, and carries out replacement assignment on the obtained accurate position data of the welding seam and theoretical data in a new off-line operation program,

and in the welding operation process, the welding robot corrects the welding seam track in real time according to the arc tracking module.

Technical Field

The invention belongs to the field of ship welding, and particularly relates to a robot self-adaptive intelligent welding system and a welding method for assembly in a ship.

Background

At present, a plurality of main domestic plane sectional flow lines of large-scale shipyards are basically the assembly of the whole production line provided by the Japanese iron and steel works or Norwegian TTS in the early years, and the problems of slow after-sale response, untimely after-sale service, high purchase price and daily maintenance cost, aging of the flow line, difficult transformation and upgrading caused by foreign technology protection and the like exist.

For the strong countries of shipbuilding such as European and American standards, Japanese and Korean standards, the difference between the digitization, the automation and the intellectualization of shipbuilding equipment in China is still huge. At present, China only achieves digitization in the single machine aspect of certain operation links, most operation links still depend on the working industry, and particularly in the production line aspect, China basically stays in a one-stop and rigid mode and has a great distance from digitization and intellectualization.

The method is characterized in that the method is used for solving the technical problem that the existing technical short plate on shipbuilding equipment in China urgently needs independent research and development, insists on innovation driving, greatly improves the independent design level and the system integration level of the shipbuilding equipment, and forms the matching capacity of the related manufacturing equipment so as to meet the requirements of ocean economic development and national important strategies.

Disclosure of Invention

The invention aims at the problems and provides a robot self-adaptive intelligent welding system and a welding method for assembly in a ship.

The purpose of the invention can be realized by the following technical scheme:

a robot self-adaptive intelligent welding system for assembly in a ship comprises an upper computer, a portal frame, a track, a walking trolley, a welding robot, a laser displacement sensor, a sensor baffle, a point laser scanner, a 3D line laser scanner and an intelligent welding control system;

the gantry is arranged on the track, and the gantry and the track are respectively provided with a laser displacement sensor and a sensor baffle which are matched with each other;

the walking trolley comprises an X-axis moving mechanism, a Y-axis moving mechanism and a Z-axis moving mechanism, wherein the Y-axis moving mechanism is installed on the gantry, the X-axis moving mechanism is installed on the Y-axis moving mechanism, and the Z-axis moving mechanism is installed on the X-axis moving mechanism;

the welding robot and the 3D line laser scanner are installed on the Z-axis moving mechanism, and the point laser scanner is installed on the welding robot;

the upper computer controls the gantry to move along the rail according to a feedback signal of the laser displacement sensor, the upper computer controls the X-axis moving mechanism, the Y-axis moving mechanism and the Z-axis moving mechanism to move the welding robot according to a scanning feedback of the 3D line laser scanner, and the welding robot determines a working position according to the scanning feedback of the point laser scanner;

the intelligent welding control system comprises an offline programming module, a welding seam self-adaptive locating module, a welding process database module and an electric arc tracking module, wherein the offline programming module, the welding seam self-adaptive locating module and the welding process database module are uniformly regulated and controlled by an upper computer to realize respective functions, and the electric arc tracking module is used for correcting the welding seam track of the welding robot in the welding operation process in real time.

Further, the portal is of a double-beam structure and comprises cross beams, stand columns, bottom beams, end beams, wheel set mechanisms, rail clamping devices and synchronous driving motors, one ends of the two cross beams are installed on the two stand columns, the lower ends of the two stand columns are installed on the bottom beams, the end beams are installed at the other ends of the two cross beams, the wheel set mechanisms and the rail clamping devices are installed on the bottom beams and the end beams, the bottom beams are provided with the synchronous driving motors for driving the wheel set mechanisms on the bottom beams, and the synchronous driving motors are connected with an upper computer. Furthermore, the tracks comprise a bottom beam track and an end beam track, the bottom beam track is matched with the wheel set mechanism and the rail clamping device on the bottom beam, and the end beam track is matched with the wheel set mechanism and the rail clamping device on the end beam. The laser displacement sensor and the sensor baffle are respectively arranged on the bottom beam of the portal and the bottom beam track.

Furthermore, an X-axis moving mechanism, a Y-axis moving mechanism and a Z-axis moving mechanism of the walking trolley are all driven by a precise gear and a precise rack to realize precise motion.

Furthermore, the number of the walking trolleys and the number of the welding robots are both two.

A robot self-adaptive intelligent welding method for assembling in a ship adopts the robot self-adaptive intelligent welding system, and comprises the following steps:

s1, extracting model information of a workpiece to be welded, combing weld joint information and carrying out integral planning by an offline programming module, generating a welding track according to the weld joint information, extracting corresponding welding parameter information from a welding process database module for matching, generating an offline operation program and then sending the offline operation program to an upper computer;

s2, controlling the movement of the gantry by the upper computer according to the welding seam self-adaptive locating module and by combining gantry position information provided by an off-line operation program, the on-site workpiece placing position and the distance from the laser displacement sensor to the sensor baffle plate;

s3, the upper computer controls the 3D line laser scanner to automatically scan the workpiece according to the welding seam self-adaptive locating module, the information of the characteristic point position of the workpiece is obtained, the actual gantry position information and the information of the characteristic point position of the workpiece are integrated, the data deviation of the corresponding information in the off-line operation program is completed, and a new off-line operation program is generated and then is issued to the welding robot;

s4, the upper computer controls the cooperative operation of the welding robot and the walking trolley, the welding robot carries out track operation according to a new off-line operation program, before the welding robot reaches the initial point of the welding seam, the welding robot automatically searches and scans the workpiece according to the control point laser scanner of the welding seam self-adaptive searching module, the precise detection of the initial point position and the end point position of the welding seam is completed, the obtained accurate position data of the welding seam and the theoretical data in the new off-line operation program are replaced and assigned, and in the welding operation process, the welding robot carries out real-time deviation correction on the welding seam track according to the arc tracking module.

The intelligent welding control system of the invention comprises:

(1) the functions of the off-line programming module are as follows: and acquiring production data from the workpiece model by adopting an offline programming mode based on the workpiece model, and generating an offline operation program of the welding robot through offline programming and simulation verification.

(2) The welding seam self-adaptive locating module has the functions of: sensing the position and working condition of a workpiece by reading data of the sensor in time, analyzing and judging, and making a decision for the action of the welding robot; scanning the workpiece by adopting a 3D line laser scanner, and enabling an off-line operation program to receive coordinate information of the workpiece and then generate a new path program to guide the welding robot to move before welding; before welding, a point laser scanner is used for searching the position of a welding seam to guide a welding robot to carry out accurate welding operation.

(3) The welding process database module has the functions of: according to the welding process specification of a shipyard, the method is constructed aiming at the material, thickness, form, welding material, welding leg and assembly gap of a welding object of a shipyard; and matching welding procedure information, such as welding voltage and welding current, for calling corresponding welding process data in the process of generating the welding track by the offline programming module.

(4) The function of the arc tracking module is: and correcting the welding seam track of the welding robot in real time in the welding operation process.

Compared with the prior art, the invention has the following beneficial effects: can adapt to the characteristics of boats and ships production, realize that welding robot need not the teaching, the automatic weld of looking for, in welding process, can rectify according to the welding seam actual conditions is automatic moreover, guarantee the accuracy of welding orbit, greatly saved the time to the degree to welded stability has been improved.

Drawings

Fig. 1 is a schematic view of the overall structure of the present invention.

Fig. 2 is a schematic structural diagram of a laser displacement sensor on a bottom beam and a sensor baffle on a bottom beam track in the invention.

FIG. 3 is a schematic view of the structure of the present invention during welding of a workpiece.

Fig. 4 is a schematic structural view of the welding robot of the present invention welding a workpiece.

FIG. 5 is a flow chart of the present invention for welding a workpiece.

The parts in the figures are numbered as follows:

1 door frame

101 crossbeam

102 column

103 bottom beam

104 end beam

2 bottom beam rail

3 walking trolley

301X-axis moving mechanism

302Y-axis moving mechanism

303Z-axis moving mechanism

4 welding robot

5 laser displacement sensor

6 sensor baffle

7-point laser scanner

83D line laser scanner

9 workpiece

a starting point of weld

b end point of weld.

Detailed Description

The following detailed description of the embodiments of the present invention will be given in conjunction with the accompanying drawings to make it clear to those skilled in the art how to practice the present invention. While the invention has been described in connection with preferred embodiments thereof, these embodiments are merely illustrative, and not restrictive, of the scope of the invention.

Referring to fig. 1, a robot self-adaptive intelligent welding system for ship assembly comprises an upper computer, a gantry 1, a track, a walking trolley 3, a welding robot 4 and an intelligent welding control system.

Referring to fig. 1, the gantry 1 includes a cross beam 101, a column 102, a bottom beam 103, an end beam 104, a wheelset mechanism, a rail clamp, and a synchronous driving motor, and the rails include a bottom beam rail 2 and an end beam rail. The portal 1 is a double-beam structure, two one ends of the cross beams 101 are installed on the two upright posts 102, two lower ends of the upright posts 102 are installed on the bottom beam 103, the other ends of the two cross beams 101 are provided with the end beam 104, the bottom beam 103 and the end beam 104 are both provided with the wheel set mechanism and the rail clamping device, the bottom beam 103 is provided with the synchronous driving motor for driving the upper wheel set mechanism, the wheel set mechanism and the rail clamping device on the bottom beam 103 are matched with the bottom beam track 2, the wheel set mechanism and the rail clamping device on the end beam 104 are matched with the end beam track, and the synchronous driving motor is connected with the upper computer.

Referring to fig. 1 and 2, a laser displacement sensor 5 is mounted on the bottom beam 103, a sensor baffle 6 matched with the laser displacement sensor 5 is mounted on the bottom beam track 2, and the laser displacement sensor 5 is connected with an upper computer. The laser displacement sensor 5 detects the distance from the sensor baffle 6 in real time and feeds the distance back to the upper computer, and the upper computer controls the synchronous driving motor to start and stop according to the real-time feedback of the laser displacement sensor 5, so that the gantry 1 is guaranteed to move to the designated welding area of the middle assembly component. After the operation is stopped, the rail clamping device works to ensure that the position of the gantry 1 is accurate and stable, so that the stability of the welding process of the welding robot 4 can be ensured.

Referring to fig. 1 and 3, the traveling trolley 3 includes an X-axis moving mechanism 301, a Y-axis moving mechanism 302, and a Z-axis moving mechanism 303, the Y-axis moving mechanism 302 is mounted on the beam 101 of the gantry 1, the X-axis moving mechanism 301 is mounted on the Y-axis moving mechanism 302 and is driven by the Y-axis moving mechanism 302 to move along the Y-axis direction, the Z-axis moving mechanism 303 is mounted on the X-axis moving mechanism 301 and is driven by the X-axis moving mechanism 301 to move along the X-axis direction, and the welding robot 4 is mounted on the Z-axis moving mechanism 303 and is driven by the Z-axis moving mechanism 303 to move along the Z-axis direction. The X-axis moving mechanism 301, the Y-axis moving mechanism 302 and the Z-axis moving mechanism 303 all adopt precise gear and rack transmission to realize precise motion, so that the welding robot 4 realizes large-scale precise motion and the welding coverage rate is ensured; x-axis moving mechanism 301, Y-axis moving mechanism 302, Z-axis moving mechanism 303 are the external axle link gear of welding robot 4, and welding robot 4 is connected with the host computer, have realized the coordinated control between X-axis moving mechanism 301, Y-axis moving mechanism 302, Z-axis moving mechanism 303, the welding robot 4.

Referring to fig. 1, 3, and 4, the welding robot 4 is provided with a point laser scanner 7, the Z-axis moving mechanism 303 is provided with a 3D line laser scanner 8, the point laser scanner 7 is connected to a system of the welding robot 4, and the 3D line laser scanner 8 is connected to a host computer. Point laser scanner 7 detects confirms the welding seam position, and feed back to welding robot 4, 3D line laser scanner 8 detects confirms the work piece position, and feed back to the host computer, the host computer is according to 3D line laser scanner 8's scanning feedback, control X axle moving mechanism 301, Y axle moving mechanism 302, Z axle moving mechanism 303 removes welding robot 4, welding robot 4 is according to the scanning feedback of point laser scanner 7, confirm welding robot 4's operating position, intelligent welding has been realized.

In this embodiment, the number of the traveling carriages 3 and the number of the welding robots 4 are two.

The intelligent welding control system comprises an offline programming module, a welding seam self-adaptive locating module, a welding process database module and an arc tracking module.

The functions of each module and the working steps of the system are as follows:

and S1, referring to FIG. 5, the offline programming module extracts information through a workpiece model which is provided by a shipyard and needs to be welded, aims to comb and integrally plan weld information, generates a welding track according to the weld information, extracts corresponding welding parameter information from the welding process database module for matching, and accordingly generates a complete offline operation program, and the offline programming module sends the offline operation program to an upper computer for unified regulation and control by the upper computer.

And S2, controlling the synchronous driving motor of the gantry 1 to work by the upper computer according to the welding seam self-adaptive locating module and by combining gantry position information provided by the off-line operation program, the on-site workpiece 9 placing position and the distance from the laser displacement sensor 5 to the sensor baffle 6, so that the gantry 1 realizes fixed-length movement until the actual gantry position is the same as the gantry position information provided by the off-line operation program.

And S3, the upper computer controls the 3D line laser scanner 8 to automatically scan the workpiece 9 according to the welding seam self-adaptive locating module, the acquisition of the position information of the characteristic point of the workpiece is completed, the upper computer integrates the position information of the actual gantry 1 and the position information of the characteristic point of the workpiece, the data offset of the corresponding information in the off-line operation program is completed, a new off-line operation program is generated, and the new off-line operation program is issued to the welding robot 4.

S4, the upper computer controls the welding robot 4 and the walking trolley 3 to work in a highly coordinated mode, and the stability of large-area and long-distance welding is guaranteed. Meanwhile, the welding power supply, the wire feeding mechanism, the welding gun, the gun cleaning and wire cutting mechanism and the point laser scanner 7 are in real-time communication with the welding robot 4. The welding robot 4 carries out track operation according to a new off-line operation program, before the welding robot 4 reaches a welding seam initial point a, the welding robot 4 automatically searches and scans a workpiece 9 according to a welding seam self-adaptive searching module control point laser scanner 7, the welding robot 4 completes the fine detection of the position of the welding seam initial point a and the position of the welding seam end point b by matching with the point laser scanner 7, see fig. 4, so that accurate position data of the welding seam is obtained, and the data and the theoretical data of the position of the welding seam initial point a and the position of the welding seam end point b in the new off-line operation program are subjected to replacement assignment, so that the precision of the welding track is greatly improved. In the welding operation process, the welding robot corrects the welding seam track in real time according to the arc tracking module, so that the high coincidence of the welding seam track is ensured, the stability is improved, and the welding quality is ensured.

It should be noted that many variations and modifications of the embodiments of the present invention fully described are possible and are not to be considered as limited to the specific examples of the above embodiments. The above examples are given by way of illustration of the invention and are not intended to limit the invention. In conclusion, the scope of the present invention should include those changes or substitutions and modifications which are obvious to those of ordinary skill in the art.