摘要
3D折线焊缝大量存在于海工装备、大型起重装备、物流运输装备等制造领域中,属于典型的复杂轨迹焊缝,主要通过示教再现的方式进行自动焊接。大量的重复示教工作严重限制了焊接效率和质量,实现焊缝实时跟踪是提高焊接质量和效率的有效途径。针对3D折线焊缝实时跟踪问题,建立一种基于轨迹在线识别的机器人摆动熔化极气体保护焊(Gasmetalarc welding,GMAW)实时跟踪系统。首先,提出一种基于点云数据处理的3D折线焊缝起焊点焊枪位姿检测方法,获取焊缝起焊点焊枪位姿;利用3D折线焊缝位姿信息在线快速提取方法获取焊接过程中焊缝位姿信息,实现焊缝轨迹在线识别。然后,利用摆动电弧偏差识别方法获取焊缝偏差。最后,提出一种基于轨迹在线识别的3D折线焊缝机器人摆动GMAW实时跟踪方法,利用模糊PID控制方法实现焊缝实时跟踪。针对折角范围为130°~230°的典型3D折线焊缝的焊接试验表明,起焊点寻位位置检测误差小于0.4mm,姿态估计误差小于1.8°,焊缝跟踪误差不超过0.4mm,满足3D折线焊缝实时跟踪的要求。
3D zigzag-line welding seams are extensively found in the manufacturing of marine engineering equipment,heavy lifting equipment,and logistics transportation equipment.They are typical complex trajectory welds,and they are mainly automatically welded through teaching.A large number of repeated teaching work severely limits welding efficiency and quality.Realizing real-time tracking of welds is an effective way to improve welding quality and efficiency.Aiming at the problem of real-time tracking of 3D zigzag-line welding seams,a robot swinging GMAW real-time tracking system based on trajectory detection is established.Firstly,a method based on point cloud data processing is proposed to detect the starting pose of 3Dzigzag-line welding seam,and the pose information is obtained by the online fast extraction method to realize the online detection of 3Dzigzag-line welding seam trajectory.Secondly,the weld deviation is obtained by using the swing arc deviation identification method.Finally,a real-time tracking method of 3D zigzag-line welding seam robot swing GMAW based on on-line trajectory detection is proposed,and the fuzzy PID control method is used to realize the real-time tracking of 3D zigzag-line welding seam.Welding experiments for typical 3D zigzag-line welding seams with a folding angle range of 130°-230° show that the detection error of the starting position is less than 0.4 mm,the attitude estimation error is less than 1.8°,and the welding seam tracking error does not exceed 0.4 mm,satisfying the Requirements for real-time tracking of 3D zigzag-line welding seams.
作者
贾爱亭
洪波
李湘文
高佳篷
吴格飞
屈原缘
JIA Aiting;HONG Bo;LI Xiangwen;GAO Jiapeng;WU Gefei;QU Yuanyuan(College of Mechanical Engineering,Xiangtan University,Xiangtan 411105)
出处
《机械工程学报》
EI
CAS
CSCD
北大核心
2022年第14期116-125,共10页
Journal of Mechanical Engineering
基金
国家自然科学基金(51575468)
长株潭标志性工程计划重大标志性创新示范工程(2019XK2303)
潭市科技计划(ZD-ZD20191007)
湖南省自然科学基金(2020JJ4089)
2019年湖南省研究生科研创新(XDCX2019B099)
2020年湖南省研究生科研创新(XDCX2020B128)资助项目。
关键词
3D折线焊缝
GMAW
轨迹在线识别
焊缝跟踪
3D zigzag-line welding seam
gas metal arc welding
online trajectory detection
seam tracking
