Rectangular Coordinate Submerged Arc Welding Robot

Abstract

Cartesian coordinate submerged arc welding robot, comprising: a controller for transmitting control instructions, receiving detection signal data and setting welding parameters to achieve automated welding; a Cartesian coordinate motion device for adjusting the welding position; a welding circuit device for forming a welding circuit to perform automatic welding, the welding circuit device including a welding power source, a wire feeding assembly and a welding torch; a flux recovery device for recovering excess flux; a wire detection device for detecting whether the welding wire is exhausted; a laser tracking device for detecting the characteristics of the weld seam, the laser tracking device including a laser sensor, a laser sensor driver and a welding assembly.

Description

Technical field:

[0001] The invention relates to a rectangular coordinate submerged arc welding robot. Background technology:

[0002] Welding, also known as fusion, is a manufacturing process and technology that joins metals or other thermoplastic materials such as plastics by heating, high temperature or high pressure.

[0003] There are many sources of energy for modern welding, including gas flame, electric arc, laser, electron beam, friction and ultrasound. In addition to being used in factories, welding can also be performed in a variety of environments, such as outdoors, underwater and in space. No matter where it is, welding may pose a danger to the operator, so appropriate protective measures must be taken when welding.

[0004] At present, the demand for long straight welds in the steel structure industry is extremely large. The characteristics of its workpieces are long welds, multiple types, difficult to ensure material deviation and assembly deviation, and thermal deformation during the welding process. The above characteristics make it difficult to implement automated welding methods, so manual handheld welding is mainly used. However, manual welding has low production efficiency, poor weld consistency, and high requirements on welder welding technology and even physical strength. The existing welding machines are complex to operate, relatively single in targeting, and low in automation and intelligence. At the same time, most of the existing industrial welding robots are articulated structures, composed of rotational degrees of freedom, and the welding gun has a flexible spatial posture, which is suitable for workpieces with complex shapes and more spatial curved surfaces, but its welding range is small, the end bearing capacity is generally 6Kg, and the mechanical arm rigidity is relatively weak, which is more suitable for the installation of light welding guns such as gas shielded welding. For submerged arc welding, it is difficult to bear the weight of welding guns, wire feeders, and flux funnels. In addition, the motion control of articulated robots is difficult, and they are not suitable for use in a large range and large space. The cost is also high, and it is difficult to solve the problem of weld deviation and weld welding with thermal deformation during welding. Summary of the invention:

[0005] The embodiment of the present invention provides a rectangular coordinate submerged arc welding robot with a reasonable structural design. It is based on the integrated control principle of the controller, cooperates with various types of electrical components and mechanical structures, adopts a single-arm structure, and is composed of three linear axes. It has good mechanical strength, strong load-bearing capacity, fast response speed, high positioning accuracy, flexible welding gun position adjustment, and the linear axis stroke can be extended with the size of the workpiece to meet the large-scale welding needs of workpieces of different lengths and heights. At the same time, a robot controller is used as the main control center, which has a high degree of intelligence, rich interfaces, and complete functions, and can realize personalized customization. It can effectively eliminate weld deviations during welding and solve the problems existing in the prior art.

[0006] The technical solution adopted by the present invention to solve the above technical problems is:

[0007] Cartesian coordinate submerged arc welding robot, comprising:

[0008] A controller, which is used to transmit control instructions, receive detection signal data and set welding parameters to achieve automatic welding;

[0009] A Cartesian coordinate motion device, which is used to adjust the welding position. The Cartesian coordinate motion device includes a Y-axis walking lower platform, a Y-axis walking upper platform, an X-axis body and a Z-axis body that are cooperatively arranged. A Y-axis walking guide rail is connected to the Y-axis walking lower platform through a transmission component. The Y-axis walking guide rail is used to drive the Y-axis walking lower platform to move. Transmission components are respectively arranged on the X-axis body and the Z-axis body to drive the X-axis body and the Z-axis body to move;

[0010] A welding circuit device, which is used to form a welding circuit for automatic welding. The welding circuit device includes a welding power source, a wire feeding component and a welding torch. The welding power source is arranged on the Y-axis walking lower platform and is connected to the welding torch through a welding cable. The wire feeding component is installed at the middle position of the Z-axis body, and the welding torch is arranged at the bottom of the Z-axis body;

[0011] A flux recovery device, which is used to recover the excess flux. The flux recovery device includes a flux recovery machine, a large flux bucket and a flux funnel connected through a flux conveying pipeline;

[0012] A welding wire detection device, which is used to detect whether the welding wire is exhausted. The welding wire detection device includes a detection switch, a relay, a power source and an alarm that are connected. The detection switch includes two cooperatively arranged detection components, and the two detection components are respectively connected to the relay and the power source to be able to form a circuit;

[0013] A laser tracking device, which is used to detect the weld seam features. The laser tracking device includes a laser sensor, a laser sensor driver and a welding component.

[0014] A digital IO unit and an analog output unit are provided on the controller. The controller is connected to the welding power source through the digital IO unit to send digital signals of starting arc, stopping arc, wire feeding and wire retracting to the welding power source. The controller is connected to the welding power source through the analog output unit to send analog signals of welding current and welding voltage to the welding power source, so as to adjust the welding current and welding voltage. The controller is connected to the upper computer through a communication line to set the welding parameters of the welding component and the motion parameters of the transmission component and transmit control instructions to the controller. The controller is connected to the transmission component through a trigger, and the trigger is used to control the start and stop of the transmission component. A radiator is also connected to the controller, and the radiator is used to reduce the temperature rise of the controller.

[0015] The welding assembly includes the end shaft of a welding robot. An installation bracket is connected to the end shaft of the welding robot. A welding torch is provided on the installation bracket. A flux feeding pipe and a flux recovery pipe that cooperate with the welding torch are provided on the installation bracket. A laser sensor is installed at the front end of the installation bracket along the welding direction of the welding robot. The laser sensor is used to identify the laser position coordinates of the weld seam. The controller is connected to the laser sensor driver through an RS232 serial port and a communication cable to transmit the laser position coordinates identified by the laser sensor to the controller. The laser sensor driver is connected to the laser sensor through an RS485 serial port and a control cable. A memory is connected to the controller. The memory is used to store the laser position coordinates when the welding wire points to the weld seam. The controller is connected to the welding robot through an electromagnetic relay to drive the welding robot to control the deflection movement of the welding torch.

[0016] The model of the controller is STM32F103C8T6. There are 64 pins on the controller. The controller is connected to the digital IO unit through the 13th, 14th, 15th, and 16th pins. The controller is connected to the radiator through the 20th and 21st pins. The controller is connected to the analog output unit through the 33rd, 34th, and 35th pins. The controller is connected to the trigger through the 44th and 45th pins. The controller is connected to the RS485 serial port through the 38th, 39th, and 40th pins.

[0017] A welding machine control aviation plug is provided between the controller and the welding power supply. There are multiple interfaces on the welding machine control aviation plug. The digital IO unit is correspondingly connected to the 11th, 12th, 13th, and 14th interfaces on the welding machine control aviation plug. The analog quantity output unit is correspondingly connected to the 2nd, 4th, and 8th interfaces on the welding machine control aviation plug.

[0018] Each detection component includes an insulating seat, a conductive carbon brush provided on the insulating seat, and a signal connection end. One end of the conductive carbon brush is used to contact the welding wire. The other end of the conductive carbon brush of one detection component is connected to a relay through the signal connection end. The other end of the conductive carbon brush of the other detection component is connected to a power supply through the signal connection end. The relay is connected to the input end of the controller. The alarm is connected to the output end of the controller.

[0019] The transmission component includes a servo motor, a reducer, and a gear rack that are cooperatively arranged.

[0020] The model of the radiator is TC4427. There are 8 pins on the radiator. The second pin of the radiator is connected to the twentieth pin of the controller, and the fourth pin of the radiator is connected to the twenty-first pin of the controller. There are an eleventh resistor and a twelfth resistor connected in parallel on the fifth pin of the controller. There is a MOS transistor on the twelfth resistor, and a cooling fan is connected to the MOS transistor.

[0021] The model of the flip-flop is FDS4495. There are 8 pins on the flip-flop. There is a first resistor between the first pin and the second pin of the flip-flop, and a second resistor between the third pin and the fourth pin of the flip-flop. The second pin of the flip-flop is connected to the forty-fifth pin of the controller, the third pin of the flip-flop is connected to the forty-fourth pin of the controller, and the fifth pin and the eighth pin of the flip-flop are connected to the transmission component.

[0022] The model of the RS485 serial port is SP3485. There are 8 pins on the RS485 serial port. The first pin of the RS485 serial port is connected to the fortieth pin of the controller, the second pin and the third pin of the RS485 serial port are short-circuited and connected to the thirty-ninth pin of the controller, and the fourth pin of the RS485 serial port is connected to the thirty-eighth pin of the controller.

[0023] The present invention adopts the above structure. By means of the controller, control instructions are transmitted, detection signal data is received, and welding parameters are set to achieve automatic welding; by means of the rectangular coordinate motion device, the welding position is adjusted to realize real-time tracking of multi-layer and multi-pass welding, which can be extended according to the size of the workpiece to meet the large-range welding requirements of workpieces with different lengths and heights; by means of the welding circuit device, a corresponding welding circuit is formed for automatic welding, which is convenient for rapid automatic welding and has a fast triggering speed; by means of the flux recovery device, the excess flux is recovered to avoid waste of flux; by means of the welding wire detection device, it is detected whether the welding wire at the corresponding position is exhausted, and when there is no welding wire, it is replenished in a timely and rapid manner; by means of the laser tracking device, the detection of weld features is realized, automatic accurate positioning of the starting point, real-time tracking during the welding process, and automatic identification of the workpiece end point are achieved, and it has the advantages of high efficiency, practicality, precision, flexibility, and complete functions. Description of the Drawings:

[0024] Figure 1 It is a schematic structural diagram of the present invention.

[0025] Figure 2 It is Figure 1 a side view of

[0026] Figure 3 It is Figure 1 a top view of

[0027] Figure 4Schematic structural diagram of the laser tracking device of the present invention.

[0028] Figure 5 Schematic diagram of the working state of the laser tracking device of the present invention.

[0029] Figure 6 Schematic control diagram of the welding wire detection device of the present invention.

[0030] Figure 7 Schematic structural diagram of the detection switch of the present invention.

[0031] Figure 8 Schematic control diagram of the present invention.

[0032] Figure 9 Schematic electrical diagram of the controller of the present invention.

[0033] Figure 10 Schematic electrical diagram of the radiator of the present invention.

[0034] Figure 11 Schematic electrical diagram of the trigger of the present invention.

[0035] Figure 12 Schematic electrical diagram of the RS485 serial port of the present invention. Specific embodiments:

[0036] To clearly illustrate the technical features of this solution, the present invention will be described in detail below through specific embodiments and in conjunction with its accompanying drawings.

[0037] As Figure 1-12 shown, the rectangular coordinate type submerged arc welding robot includes:

[0038] A controller, which is used to transmit control instructions, receive detection signal data and set welding parameters to achieve automatic welding;

[0039] A rectangular coordinate motion device, which is used to adjust the welding position. The rectangular coordinate motion device includes a Y-axis walking lower platform, a Y-axis walking upper platform, an X-axis body and a Z-axis body that are cooperatively arranged. A Y-axis walking guide rail is connected to the Y-axis walking lower platform through a transmission component, and the Y-axis walking guide rail is used to drive the Y-axis walking lower platform to move. Transmission components are respectively provided on the X-axis body and the Z-axis body to drive the X-axis body and the Z-axis body to move;

[0040] A welding circuit device, which is used to form a welding circuit for automatic welding. The welding circuit device includes a welding power source, a wire feeding component and a welding torch. The welding power source is arranged on the Y-axis walking lower platform and is connected to the welding torch through a welding cable. The wire feeding component is installed at the middle position of the Z-axis body, and the welding torch is arranged at the bottom of the Z-axis body;

[0041] A flux recovery device, which is used to recover excess flux. The flux recovery device includes a flux recovery machine, a large flux barrel, and a flux funnel connected through a flux delivery pipeline.

[0042] A welding wire detection device, which is used to detect whether the welding wire is exhausted. The welding wire detection device includes a detection switch, a relay, a power supply, and an alarm connected to each other. The detection switch includes two cooperating detection components, and the two detection components are respectively connected to the relay and the power supply to form a circuit.

[0043] A laser tracking device, which is used to detect the characteristics of the weld seam. The laser tracking device includes a laser sensor, a laser sensor driver, and a welding component.

[0044] A digital IO unit and an analog output unit are provided on the controller. The controller is connected to the welding power supply through the digital IO unit to send digital signals of starting arc, stopping arc, wire feeding, and wire retracting to the welding power supply. The controller is connected to the welding power supply through the analog output unit to send analog signals of welding current and welding voltage to the welding power supply, so as to adjust the welding current and welding voltage. The controller is connected to the upper computer through a communication line to set the welding parameters of the welding component and the motion parameters of the transmission component and transmit control instructions to the controller. The controller is connected to the transmission component through a trigger, and the trigger is used to control the start and stop of the transmission component. A radiator is also connected to the controller, and the radiator is used to reduce the temperature rise of the controller.

[0045] The welding component includes the end shaft of a welding robot. An installation bracket is connected to the end shaft of the welding robot. A welding torch is provided on the installation bracket. A flux feeding pipe and a flux recovery pipe that cooperate with the welding torch are provided on the installation bracket. A laser sensor is installed at the front end of the installation bracket along the welding direction of the welding robot. The laser sensor is used to identify the laser position coordinates of the weld seam. The controller is connected to the laser sensor driver through an RS232 serial port and a communication cable to transmit the laser position coordinates identified by the laser sensor to the controller. The laser sensor driver is connected to the laser sensor through an RS485 serial port and a control cable. A memory is connected to the controller, and the memory is used to store the laser position coordinates when the welding wire points to the weld seam. The controller is connected to the welding robot through an electromagnetic relay to drive the welding robot to control the deflection action of the welding torch.

[0046] The model of the controller is STM32F103C8T6. There are 64 pins on the controller. The controller is connected to the digital IO unit through the 13th, 14th, 15th, and 16th pins. The controller is connected to the radiator through the 20th and 21st pins. The controller is connected to the analog output unit through the 33rd, 34th, and 35th pins. The controller is connected to the trigger through the 44th and 45th pins. The controller is connected to the RS485 serial port through the 38th, 39th, and 40th pins.

[0047] A welding machine control aviation plug is provided between the controller and the welding power supply. There are multiple interfaces on the welding machine control aviation plug. The digital IO unit is correspondingly connected to the 11th, 12th, 13th, and 14th interfaces on the welding machine control aviation plug; the analog quantity output unit is correspondingly connected to the 2nd, 4th, and 8th interfaces on the welding machine control aviation plug.

[0048] Each detection component includes an insulating seat, a conductive carbon brush provided on the insulating seat, and a signal connection end. One end of the conductive carbon brush is used to contact the welding wire. The other end of the conductive carbon brush of one detection component is connected to the relay through the signal connection end. The other end of the conductive carbon brush of the other detection component is connected to the power supply through the signal connection end. The relay is connected to the input end of the controller, and the alarm is connected to the output end of the controller.

[0049] The transmission component includes a servo motor, a reducer, and a gear rack that are cooperatively arranged.

[0050] The model of the radiator is TC4427. There are 8 pins on the radiator. The 2nd pin of the radiator is connected to the 20th pin of the controller. The 4th pin of the radiator is connected to the 21st pin of the controller. A parallel connection of the 11th resistor and the 12th resistor is provided on the 5th pin of the controller. A MOS tube is provided on the 12th resistor, and a cooling fan is connected to the MOS tube.

[0051] The model of the trigger is FDS4495. There are 8 pins on the trigger. A first resistor is provided between the 1st pin and the 2nd pin of the trigger. A second resistor is provided between the 3rd pin and the 4th pin of the trigger. The 2nd pin of the trigger is connected to the 45th pin of the controller. The 3rd pin of the trigger is connected to the 44th pin of the controller. The 5th pin and the 8th pin of the trigger are connected to the transmission component.

[0052] The model of the RS485 serial port is SP3485. There are 8 pins on the RS485 serial port. The first pin of the RS485 serial port is connected to the fortieth pin of the controller. The second and third pins of the RS485 serial port are short-circuited and connected to the thirty-ninth pin of the controller. The fourth pin of the RS485 serial port is connected to the thirty-eighth pin of the controller.

[0053] The working principle of the rectangular coordinate submerged arc welding robot in the embodiment of the present invention is as follows: Based on the integrated control principle of the controller, with the cooperation of various types of electrical components and mechanical structures, it adopts a single-arm structure, which consists of three linear axes. It has good mechanical strength, strong load-bearing capacity, fast response speed, high positioning accuracy, flexible adjustment of the position of the welding torch, and the stroke of the linear axis can be extended according to the size of the workpiece, so as to meet the large-range welding requirements of workpieces with different lengths and heights; At the same time, a robot controller is used as the main control center, which has a high degree of intelligence, rich interfaces, and complete functions. It can be customized individually, and can effectively eliminate the weld deviation during the welding process. Specifically, the three linear axes can be customized according to the size of the workpiece to meet the market demand. The operation is simple, and the unmanned intelligent welding during the welding process is realized, which greatly improves the production efficiency and weld consistency, and is very suitable for batch welding operations of long straight welds.

[0054] In the overall solution, it mainly includes a controller, which is used to transmit control instructions, receive detection signal data and set welding parameters to achieve automatic welding; a rectangular coordinate motion device, which is used to adjust the welding position; a welding circuit device, which is used to form a welding circuit for automatic welding; a flux recovery device, which is used to recover the excess flux; a wire detection device, which is used to detect whether the welding wire is exhausted; a laser tracking device, which is used to detect the weld features; and each functional device cooperates with each other to effectively eliminate the weld deviation during the welding process and complete automatic welding.

[0055] For the electrical components, the controller is the core component, and the model of the controller is STM32F103C8T6. There are 64 pins on the controller. The controller is connected to the digital IO unit through the thirteenth, fourteenth, fifteenth, and sixteenth pins. The controller is connected to the radiator through the twentieth and twenty-first pins. The controller is connected to the analog output unit through the thirty-third, thirty-fourth, and thirty-fifth pins. The controller is connected to the trigger through the forty-fourth and forty-fifth pins. The controller is connected to the RS485 serial port through the thirty-eighth, thirty-ninth, and fortieth pins, forming the overall hardware circuit. And relying on the above overall hardware circuit, automatic welding is realized, and the overall welding quality is improved.

[0056] Preferably, a welding machine control aviation plug is provided between the controller and the welding power source. The welding machine control aviation plug is provided with a plurality of interfaces. The digital IO unit is correspondingly connected to the eleventh, twelfth, thirteenth, and fourteenth interfaces on the welding machine control aviation plug; the analog quantity output unit is correspondingly connected to the second, fourth, and eighth interfaces on the welding machine control aviation plug. Under the action of the welding machine control aviation plug, the wiring is clearer and more orderly, preventing wiring mistakes. At the same time, it can also prevent electrical accidents such as short circuits or open circuits, and the safety is higher.

[0057] In the rectangular coordinate motion device, it mainly includes a Y-axis walking lower platform, a Y-axis walking upper platform, an X-axis body, and a Z-axis body that are arranged in cooperation. A Y-axis walking guide rail is connected to the Y-axis walking lower platform through a transmission component. The Y-axis walking guide rail is used to drive the Y-axis walking lower platform to move. Transmission components are respectively arranged on the X-axis body and the Z-axis body to drive the X-axis body and the Z-axis body to move, so that the three linear axes of the X-axis, Y-axis, and Z-axis form a right-angle three-coordinate. The mutual movement is realized through a servo motor, a reducer, and a gear rack arranged in cooperation. The welding torch can be accurately adjusted to the required position for welding according to actual needs.

[0058] Under the action of the mutual cooperation of multiple working function devices, the rectangular coordinate submerged arc welding robot in the embodiment of the present invention has a weld profile automatic recognition technology, which can realize real-time tracking of multi-layer and multi-pass welding, high-precision positioning of the starting point, and automatic recognition of the welding end point. Through these technologies, the device has the ability to accurately position the starting point, so as to accurately control key welding parameters such as the height of the welding torch and the offset distance of the welding torch. The automatic recognition function of the welding end point can realize unattended welding operations.

[0059] Generally, the controller is communicatively connected to the upper computer. A human-machine interface is set on the upper computer. Through the human-machine interface, the motion parameters related to the transmission component can be set, and information can be exchanged with welding auxiliary equipment (such as tooling, turntable, etc.); a welding parameter process library is set through the human-machine interface to save the welding parameters of different workpieces. The wizard-style editing function makes parameter editing simple and clear; through simple parameter setting, the segmented variable process welding technology during the welding process can be realized to meet the customized welding requirements, and the real-time adjustment of process parameters during the welding process can also be realized; it has an online self-check function for the presence or absence of welding wire and welding flux during the welding process, as well as a self-check and self-processing function for welding faults, such as sticking wire and breaking wire. The equipment should be able to detect special conditions and alarm or stop.

[0060] For the flux recovery device, it includes a flux recovery machine, a large flux bucket, and a flux funnel connected through a flux delivery pipeline. When there is remaining flux, it can be recovered in time.

[0061] Since the welding wire is a welding material in the form of a filler metal or a metal wire used for both conduction and filling purposes, it serves as a filler metal in gas welding and gas tungsten arc welding; in submerged arc welding, electroslag welding, and other gas metal arc welding processes, the welding wire is not only a filler metal but also a conductive electrode. The surface of the welding wire is not coated with a flux for anti-oxidation purposes. Therefore, for a welding wire detection device, including a connected detection switch, relay, power supply, and alarm, the detection switch includes two cooperating detection components, and the two detection components are respectively connected to the relay and the power supply to form a circuit; preferably, each detection component includes an insulating base, a conductive carbon brush disposed on the insulating base, and a signal connection terminal. One end of the conductive carbon brush is used to contact the welding wire. The other end of the conductive carbon brush of one detection component is connected to the relay through the signal connection terminal, and the other end of the conductive carbon brush of the other detection component is connected to the power supply through the signal connection terminal. The relay is connected to the input end of the controller, and the alarm is connected to the output end of the controller.

[0062] During use, the two detection components are arranged on both sides of the welding wire, and the welding wire is respectively in contact with the conductive carbon brushes of each detection component (the following structures can be used but are not limited to achieve the moving contact between the welding wire and the conductive carbon brush: specifically, a welding wire channel can be formed between the conductive carbon brush and the insulating base, and the welding wire channel can be an arc-shaped channel with the conductive carbon brush as an arc-shaped contact surface; or the conductive carbon brushes of the two detection components form a welding wire channel). When the welding wire is sufficient, the conductive carbon brushes of both detection components are in contact with the welding wire, and the circuit formed by the two detection components, the welding wire, the relay, and the power supply is in a conducting state; when the welding wire is lacking, at least one of the conductive carbon brushes of the detection components cannot be in contact with the welding wire, so that the circuit formed by the two detection components, the welding wire, the relay, and the power supply is in a power-off state. The relay can be a normally open relay or a normally closed relay. If a normally open relay is used, in the conducting state, the normally open signal of the relay is transmitted to the controller, and the controller controls the normal progress of the welding operation; in the power-off state, the closing signal of the relay will be transmitted to the controller to control the alarm to give an alarm, which can timely notify the operator to replace the welding wire, greatly reducing the ineffective working time of the welding equipment and improving the production efficiency.

[0063] For a laser tracking device, it mainly includes a laser sensor, a laser sensor driver, and a welding component. Specifically, the welding component includes the end shaft of a welding robot. An installation bracket is connected to the end shaft of the welding robot. A welding torch is provided on the installation bracket. A flux feeding pipe and a flux recovery pipe that cooperate with the welding torch are provided on the installation bracket. A laser sensor is installed at the front end of the installation bracket along the welding direction of the welding robot. The laser sensor is used to identify the laser position coordinates of the weld seam. The controller is connected to the laser sensor driver through an RS232 serial port and a communication cable to transmit the laser position coordinates identified by the laser sensor to the controller. The laser sensor driver is connected to the laser sensor through an RS485 serial port and a control cable. A memory is connected to the controller, and the memory is used to store the laser position coordinates when the welding wire points to the weld seam. The controller is connected to the welding robot through an electromagnetic relay to drive the welding robot to control the deflection movement of the welding torch.

[0064] Through the laser tracking device, automatic and precise positioning of the starting point, real-time tracking during the welding process, and automatic identification of the workpiece end point can be achieved.

[0065] For the automatic and precise starting point positioning function, move the welding torch to the rough position of the starting welding point, and the range is within ±15 mm. Start the positioning function. The laser sensor sends the currently detected laser coordinate data LY1 (left-right position) and LZ1 (height position) to the controller. The controller calculates the data that the welding torch should offset in the X direction as ΔX = LY1 - LY and in the Z direction as ΔZ = LZ1 - LZ based on the comparison of this data with the pre-stored sample calibration data. When ΔX is a positive number, the robot runs in the negative X-axis direction; when it is a negative number, it runs in the positive direction. When ΔZ is a positive number, the robot runs in the negative Z-axis direction; when it is a negative number, it runs in the positive direction. The welding torch starts to run at a lower safe speed in the direction of reducing the deviation according to the data of ΔX and ΔZ. During the running process, the laser sensor continuously returns the laser coordinates of LY1 and LZ1 to the controller, and the controller calculates the data of ΔX and ΔZ in real time until ΔX and ΔZ are 0, at which point it is considered that the welding torch has moved to the coordinate position of the initial sample calibration, and the action is executed in place, realizing the high-precision starting point positioning process.

[0066] For the real-time tracking function of the welding process, the laser coordinate positions should be the initial calibration data, namely LY and LZ. This data serves as the reference value during the robot welding process. The relative position between the laser sensor and the welding wire is fixed. It is necessary to ensure that the laser detection data always stably approaches LY and LZ through the offset movements of the X-axis and Z-axis of the robot to ensure that the welding wire always runs on the correct weld seam. The front-back distance between the laser line and the welding wire is a fixed pre-set distance. Within the length of the pre-set distance, it can be considered that there is no deviation in the weld seam and no tracking control is required. After starting welding, the laser sensor returns a current laser coordinate value (LY1, LY2, LY3.....LYN and LZ1, LZ2, LZ3......LZN) to the controller every 200 ms. In this way, a weld seam offset trajectory is formed. Therefore, at each point, the robot calculates a motion deviation data to eliminate the current weld seam offset, that is, ΔX = LY1 - LY and ΔZ = LZ1 - LZ. The controller controls the X-axis and Z-axis of the welding torch to move in the direction of eliminating ΔX and ΔZ in real time. The welding torch always moves along an absolute coordinate offset position in real time to ensure that the welding torch always stably welds at the correct weld seam position.

[0067] For the automatic identification function of the workpiece end point, when welding to the end of the workpiece, the laser line will leave the weld seam contour position. At this time, the irradiation position of the laser line is quite different from the normal weld seam contour, and the detected data also differs greatly from the normal weld seam deviation data. When it is detected that this data continuously exceeds a certain set value, the controller determines that the laser line has left the end of the workpiece. At this time, the distance between the welding torch and the laser sensor is the pre-set distance, and the robot will continue welding until the length of the pre-set distance is completed and then automatically stop the welding process.

[0068] Specifically, for long straight weld workpieces such as I-beams, box girders, large vehicle chassis, and large equipment main bodies, the rectangular coordinate submerged arc welding robot in the embodiment of the present invention has absolute advantages compared with the existing articulated robots and ordinary welding special machines.

[0069] In summary, the rectangular coordinate submerged arc welding robot in the embodiment of the present invention is based on the integrated control principle of the controller, cooperates with various types of electrical components and mechanical structures, adopts a single-arm structure, consists of three linear axes, has good mechanical strength, strong load-bearing capacity, fast response speed, high positioning accuracy, flexible adjustment of the welding torch position, and the stroke of the linear axis can be extended according to the size of the workpiece to meet the large-range welding requirements of workpieces with different lengths and heights; at the same time, using the robot controller as the main control center, it has high intelligence, rich interfaces, complete functions, can be customized, and can effectively eliminate the weld seam deviation during the welding process. Specifically, the three linear axes can be customized according to the size of the workpiece to meet the market demand, with simple operation, realizing unmanned intelligent welding during the welding process, greatly improving production efficiency and weld seam consistency, and is very suitable for batch welding operations of long straight welds.

[0070] The above specific embodiments shall not be construed as limiting the scope of protection of the present invention. For those skilled in the art of this technology, any alternative improvements or transformations made to the embodiments of the present invention shall fall within the scope of protection of the present invention.

[0071] Where the present invention is not described in detail, it is common knowledge to those skilled in the art of this technology.

Claims

1. Cartesian coordinate submerged arc welding robot, characterized in that Including: A controller, which is used to transmit control instructions, receive detection signal data and set welding parameters to achieve automated welding; A rectangular coordinate motion device, which is used to adjust the welding position. The rectangular coordinate motion device includes a Y-axis walking lower platform, a Y-axis walking upper platform, an X-axis body and a Z-axis body that are cooperatively arranged. A Y-axis walking guide rail is connected to the Y-axis walking lower platform through a transmission component. The Y-axis walking guide rail is used to drive the Y-axis walking lower platform to move. Transmission components are respectively arranged on the X-axis body and the Z-axis body to drive the X-axis body and the Z-axis body to move; A welding circuit device, which is used to form a welding circuit for automatic welding. The welding circuit device includes a welding power source, a wire feeding component and a welding torch. The welding power source is arranged on the Y-axis walking lower platform and is connected to the welding torch through a welding cable. The wire feeding component is installed at the middle position of the Z-axis body, and the welding torch is arranged at the bottom of the Z-axis body; A flux recovery device, which is used to recover the excess flux. The flux recovery device includes a flux recovery machine, a flux bulk bucket and a flux funnel connected through a flux delivery pipeline; A wire detection device, which is used to detect whether the welding wire is exhausted. The wire detection device includes a detection switch, a relay, a power supply and an alarm that are connected. The detection switch includes two cooperatively arranged detection components. The two detection components are respectively connected to the relay and the power supply to be able to form a circuit; A laser tracking device, which is used to detect the weld seam features. The laser tracking device includes a laser sensor, a laser sensor driver and a welding component; The welding component includes the end shaft of a welding robot. An installation bracket is connected to the end shaft of the welding robot. A welding torch is arranged on the installation bracket. A flux feeding pipe and a flux recovery pipe that cooperate with the welding torch are arranged on the installation bracket. A laser sensor is installed at the front end of the installation bracket along the welding direction of the welding robot. The laser sensor is used to identify the laser position coordinates of the weld seam. The controller is connected to the laser sensor driver through an RS232 serial port and a communication cable to transmit the laser position coordinates identified by the laser sensor to the controller. The laser sensor driver is connected to the laser sensor through an RS485 serial port and a control cable. A memory is connected to the controller. The memory is used to store the laser position coordinates when the welding wire points to the weld seam. The controller is connected to the welding robot through an electromagnetic relay to drive the welding robot to control the deflection action of the welding torch; Each detection component includes an insulating seat, a conductive carbon brush arranged on the insulating seat and a signal connection end. One end of the conductive carbon brush is used to contact the welding wire. The other end of the conductive carbon brush of one of the detection components is connected to the relay through the signal connection end. The other end of the conductive carbon brush of the other detection component is connected to the power supply through the signal connection end. The relay is connected to the input end of the controller, and the alarm is connected to the output end of the controller.

2. The Cartesian coordinate submerged arc welding robot according to claim 1, characterized in that: The controller is provided with a digital IO unit and an analog output unit. The controller is connected to the welding power supply through the digital IO unit to send digital signals of arc starting, arc stopping, wire feeding, and wire retracting to the welding power supply. The controller is connected to the welding power supply through the analog output unit to send analog signals of welding current and welding voltage to the welding power supply, thereby adjusting the welding current and welding voltage. The controller is connected to the upper computer through a communication line to set the welding parameters of the welding component and the motion parameters of the transmission component and transmit control instructions to the controller. The controller is connected to the transmission component through a trigger, and the trigger is used to control the start and stop of the transmission component. A radiator is also connected to the controller, and the radiator is used to reduce the temperature rise of the controller.

3. The Cartesian coordinate submerged arc welding robot according to claim 1, characterized in that: The model of the controller is STM32F103C8T6. There are 64 pins on the controller. The controller is connected to the digital IO unit through the 13th, 14th, 15th, and 16th pins. The controller is connected to the radiator through the 20th and 21st pins. The controller is connected to the analog output unit through the 33rd, 34th, and 35th pins. The controller is connected to the trigger through the 44th and 45th pins. The controller is connected to the RS485 serial port through the 38th, 39th, and 40th pins.

4. The Cartesian coordinate submerged arc welding robot according to claim 2, characterized in that: A welding machine control aviation plug is provided between the controller and the welding power supply. There are multiple interfaces on the welding machine control aviation plug. The digital IO unit is correspondingly connected to the 11th, 12th, 13th, and 14th interfaces on the welding machine control aviation plug. The analog output unit is correspondingly connected to the 2nd, 4th, and 8th interfaces on the welding machine control aviation plug.

5. The Cartesian coordinate submerged arc welding robot according to claim 1, characterized in that: The transmission component includes a servo motor, a reducer, and a gear rack that are cooperatively arranged.

6. The Cartesian coordinate submerged arc welding robot according to claim 3, characterized in that: The model of the radiator is TC4427. There are 8 pins on the radiator. The 2nd pin of the radiator is connected to the 20th pin of the controller. The 4th pin of the radiator is connected to the 21st pin of the controller. A 11th resistor and a 12th resistor are connected in parallel on the 5th pin of the controller. A MOS tube is provided on the 12th resistor, and a cooling fan is connected to the MOS tube.

7. The Cartesian coordinate submerged arc welding robot according to claim 3, characterized in that: The model of the trigger is FDS4495. There are 8 pins on the trigger. A first resistor is provided between the 1st pin and the 2nd pin of the trigger. A second resistor is provided between the 3rd pin and the 4th pin of the trigger. The 2nd pin of the trigger is connected to the 45th pin of the controller. The 3rd pin of the trigger is connected to the 44th pin of the controller. The 5th pin and the 8th pin of the trigger are connected to the transmission component.

8. The Cartesian coordinate submerged arc welding robot according to claim 3, characterized in that: The model of the RS485 serial port is SP3485. There are 8 pins on the RS485 serial port. The 1st pin of the RS485 serial port is connected to the 40th pin of the controller. The 2nd pin and the 3rd pin of the RS485 serial port are short-circuited and connected to the 39th pin of the controller. The 4th pin of the RS485 serial port is connected to the 38th pin of the controller.

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