A servo drive system and method for spot welding robot with automatic path adjustment

Abstract

The invention relates to the technical field of intelligent manufacturing, and discloses a servo drive system of a spot welding robot with automatic path adjustment and a method thereof. The method comprises the following steps: step one, calculating the influence coefficient of environmental data monitored by an online monitoring system on a welding point distance index; step two, a computer control system is responsible for receiving a data set of the online monitoring system and image information of a spot welding robot, and preprocessing the received information; step three, the spot welding robot collects the data of the above steps, and calculates an optimal welding distance parameter, and eliminates the influence coefficient of the environmental data detected by the online monitoring system on the welding point distance index through calculation, and then, based on the adjusted welding distance data, further calculates the optimal welding distance, thereby optimizing the entire welding process. This method not only improves the efficiency and accuracy of the welding operation, but also ensures that various system modules can work together to exert the maximum overall efficiency.

Description

Technical Field

[0001] The present invention relates to the technical field of intelligent manufacturing, and in particular to a servo drive system for a spot welding robot with automatic path adjustment and a method thereof. Background Art

[0002] With the rapid development of the manufacturing industry, especially in the field of automobile manufacturing, the requirements for welding quality and efficiency of body-in-white spot welding process are increasing day by day. The traditional spot welding robot path planning relies on the teaching experiment of engineers, which is not only time-consuming and labor-intensive, but also difficult to find the best path. Especially when there are a large number of welding spots, the path planning results vary from person to person and lack the support of mathematical models. Therefore, it is of great significance to study and develop a spot welding robot servo drive system and method that can automatically adjust the path to improve the automation level and production efficiency of welding operations. Summary of the invention

[0003] 1. Technical issues to be resolved

[0004] In view of the deficiencies in the prior art, the present invention provides a spot welding robot servo drive system with automatic path adjustment and a method thereof, which has the advantage of automatically adjusting the path and solves the problem of difficult path planning.

[0005] (II) Technical solution

[0006] To achieve the above object, the present invention provides the following technical solutions: a servo drive system for a spot welding robot with automatic path adjustment, the system comprising the following parts: an online monitoring system, a computer control system and a spot welding robot;

[0007] The online monitoring system is responsible for monitoring the environmental data set in the welding area and transmitting the environmental data set to the computer control system through the wireless network for data set preprocessing and classification;

[0008] The computer control system is responsible for receiving the data set of the online monitoring system and the image information of the spot welding robot, and the computer control system is connected to the spot welding robot via a wireless network;

[0009] The spot welding robot includes a visual capture module, a wireless transmission module, an analysis module, a control module and a spot welding module; the visual capture module is used to capture image information of the welding area, and the wireless transmission module is responsible for transmitting the image information to the computer control system for image preprocessing to extract data; the analysis module is used to calculate the data extracted from the computer control system and classify and number the extracted data; the control module optimizes the calculation results of the analysis module and transmits the optimized data to the spot welding module through the wireless network, and the spot welding module is used to execute electric welding commands.

[0010] Preferably, the computer system transmits the environmental data set in the electric welding area to the analysis module of the spot welding robot through a wireless network, and the analysis module performs subset numbering on the environmental data set. The analysis module performs subset classification on the environmental data set according to the characteristics of the environmental data set in the electric welding area, and the subset classification is environmental temperature data, pressure data and humidity data, and the environmental temperature data, pressure data and humidity data are numbered as follows: , , .

[0011] Preferably, the visual capture module is used to capture image information of the welding area, and the image information includes tiny defect patterns, moderate defect patterns and severe defect patterns within 50% of the included area, and converts them into tiny defect data sets, moderate defect data sets and severe defect data sets through a computer system. By capturing and processing detailed image information of the welding area in real time, the system can automatically adjust the welding parameters.

[0012] Preferably, the analysis module classifies and numbers the data extracted from the computer control system; the minor defect data set, the moderate defect data set and the severe defect data set are each divided into three subsets, the three subsets include a defect length data set, a defect width data set and a defect depth data set, and the minor defect length data set is numbered , , ,… , the minor defect width data set number is , , ,… , the minor defect depth set number is , , ,… , the medium defect length data set number is , , ,… , the medium defect width data set number is , , ,… , the medium defect depth set number is , , ,… .

[0013] Preferably, the severe defect length data set is numbered as , , ,… , the severe defect width data set number is , , ,… , the severe defect depth set number is , , ,… .

[0014] Preferably, the analysis module calculates the micro-welding point distance index according to the micro-defect length data set, the micro-defect width data set, the micro-defect depth data set and the environmental data set. , and its calculation formula is:

[0015]

[0016]

[0017]

[0018] In the formula, Indicates the distance index of small welding points, Indicates the total number of minor defects. … Indicates minor defects from 1 to The total number type, , , ,… represents a dataset of tiny defect lengths, , , ,… represents a dataset of tiny defect widths, , , ,… represents the depth set of minor defects, , , They represent the ambient temperature data, pressure data and humidity data corresponding to the nth defect respectively. Indicates the influence coefficient of environmental data on the distance index of small welding points, , , Respectively represent the ambient temperature data, pressure data and humidity data in The weight of .

[0019] Preferably, the analysis module calculates the medium weld distance index according to the medium defect length data set, the medium defect width data set, the medium defect depth data set and the environment data set. , and its calculation formula is:

[0020]

[0021]

[0022]

[0023] In the formula, Indicates the medium weld distance index, Indicates the total number of medium defects. … Indicates moderate blemishes from 1 to The total number type, , , ,… represents a medium defect length data set, , , ,… represents a medium defect width data set, , , ,… represents a medium blemish depth set, , , They represent the ambient temperature data, pressure data and humidity data corresponding to the nth defect respectively. Indicates the influence coefficient of environmental data on the distance index of moderate welding points, , , Respectively represent the ambient temperature data, pressure data and humidity data in The weight of .

[0024] Preferably, the analysis module calculates the severe welding point distance index according to the severe defect length data set, the severe defect width data set, the severe defect depth data set and the environmental data set. , and its calculation formula is:

[0025]

[0026]

[0027]

[0028] In the formula, Indicates the distance index of heavy welding points, Indicates the total number of severe defects. … Indicates severe defects from 1 to The total number type, , , ,… represents a severely defective length dataset, , , ,… represents the severe defect width dataset, , , ,… Indicates the severe defect depth set, , , They represent the ambient temperature data, pressure data and humidity data corresponding to the nth defect respectively. Indicates the influence coefficient of environmental data on the distance index of heavy welding points, , , Respectively represent the ambient temperature data, pressure data and humidity data in The weight of .

[0029] Preferably, the analysis module is based on the micro welding point distance index ,… , Medium Welding Point Distance Index ,… n Heavy Welding Distance Index … To calculate the welding ease of operation data set ， The calculation formula is:

[0030]

[0031] In the formula, represents the welding operability data set, ,… Indicates the distance index of the slight welding point, ,… Indicates the medium weld distance index, … Indicates the distance index of heavy welding points, Indicates three degrees of weld point overlap area;

[0032] The control module is based on the micro welding point distance index ,… , Medium Welding Point Distance Index ,… Distance index from heavy welding points ,… To optimize the welding distance parameters Calculation, the calculation formula is as follows:

[0033]

[0034] In the formula, represents the optimal welding distance parameter, Indicates the distance index of small welding points ,… , Medium Welding Point Distance Index ,… Heavy Welding Distance Index ,… The concentrated expression of Represents the actual distance parameter obtained by the spot welding robot through the visual capture module.

[0035] Preferably, a servo driving method for a spot welding robot with automatic path adjustment comprises the following steps:

[0036] Step 1: Calculate the influence coefficient of the environmental data monitored by the online monitoring system on the welding point distance index;

[0037] Step 2: The computer control system is responsible for receiving the data set of the online monitoring system and the image information of the spot welding robot, and preprocessing the received information;

[0038] Step 3: The spot welding robot collects the data from the above steps and calculates the optimal welding distance parameters.

[0039] Compared with the prior art, the present invention provides a spot welding robot servo drive system with automatic path adjustment and a method thereof, which has the following beneficial effects:

[0040] 1. The present invention uses the spot welding robot servo drive system with automatic path adjustment, and through the wireless connectivity collaboration between its online monitoring system, computer control system and spot welding robot, it not only improves welding quality, but also optimizes production efficiency. During the entire system processing process, the analysis module of the spot welding robot not only calculates the influence coefficients of ambient temperature, pressure and humidity on the distance index of small, medium and severe welding points, but also effectively eliminates welding quality problems caused by environmental changes. The analysis module provides basic judgment for subsequent calculations by subset numbering the data set extracted by the computer system.

[0041] 2. The present invention uses the analysis module to calculate the distance index of different welding points in depth. The system can comprehensively consider the comprehensive influence of environmental factors and the length, width and depth data of actual defects. After calculation and exclusion, it ensures that the welding operation is carried out under the best conditions, thereby improving the accuracy of welding. The control module further calculates the distance index of tiny welding points according to the distance index of the tiny welding points. ,… , Medium Welding Point Distance Index ,… Heavy Welding Distance Index ,… Calculate the optimal welding distance parameters By comparing the data with the actual distance, the welding operation can be completed at the most suitable distance, reducing the welding deviation caused by direct calculation of the actual distance. BRIEF DESCRIPTION OF THE DRAWINGS

[0042] Figure 1 It is a schematic diagram of the structure of the present invention;

[0043] Figure 2 It is a step diagram of the method of the present invention. DETAILED DESCRIPTION

[0044] The following will be combined with the drawings in the embodiments of the present invention to clearly and completely describe the technical solutions in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0045] See also Figure 1 ,A servo drive system for spot welding robot with automatic path adjustment, the system consists of the following parts: an online monitoring system, a computer control system and a spot welding robot;

[0046] The online monitoring system is responsible for monitoring the environmental data set in the welding area, and transmitting the environmental data set to the computer control system through the wireless network for data set preprocessing and classification. By monitoring the environmental temperature, pressure and humidity data in the welding area, it ensures that the welding process is carried out in the best environment, thereby reducing welding defects caused by adverse environmental factors. The collected environmental data set is transmitted to the computer control system for preprocessing to provide accurate basic data for subsequent data analysis, and the environmental data is subset classified and numbered to facilitate the analysis module to process data more efficiently and ensure more accurate adjustment of welding parameters;

[0047] The computer control system is responsible for receiving the data set of the online monitoring system and the image information of the spot welding robot. The computer control system and the spot welding robot are connected through a wireless network. The wireless network connection between the computer control system and the spot welding robot ensures the real-time transmission of data and improves the efficiency of data processing;

[0048] The spot welding robot includes a visual capture module, a wireless transmission module, an analysis module, a control module and a spot welding module; the visual capture module is used to capture the image information of the welding area, and by capturing the image information of the welding area, including small defects, medium defects and severe defects, it provides an intuitive basis for identifying and correcting welding defects. The wireless transmission module is responsible for transmitting the image information to the computer control system for image preprocessing to extract data, and converting the image information into a small defect data set, a medium defect data set and a severe defect data set, so that welding defects can be quantitatively analyzed, thereby improving the accuracy of welding quality control; the analysis module is used to calculate the data extracted from the computer control system, The extracted data is classified and numbered, and the data extracted from the computer control system is analyzed and classified and numbered, providing a mathematical model basis for the decision-making of the control module; the control module optimizes the calculation results of the analysis module to ensure the optimization of welding paths and parameters, reduce unnecessary motion waste, and transmits the optimized data to the spot welding module through a wireless network. The spot welding module is used to execute electric welding commands and automatically adjust the welding parameters based on the analysis results to adapt to different welding conditions and requirements, thereby ensuring the consistency and reliability of welding quality. The spot welding module can adjust the welding strategy according to real-time feedback, reduce manual intervention, and improve the continuity and automation level of production.

[0049] The computer system transmits the environmental data set in the electric welding area to the analysis module of the spot welding robot through the wireless network. The analysis module subsets the environmental data set and classifies it into subsets according to the characteristics of the environmental data set in the electric welding area. The subsets are classified into environmental temperature data, pressure data and humidity data. The environmental temperature data, pressure data and humidity data are numbered as follows: , , .

[0050] The visual capture module is used to capture image information of the welding area, which includes tiny defect patterns, moderate defect patterns and severe defect patterns within 50% of the area, and converts them into tiny defect data sets, moderate defect data sets and severe defect data sets through a computer system. By capturing and processing detailed image information of the welding area in real time, the system can automatically adjust welding parameters.

[0051] The analysis module classifies and numbers the data extracted from the computer control system; the minor defect data set, the moderate defect data set and the severe defect data set are divided into three subsets, the three subsets include a defect length data set, a defect width data set and a defect depth data set, and the minor defect length data set is numbered , , ,… , the minor defect width data set number is , , ,… , the minor defect depth set number is , , ,… , the medium defect length data set number is , , ,… , the medium defect width data set number is , , ,… , the medium defect depth set number is , , ,… .

[0052] The data set number for severe defect length is , , ,… , the severe defect width data set number is , , ,… , the severe defect depth set number is , , ,… .

[0053] The analysis module calculates the micro-welding point distance index based on the micro-defect length data set, micro-defect width data set, micro-defect depth data set and environmental data set. , and its calculation formula is:

[0054]

[0055]

[0056]

[0057] In the formula, Indicates the distance index of small welding points, Indicates the total number of minor defects. … Indicates minor defects from 1 to The total number type, , , ,… represents a dataset of tiny defect lengths, , , ,… represents a dataset of tiny defect widths, , , ,… represents the depth set of minor defects, , , They represent the ambient temperature data, pressure data and humidity data corresponding to the nth defect respectively. Indicates the influence coefficient of environmental data on the distance index of small welding points, , , Respectively represent the ambient temperature data, pressure data and humidity data in The weight of .

[0058] The analysis module calculates the medium weld distance index based on the medium defect length data set, medium defect width data set, medium defect depth data set and environmental data set. , and its calculation formula is:

[0059]

[0060]

[0061]

[0062] In the formula, Indicates the medium weld distance index, Indicates the statistical total number of medium defects, … Indicates moderate blemishes from 1 to The total number type, , , ,… represents a medium defect length data set, , , ,… represents a medium defect width data set, , , ,… represents a medium blemish depth set, , , They represent the ambient temperature data, pressure data and humidity data corresponding to the nth defect respectively. Indicates the influence coefficient of environmental data on the distance index of moderate welding points, , , Respectively represent the ambient temperature data, pressure data and humidity data in The weight of .

[0063] The analysis module calculates the severe weld distance index based on the severe defect length data set, severe defect width data set, severe defect depth data set and environmental data set. , and its calculation formula is:

[0064]

[0065]

[0066]

[0067] In the formula, Indicates the distance index of heavy welding points, Indicates the total number of severe defects. … Indicates severe defects from 1 to The total number type, , , ,… represents a severely defective length dataset, , , ,… represents the severe defect width dataset, , , ,… Indicates the severe defect depth set, , , They represent the ambient temperature data, pressure data and humidity data corresponding to the nth defect respectively. Indicates the influence coefficient of environmental data on the distance index of heavy welding points, , , Respectively represent the ambient temperature data, pressure data and humidity data in The weight of .

[0068] The advantages are: this spot welding robot servo drive system with automatic path adjustment, through the wireless connectivity collaboration between its online monitoring system, computer control system and spot welding robot, not only improves welding quality, but also optimizes production efficiency. During the entire system processing process, the analysis module of the spot welding robot not only calculates the influence coefficients of ambient temperature, pressure and humidity on the distance index of small, medium and severe welding points, but also effectively eliminates welding quality problems caused by environmental changes. The analysis module provides basic judgment for subsequent calculations by subset numbering the data set extracted by the computer system.

[0069] The analysis module is based on the distance index of small welding points ,… , Medium Welding Point Distance Index ,… Heavy Welding Distance Index … To calculate the welding ease of operation data set ， The calculation formula is:

[0070]

[0071] In the formula, represents the welding operability data set, ,… Indicates the distance index of the slight welding point, ,… Indicates the medium weld distance index, … Indicates the distance index of heavy welding points, Indicates three degrees of weld point overlap area;

[0072] The control module is based on the distance index of the tiny welding point ,… , Medium Welding Point Distance Index ,… Distance index from heavy welding points ,… To optimize the welding distance parameters Calculation, the calculation formula is as follows:

[0073]

[0074] In the formula, represents the optimal welding distance parameter, Indicates the distance index of small welding points ,… , Medium Welding Point Distance Index ,… Heavy Welding Distance Index ,… The concentrated expression of Represents the actual distance parameter obtained by the spot welding robot through the visual capture module.

[0075] The advantages are: through the in-depth calculation of the distance index of different welding points by the analysis module, the system can comprehensively consider the comprehensive influence of environmental factors and the length, width and depth data of the actual defects. After calculation and exclusion, it ensures that the welding operation is carried out under the best conditions, thereby improving the accuracy of welding. The control module further calculates the distance index of the tiny welding points. ,… , Medium Welding Point Distance Index ,… Heavy Welding Distance Index ,… Calculate the optimal welding distance parameters By comparing the data with the actual distance, the welding operation can be completed at the most suitable distance, reducing the welding deviation caused by direct calculation of the actual distance.

[0076] A servo driving method for a spot welding robot with automatic path adjustment, the driving method comprising the following steps:

[0077] Step 1: Calculate the influence coefficient of the environmental data monitored by the online monitoring system on the welding point distance index;

[0078] Step 2: The computer control system is responsible for receiving the data set of the online monitoring system and the image information of the spot welding robot, and preprocessing the received information;

[0079] Step 3: The spot welding robot collects the data from the above steps and calculates the optimal welding distance parameters.

[0080] The advantages are: the influence coefficient of the environmental data detected by the online monitoring system on the welding point distance index is eliminated through calculation. Subsequently, based on these adjusted welding distance data, the optimal welding distance is further calculated, thereby optimizing the entire welding process. This method not only improves the efficiency and accuracy of the welding operation, but also ensures that the various system modules can work together to maximize the overall efficiency.

[0081] Although embodiments of the present invention have been shown and described, it will be appreciated by those skilled in the art that various changes, modifications, substitutions and variations may be made to the embodiments without departing from the principles and spirit of the present invention, and that the scope of the present invention is defined by the appended claims and their equivalents.

Claims

1. A servo drive system for a spot welding robot with automatic path adjustment, characterized in that: The system consists of the following parts: online monitoring system, computer control system and spot welding robot; The online monitoring system is responsible for monitoring the environmental data set in the welding area and transmitting the environmental data set to the computer control system through the wireless network for data set preprocessing and classification; The computer control system is responsible for receiving the data set of the online monitoring system and the image information of the spot welding robot, and the computer control system is connected to the spot welding robot via a wireless network; The spot welding robot includes a visual capture module, a wireless transmission module, an analysis module, a control module and a spot welding module; the visual capture module is used to capture image information of the welding area, and the wireless transmission module is responsible for transmitting the image information to the computer control system for image preprocessing to extract data; the analysis module is used to calculate the data extracted from the computer control system and classify and number the extracted data; the control module optimizes the calculation results of the analysis module and transmits the optimized data to the spot welding module through the wireless network, and the spot welding module is used to execute the electric welding command; The computer control system transmits the environmental data set in the electric welding area to the analysis module of the spot welding robot through the wireless network. The analysis module performs subset numbering on the environmental data set. The analysis module performs subset classification on the environmental data set according to the characteristics of the environmental data set in the electric welding area. The subset classification is environmental temperature data, pressure data and humidity data. The environmental temperature data, pressure data and humidity data are numbered as follows: , , ; The visual capture module is used to capture image information of the welding area, and the image information includes small defect patterns, medium defect patterns and severe defect patterns within 50% of the area, and converts them into small defect data sets, medium defect data sets and severe defect data sets through a computer control system. By capturing and processing detailed image information of the welding area in real time, the system can automatically adjust welding parameters; The analysis module classifies and numbers the data extracted from the computer control system; the minor defect data set, the moderate defect data set and the severe defect data set are each divided into three subsets, the three subsets include a defect length data set, a defect width data set and a defect depth data set, and the minor defect length data set is numbered , , ,… , the minor defect width data set number is , , ,… , the minor defect depth dataset is numbered as , , ,… , the medium defect length data set number is , , ,… , the medium defect width data set number is , , ,… , the medium defect depth dataset is numbered as , , ,… ; The severe defect length data set number is , , ,… , the severe defect width data set number is , , ,… , the severe defect depth dataset is numbered as , , ,… ; The analysis module calculates the micro-welding point distance index based on the micro-defect length data set, the micro-defect width data set, the micro-defect depth data set and the environmental data set. , and its calculation formula is: ； ； ； In the formula, Indicates the distance index of small welding points, Indicates the total number of minor defects. … Indicates minor defects from 1 to The total number type, , , ,… represents a dataset of tiny defect lengths, , , ,… represents a dataset of tiny defect widths, , , ,… represents a small defect depth dataset, , , They represent the ambient temperature data, pressure data, and humidity data corresponding to the nth defect, respectively. Indicates the influence coefficient of environmental data on the distance index of small welding points, , , Respectively represent the ambient temperature data, pressure data and humidity data in The weight of The analysis module calculates the medium welding point distance index according to the medium defect length data set, the medium defect width data set, the medium defect depth data set and the environment data set. , and its calculation formula is: ; ； ; In the formula, Indicates the medium weld distance index, Indicates the total number of medium defects. … Indicates moderate blemishes from 1 to The total number type, , , ,… represents a medium defect length data set, , , ,… represents a medium defect width data set, , , ,… represents a medium defect depth dataset, , , They represent the ambient temperature data, pressure data and humidity data corresponding to the nth defect respectively. Indicates the influence coefficient of environmental data on the distance index of moderate welding points, , , Respectively represent the ambient temperature data, pressure data and humidity data in The weight of The analysis module calculates the severe welding point distance index according to the severe defect length data set, the severe defect width data set, the severe defect depth data set and the environmental data set. , and its calculation formula is: ; ； ; In the formula, Indicates the distance index of heavy welding points, Indicates the total number of severe defects. … Indicates severe defects from 1 to The total number type, , , ,… represents a severely defective length dataset, , , ,… represents the severe defect width dataset, , , ,… represents a heavily defective depth dataset, , , They represent the ambient temperature data, pressure data, and humidity data corresponding to the nth defect, respectively. Indicates the influence coefficient of environmental data on the distance index of heavy welding points, , , Respectively represent the ambient temperature data, pressure data and humidity data in The weight of The analysis module is based on the micro welding point distance index ,… , Medium Welding Point Distance Index ,… Heavy Welding Distance Index … To calculate the welding ease of operation data set ， The calculation formula is: ; In the formula, represents the welding operability data set, ,… Indicates the distance index of the slight welding point, ,… Indicates the medium weld distance index, … Indicates the distance index of heavy welding points, Indicates three degrees of weld point overlap area; The control module is based on the micro welding point distance index ,… , Medium Welding Point Distance Index ,… Distance index from heavy welding points ,… To optimize the welding distance parameters Calculation, the calculation formula is as follows: ; In the formula, represents the optimal welding distance parameter, Indicates the distance index of small welding points ,… , Medium Welding Point Distance Index ,… Heavy Welding Distance Index ,… The concentrated expression of Represents the actual distance parameter obtained by the spot welding robot through the visual capture module.

2. A servo drive method for a spot welding robot with automatic path adjustment, using the servo drive system for a spot welding robot with automatic path adjustment according to claim 1, characterized in that: The driving method comprises the following steps: Step 1: Calculate the influence coefficient of the environmental data monitored by the online monitoring system on the welding point distance index; Step 2: The computer control system is responsible for receiving the data set of the online monitoring system and the image information of the spot welding robot, and preprocessing the received information; Step 3: The spot welding robot collects the data from the above steps and calculates the optimal welding distance parameters.

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