A teaching-free welding positioning control system and control method thereof

Abstract

The present invention relates to the technical field of robot welding control, and specifically discloses a teaching-free welding positioning control system and a control method thereof, comprising a PLC controller, a power management module, a sensor detection module, and a visual recognition module. The power management module of the teaching-free welding positioning control system has the functions of voltage stabilization, reasonable power distribution, battery status monitoring, abnormal warning, and regular maintenance, etc., providing stable and reliable power support for the entire system. These modules ensure the stable operation of the system and lay the foundation for solving the problems of existing welding robots. The basic modules of the system provide guarantees for realizing automation and adaptive adjustment from the hardware level, reducing the dependence on manual debugging.

Description

Technical Field

[0001] The invention relates to the technical field of robot welding control, in particular to a teaching-free welding positioning control system and a control method thereof. Background Art

[0002] Welding robot welding is an advanced automated welding technology. The welding robot is composed of a robotic arm, a control system, a welding power supply and other parts. It can accurately perform welding operations according to pre-set programs and trajectories. The welding robot has the characteristics of high precision, high speed and high stability. It can perform welding in various complex environments, such as high temperature, high radiation and other harsh conditions. The welding robot can realize continuous and efficient welding operations, greatly improving production efficiency and welding quality. At the same time, it can also reduce the errors and safety risks caused by manual welding and reduce labor intensity. Welding robots are widely used in automobile manufacturing, mechanical processing, aerospace and other fields, bringing major changes to modern industrial production.

[0003] In the related technology, the control system of the railless welding robot, in terms of communication, on the one hand, the system communicates efficiently with the host computer through the CAN communication bus, so that the host computer can issue real-time instructions and monitor the status of the welding robot; on the other hand, with the help of the wireless communication GPRS module to establish a connection with the remote terminal, this design greatly facilitates the staff to remotely monitor the welding robot no matter where they are. In addition, the system also specially adds a GPS positioning module, through which the current position of the robot can be located extremely accurately. Whether in the complex environment of a large factory or in an outdoor operation scene, the staff can grasp the specific position of the welding robot at any time, which brings many conveniences to practical applications. Moreover, this control system adopts an advanced modular design concept. This design method not only makes the overall cost lower and reduces the equipment investment cost for the enterprise, but also shows great convenience in the development process, which is convenient for R&D personnel to expand and optimize functions according to different needs, and has a very broad application prospect.

[0004] However, the overall operating system of most welding robots currently on the market is relatively simple during the production and processing process. In specific practical applications, a large amount of manual debugging and operation is often required. From the startup of the welding robot to the execution of each welding step, almost every link is inseparable from manual assisted debugging. During actual application, this type of welding robot cannot adaptively adjust the processing according to the specific shape, size, material, etc. of different workpieces. For example, when faced with workpieces with complex shapes, the welding robot cannot automatically adjust the welding path and parameters, and still requires manual intervention for tedious debugging. In terms of robot control, its flexibility is obviously insufficient, and it is difficult to meet the diversified and personalized needs of modern industrial production. In view of this, in order to improve the working efficiency and quality of welding robots and meet the ever-changing industrial production needs, it is urgent to comprehensively improve and optimize the existing system so that it can better adapt to the complex and changing production environment. Summary of the invention

[0005] The object of the present invention is to provide a teaching-free welding positioning control system and a control method thereof, so as to solve the problem of poor autonomous control performance of the existing control system mentioned in the above background technology.

[0006] To achieve the above-mentioned purpose, in a first aspect, the present invention provides a teaching-free welding positioning control system, comprising a PLC controller, a power management module, a sensor detection module, a visual recognition module, a communication interaction module, a motion trajectory module, a process quality module, a teaching-free module and a welding robot, wherein the PLC controller and the communication interaction module are electrically connected, and the power management module, the sensor detection module, the visual recognition module, the motion trajectory module, the process quality module, the teaching-free module and the welding robot are respectively connected to the PLC controller by signal;

[0007] The communication interaction module includes a network communication stabilization module, a serial port communication connection module, a communication protocol conversion module, a human-computer interaction interface module, an alarm information push module and a wireless communication control module. The network communication stabilization module is electrically connected to the PLC controller and the serial port communication connection module is also electrically connected to the PLC controller. The wireless communication control module is signal-connected to the PLC controller. The communication protocol conversion module, the human-computer interaction interface module, the welding robot and the alarm information push module are respectively signal-connected to the PLC controller through the wireless communication control module.

[0008] In a further embodiment, the motion trajectory module includes an axis motion control module, a trajectory planning module, a speed curve setting module, a position feedback analysis module and a motion coordination management module, and the axis motion control module, the trajectory planning module, the speed curve setting module, the position feedback analysis module and the motion coordination management module are respectively connected to the PLC controller signal through the wireless communication control module.

[0009] In a further embodiment, the sensor detection module includes a position sensor data acquisition module, a force sensor monitoring module, a temperature sensor management and control module, a proximity sensor warning module and a collision sensor response module. The position sensor data acquisition module, the force sensor monitoring module, the temperature sensor management and control module, the proximity sensor warning module and the collision sensor response module are respectively connected to the PLC controller signal through the wireless communication control module.

[0010] In a further embodiment, the visual recognition module includes a high-definition image acquisition module, an image feature extraction module, a weld precision recognition module, a workpiece three-dimensional reconstruction module, a visual data processing module and a visual system calibration module. The high-definition image acquisition module, the image feature extraction module, the weld precision recognition module, the workpiece three-dimensional reconstruction module, the visual data processing module and the visual system calibration module are respectively connected to the PLC controller signal through the wireless communication control module.

[0011] In a further embodiment, the process quality module includes a welding data module, a process design module, a welding quality assessment module, a parameter dynamic adjustment module and a quality problem analysis module, and the welding data module, the process design module, the welding quality assessment module, the parameter dynamic adjustment module and the quality problem analysis module are respectively connected to the PLC controller signal through the wireless communication control module.

[0012] In a further embodiment, the power management module includes a power input voltage stabilization module, a power distribution scheduling module, a battery charge and discharge management module, a power monitoring and early warning module, an energy-saving mode switching module and a power system maintenance module. The power input voltage stabilization module, the power distribution scheduling module, the battery charge and discharge management module, the power monitoring and early warning module, the energy-saving mode switching module and the power system maintenance module are respectively connected to the PLC controller signal through the wireless communication control module.

[0013] In a further embodiment, the teaching-free module includes a visual recognition retrieval module, an intelligent decision-making module, an algorithm library and a learning module. The visual recognition retrieval module, the intelligent decision-making module, the algorithm library and the learning module are respectively connected to the PLC controller signal through the wireless communication control module.

[0014] In a further embodiment, the visual recognition retrieval module is composed of an image processing unit and a three-dimensional reconstruction unit, and the image processing unit and the three-dimensional reconstruction unit are respectively connected to the PLC controller signal through a wireless communication control module.

[0015] In a second aspect, the present invention provides a teaching-free welding positioning control method, comprising the following steps:

[0016] Step 1: Power supply preparation. The power input voltage regulator module receives external power and converts it into a stable voltage output through the voltage regulator circuit and filter to provide a reliable power foundation for the system. The power distribution and scheduling module reasonably allocates power according to the needs of each module, such as providing a large current for the motor drive part of the motion trajectory module and providing a low voltage for the microprocessor of the communication interaction module.

[0017] Step 2: Battery management. If the system has a backup battery, the battery charge and discharge management module monitors the battery charge status, charges when needed, and automatically switches to battery power when the main power fails. At the same time, it reasonably controls the battery discharge process to extend the life;

[0018] Step 3: Power supply monitoring and early warning. The power supply monitoring and early warning module monitors the voltage, current, power and other parameters of the power supply in real time. Once an abnormal situation such as over-high or under-voltage, over-current, etc. is found, an early warning signal will be issued immediately to notify the operator or other modules to take corresponding measures.

[0019] Step 4: Sensor startup. The position sensor data acquisition module uses encoders, grating rulers and other position sensors to measure the position and posture of the robot in real time, and converts the position information into electrical signals to transmit to the control system. The force sensor monitoring module is installed on the welding tool or robot arm to detect the contact force during the welding process. The temperature sensor control module installs temperature sensors near the welding area and inside the robot to monitor the temperature in real time. The proximity sensor warning module detects the distance between the robot and the surrounding environment. The collision sensor response module detects collision signals at key parts of the robot.

[0020] Step 5: Visual acquisition and processing. The high-definition image acquisition module obtains the image of the welding workpiece through image acquisition devices such as cameras. The image feature extraction module processes the image and extracts key features. The weld seam precision recognition module uses image processing algorithms and machine learning technology to accurately identify the weld seam position, shape and size. The workpiece 3D reconstruction module reconstructs the workpiece 3D model. The visual data processing module processes and analyzes the image data to verify and optimize the weld seam recognition and workpiece positioning results. The visual system calibration module regularly calibrates the visual system.

[0021] Step 6: Process parameter setting. The welding data module stores various welding process parameters, which are set and adjusted according to different welding tasks and workpiece materials. The process design module selects the appropriate welding process.

[0022] Step 7: Quality assessment and adjustment. The welding quality assessment module assesses the quality of the welded workpiece, including appearance quality, internal quality and dimensional accuracy. The parameter dynamic adjustment module dynamically adjusts the parameters according to the real-time monitored welding parameters and workpiece status during the welding process. The quality problem analysis module analyzes the causes when welding quality problems occur, providing a reference for improving the process.

[0023] Step 8: Communication establishment. The network communication stabilization module ensures that the network communication between the robot and the host computer and other devices is stable and reliable. It can use wired or wireless network technology to achieve high-speed data transmission and remote monitoring, and has network fault detection and recovery functions. The serial communication connection module is used for serial communication with specific devices, and has compatibility and stability as well as data verification and error handling functions. The communication protocol conversion module converts between different communication protocols to achieve interconnection between devices.

[0024] Step 9: Human-computer interaction. The human-computer interaction interface module provides a friendly operation interface, which is convenient for operators to set parameters and monitor the operation status of the robot. The alarm information push module promptly sends out sound and light alarm signals and pushes information when the robot encounters abnormal conditions. The wireless communication control module provides wireless communication function, which is convenient for remote monitoring and operation.

[0025] Step 10: Motion control and trajectory planning. The axis motion control module achieves high-precision motion control by controlling the motors of the robot's six axes, and has motion planning and trajectory tracking functions. The trajectory planning module plans the robot's motion trajectory according to the welding task requirements, taking into account the weld shape, size, position, robot motion performance and constraints, generates the optimal trajectory and optimizes it. The speed curve setting module sets the robot's motion speed curve, and also considers multiple factors for optimization. The position feedback analysis module uses encoders and other sensors to provide real-time feedback on the robot's position information, performs error compensation and adjustment, and the motion coordination management module coordinates the motion of the six axes to ensure that the robot performs welding operations smoothly and accurately, and has motion conflict detection and resolution functions. At the same time, the visual recognition retrieval module, intelligent decision-making module, algorithm library and learning module in the teaching-free module automatically plan the welding path, select process parameters and generate programs based on visual information, continuously learn and optimize the welding process, and realize the teaching-free function.

[0026] Compared with the prior art, the present invention has the following beneficial effects:

[0027] First, the power management module of the welding robot system provides stable and reliable power support for the entire system through functions such as voltage stabilization, reasonable power distribution, battery status monitoring, abnormal warning and regular maintenance. The sensor data acquisition module, force sensor monitoring module, temperature sensor management and control module, proximity sensor warning module and collision sensor response module in the sensor detection module monitor various parameters of the robot and welding process in real time, providing a data basis for the precise control and safe operation of the system. These modules ensure the stable operation of the system and lay the foundation for solving the problems of existing welding robots. The operating systems of welding robots on the market are simple and rely on manual debugging and assistance. The basic modules of this system provide guarantees for the realization of automation and adaptive adjustment from the hardware level, reducing dependence on manual debugging.

[0028] Secondly, the visual recognition module, process quality module and motion trajectory module are the core of realizing adaptive processing. The visual recognition module can accurately acquire the image of the welding workpiece, extract features, identify welds and reconstruct three-dimensional models, and provide accurate information for welding path planning. The process quality module can select suitable processes according to different tasks and materials, store and call parameters, evaluate quality and adjust dynamically. The motion trajectory module accurately controls the robot movement, plans and optimizes the trajectory, sets the speed curve and coordinates the movement of each axis. These three modules cooperate with each other, enabling the system to automatically adjust the processing according to different workpiece conditions without too much manual intervention, thereby improving the flexibility and efficiency of processing.

[0029] Thirdly, the communication interaction module ensures stable communication between the system and external equipment, provides human-computer interaction and alarm functions, and the visual recognition retrieval module, intelligent decision-making module, algorithm library and learning module in the teaching-free module can automatically plan the welding path, select process parameters and generate programs based on visual information, and can continuously learn and optimize the welding process. These intelligent modules further enhance the intelligence of the system and make up for the shortcomings of welding robots on the market in adaptive adjustment and intelligence. Through the synergy of various modules, the system effectively solves the problems of existing welding robots and realizes efficient and precise adaptive welding processing. BRIEF DESCRIPTION OF THE DRAWINGS

[0030] Figure 1 It is a schematic diagram of the overall system module of the present invention;

[0031] Figure 2 This is a schematic diagram of the power management module system in the present invention;

[0032] Figure 3 It is a schematic diagram of the motion trajectory module system module in the present invention;

[0033] Figure 4 It is a schematic diagram of the sensing and monitoring module system in the present invention;

[0034] Figure 5 This is a schematic diagram of the visual recognition module system in the present invention;

[0035] Figure 6 It is a schematic diagram of the process quality module system module in the present invention;

[0036] Figure 7 This is a schematic diagram of the communication interaction module system in the present invention;

[0037] Figure 8 It is a schematic diagram of the teaching-free module system module in the present invention. DETAILED DESCRIPTION

[0038] 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.

[0039] See also Figure 1-Figure 8In an embodiment of the present invention, a teaching-free welding positioning control system includes a PLC controller, a power management module, a sensor detection module, a visual recognition module, a communication interaction module, a motion trajectory module, a process quality module, a teaching-free module and a welding robot, wherein the PLC controller and the communication interaction module are electrically connected, and the power management module, the sensor detection module, the visual recognition module, the motion trajectory module, the process quality module, the teaching-free module and the welding robot are respectively connected to the PLC controller signal.

[0040] The communication interaction module includes a network communication stabilization module, a serial port communication connection module, a communication protocol conversion module, a human-computer interaction interface module, an alarm information push module and a wireless communication control module. The network communication stabilization module is electrically connected to the PLC controller and the serial port communication connection module is also electrically connected to the PLC controller. The wireless communication control module is signal-connected to the PLC controller. The communication protocol conversion module, the human-computer interaction interface module, the welding robot and the alarm information push module are respectively signal-connected to the PLC controller through the wireless communication control module.

[0041] See also Figure 1 and Figure 3 The motion trajectory module includes an axis motion control module, a trajectory planning module, a speed curve setting module, a position feedback analysis module and a motion coordination management module. The axis motion control module, the trajectory planning module, the speed curve setting module, the position feedback analysis module and the motion coordination management module are respectively connected to the PLC controller signal through the wireless communication control module.

[0042] The axis motion control module is used to ensure high-precision movement of the robot's six axes, the trajectory planning module is used to generate and optimize the welding path, the speed curve setting module is used to reasonably plan the robot's motion speed curve, the position feedback analysis module is used to analyze the position feedback information to ensure motion accuracy, and the motion coordination management module is used to coordinate the motion coordination of the six axes.

[0043] See also Figure 1 and Figure 4 The sensor detection module includes a position sensor data acquisition module, a force sensor monitoring module, a temperature sensor management and control module, a proximity sensor warning module and a collision sensor response module. The position sensor data acquisition module, the force sensor monitoring module, the temperature sensor management and control module, the proximity sensor warning module and the collision sensor response module are respectively connected to the PLC controller signal through the wireless communication control module.

[0044] The position sensor data acquisition module is used to accurately collect the robot's position and posture data, the force sensor monitoring module is used to monitor the welding contact force in real time, the temperature sensor control module is used to control the temperature of the welding area within a reasonable range, the proximity sensor warning module is used to issue a warning when approaching a dangerous distance, and the collision sensor response module is used to respond quickly to collisions.

[0045] See also Figure 1-Figure 5 The visual recognition module includes a high-definition image acquisition module, an image feature extraction module, a weld precision recognition module, a workpiece three-dimensional reconstruction module, a visual data processing module and a visual system calibration module. The high-definition image acquisition module, the image feature extraction module, the weld precision recognition module, the workpiece three-dimensional reconstruction module, the visual data processing module, and the visual system calibration module are respectively connected to the PLC controller signal through the wireless communication control module. The process quality module includes a welding data module, a process design module, a welding quality assessment module, a parameter dynamic adjustment module and a quality problem analysis module. The welding data module, the process The design module, the welding quality assessment module, the parameter dynamic adjustment module, and the quality problem analysis module are respectively connected to the PLC controller signal through the wireless communication control module. The power management module includes a power input voltage stabilization module, a power distribution scheduling module, a battery charge and discharge management module, a power monitoring and early warning module, an energy-saving mode switching module and a power system maintenance module. The power input voltage stabilization module, the power distribution scheduling module, the battery charge and discharge management module, the power monitoring and early warning module, the energy-saving mode switching module, and the power system maintenance module are respectively connected to the PLC controller signal through the wireless communication control module.

[0046] The high-definition image acquisition module is used to obtain high-quality welding workpiece images, the image feature extraction module is used to extract key features from the image, the weld precision identification module is used to accurately identify the weld position and shape, the workpiece 3D reconstruction module is used to provide an accurate model for welding path planning, the visual data processing module is used to process vision-related data, the visual system calibration module is used to calibrate the visual recognition system, the welding data module is used to store and call various welding process parameters, the process design module is used to select the appropriate process according to the task and material, the welding quality assessment module is used to assess the quality of the workpiece after welding, the parameter dynamic adjustment module is used to adjust the welding parameters according to the actual situation, and the quality problem analysis module is used to analyze the causes of welding quality problems. The power input voltage regulator module ensures the stability of the input power, prevents voltage fluctuations from damaging precision electronic components, and improves welding quality and stability. The power distribution and scheduling module can reasonably allocate power, dynamically adjust according to different working conditions, improve power utilization efficiency, and ensure power supply to key components. The battery charge and discharge management module can effectively manage the battery, extend its life, ensure safe charging and discharging and stable power supply. The power monitoring and early warning module monitors the power status in real time, and promptly warns in case of abnormalities to ensure safe operation of the robot. The energy-saving mode switching module can switch the energy-saving mode according to demand to reduce energy consumption and cost. The power system maintenance module regularly maintains and detects the power system, repairs problems in a timely manner, ensures long-term stable operation, reduces downtime, and improves production efficiency.

[0047] See also Figure 1 and Figure 8 The teaching-free module includes a visual recognition retrieval module, an intelligent decision-making module, an algorithm library and a learning module. The visual recognition retrieval module, the intelligent decision-making module, the algorithm library and the learning module are respectively connected to the PLC controller signal through the wireless communication control module. The visual recognition retrieval module is composed of an image processing unit and a three-dimensional reconstruction unit. The image processing unit and the three-dimensional reconstruction unit are respectively connected to the PLC controller signal through the wireless communication control module. The visual recognition retrieval module uses a 3D camera sensor to collect three-dimensional image information of the welding workpiece, and accurately identifies the position, shape, size of the weld and the posture of the workpiece. The image processing unit processes the collected images, including denoising, enhancement, feature extraction and other operations, to improve the image quality and the accuracy of weld recognition, while the 3D reconstruction unit reconstructs the workpiece in 3D based on the image information, providing a more accurate model for welding path planning. The intelligent decision-making module is equipped with an autonomous decision-making system, which can automatically plan the welding path, select appropriate welding process parameters and generate welding procedures according to the information provided by the visual recognition module. Its algorithm library contains path planning algorithms, process parameter optimization algorithms, etc., to achieve efficient and high-quality welding, and the setting of the learning module can continuously learn and optimize the welding process, thereby improving the adaptability and stability of the system.

[0048] The present invention provides a teaching-free welding positioning control method, comprising the following steps:

[0049] Step 1: Power supply preparation. The power input voltage regulator module receives external power and converts it into a stable voltage output through the voltage regulator circuit and filter to provide a reliable power foundation for the system. The power distribution and scheduling module reasonably allocates power according to the needs of each module, such as providing a larger current for the motor drive part of the motion trajectory module and providing low voltage for the microprocessor of the communication interaction module.

[0050] Step 2: Battery management. If the system has a backup battery, the battery charge and discharge management module monitors the battery charge status, charges when needed, and automatically switches to battery power when the main power fails. At the same time, it reasonably controls the battery discharge process to extend its life.

[0051] Step 3: Power supply monitoring and early warning. The power supply monitoring and early warning module monitors the voltage, current, power and other parameters of the power supply in real time. Once an abnormal situation such as excessively high or low voltage, current overload, etc. is found, an early warning signal is immediately issued to notify the operator or other modules to take corresponding measures.

[0052] Step 4: Sensor start-up. The position sensor data acquisition module uses encoders, grating rulers and other position sensors to measure the position and posture of the robot in real time, and converts the position information into electrical signals and transmits it to the control system. The force sensor monitoring module is installed on the welding tool or robot arm to detect the contact force during the welding process. The temperature sensor control module installs temperature sensors near the welding area and inside the robot to monitor the temperature in real time. The proximity sensor warning module detects the distance between the robot and the surrounding environment. The collision sensor response module detects collision signals at key parts of the robot.

[0053] Step 5: Visual acquisition and processing. The high-definition image acquisition module obtains the image of the welding workpiece through image acquisition devices such as cameras. The image feature extraction module processes the image and extracts key features. The weld precision identification module uses image processing algorithms and machine learning technology to accurately identify the weld position, shape and size. The workpiece 3D reconstruction module reconstructs the workpiece 3D model. The visual data processing module processes and analyzes the image data to verify and optimize the weld identification and workpiece positioning results. The visual system calibration module regularly calibrates the visual system.

[0054] Step 6: Process parameter setting. The welding data module stores various welding process parameters, which are set and adjusted according to different welding tasks and workpiece materials. The process design module selects the appropriate welding process.

[0055] Step 7: Quality assessment and adjustment. The welding quality assessment module assesses the quality of the workpiece after welding, including appearance quality, internal quality and dimensional accuracy. The parameter dynamic adjustment module dynamically adjusts the parameters according to the real-time monitored welding parameters and workpiece status during the welding process. The quality problem analysis module analyzes the causes when welding quality problems occur and provides a reference for improving the process.

[0056] Step 8: Communication establishment. The network communication stabilization module ensures that the network communication between the robot and the host computer and other devices is stable and reliable. It can use wired or wireless network technology to achieve high-speed data transmission and remote monitoring, and has network fault detection and recovery functions. The serial communication connection module is used for serial communication with specific devices. It has compatibility and stability as well as data verification and error handling functions. The communication protocol conversion module converts between different communication protocols to achieve interconnection between devices.

[0057] Step 9: Human-computer interaction. The human-computer interaction interface module provides a friendly operation interface, which is convenient for operators to set parameters and monitor the operation status of the robot. The alarm information push module will promptly send out sound and light alarm signals and push information when an abnormal situation occurs in the robot. The wireless communication control module provides wireless communication function to facilitate remote monitoring and operation.

[0058] Step 10: Motion control and trajectory planning. The axis motion control module achieves high-precision motion control by controlling the motors of the robot's six axes, and has motion planning and trajectory tracking functions. The trajectory planning module plans the robot's motion trajectory according to the welding task requirements, taking into account the weld shape, size, position, robot motion performance and constraints, generates the optimal trajectory and optimizes it. The speed curve setting module sets the robot's motion speed curve, and also considers multiple factors for optimization. The position feedback analysis module uses encoders and other sensors to provide real-time feedback on the robot's position information, performs error compensation and adjustment, and the motion coordination management module coordinates the motion of the six axes to ensure that the robot performs welding operations smoothly and accurately, and has motion conflict detection and resolution functions. At the same time, the visual recognition retrieval module, intelligent decision-making module, algorithm library and learning module in the teaching-free module automatically plan the welding path, select process parameters and generate programs based on visual information, continuously learn and optimize the welding process, and realize the teaching-free function.

[0059] The working principle of the present invention is: the system adopts the setting of each module, so that after the power input voltage stabilization module receives the external power input, it can convert the external power into a stable voltage output through the voltage stabilization circuit and the filter, providing a power basis for the welding robot system, preventing damage to other modules or affecting their normal operation due to power fluctuations, and the power distribution scheduling module reasonably allocates power according to the power requirements of each module, for example, providing a larger current for the motor drive part in the motion trajectory module, providing a low voltage for the microprocessor in the communication interaction module, etc., to ensure that each module is properly supplied with power and realizes its specific functions. If the system is equipped with a backup battery, the battery charge and discharge management module is responsible for monitoring the battery power state, charging when necessary, and automatically switching to battery power supply when the main power fails. At the same time, it reasonably controls the battery discharge process to extend the battery life. The power monitoring and early warning module monitors the voltage, current, power and other parameters of the power supply in real time. Once an abnormal situation is found, such as too high or too low voltage, current overload, etc., an early warning signal is immediately issued to notify the operator or other modules to take corresponding measures to protect the system safety. The energy-saving mode switching module automatically switches to energy-saving mode when the robot is idle or in low-load state, for example, by reducing the speed of the motor, turning off unnecessary electronic equipment, etc., to reduce energy consumption and improve energy utilization efficiency. The power system maintenance module regularly inspects and maintains the power system, including cleaning the power supply equipment, checking whether the cable connection is loose, replacing aging components, etc., to ensure the long-term and stable operation of the power system.

[0060] The position sensor data acquisition module uses position sensors such as encoders and grating rulers to measure the position and posture of the robot in real time, convert the position information into electrical signals, and transmit it to the control system so that the control system knows the current position of the robot and provides basic data for motion control and trajectory planning. The force sensor monitoring module is installed on the welding tool or robot arm to detect the contact force during the welding process. By monitoring the size and change of the contact force, the welding parameters are adjusted to ensure the welding quality. At the same time, it is used to detect the collision between the robot and the workpiece and take protective measures in time. The temperature sensor control module installs a temperature sensor near the welding area to monitor the temperature of the welding area in real time. When the temperature is too high, the control system takes measures such as reducing the welding current and increasing the cooling time to prevent overheating from damaging the equipment and workpiece. At the same time, it is used to monitor the temperature inside the robot to ensure that the robot operates within the appropriate temperature range. The proximity sensor warning module detects the distance between the robot and the surrounding environment. When the robot approaches an obstacle or a dangerous area, a warning signal is issued to remind the operator or the control system to take corresponding measures to avoid collision accidents. Collision sensor response module The collision sensor is installed in the key parts of the robot. When the robot collides, the collision signal is detected and transmitted to the control system. The control system quickly takes emergency braking measures to stop the movement of the robot to prevent further damage. At the same time, the collision location and intensity and other information are recorded to provide a basis for subsequent fault diagnosis and maintenance.

[0061] The high-definition image acquisition module obtains the image of the welding workpiece through image acquisition devices such as cameras. The image can be a static photo or a dynamic video stream. It must have high resolution, high frame rate and good image quality to accurately identify the characteristics of the weld and the workpiece. The image feature extraction module processes the collected image and extracts key features, such as the edge, shape, color and other features of the weld, as well as the contour, texture and other features of the workpiece, to provide basic data for weld identification and workpiece positioning.

[0062] The weld seam precision identification module uses image processing algorithms and machine learning technology to accurately identify the position, shape and size of the weld seam, ensuring that the robot can accurately perform welding operations. The workpiece 3D reconstruction module processes images from multiple angles to reconstruct the 3D model of the workpiece, providing more accurate information for welding path planning, and is also used to detect whether the shape and size of the workpiece meet the requirements. The visual data processing module processes and analyzes the collected image data, including image enhancement, denoising, segmentation and other operations. At the same time, it verifies and optimizes the results of weld seam identification and workpiece positioning to improve the accuracy and reliability of the visual system. The visual system calibration module regularly calibrates the visual system, adjusts the camera's focal length, angle, position and other parameters, and optimizes and updates the image processing algorithm and machine learning model to ensure its accuracy and stability.

[0063] The welding data module stores various welding process parameters, such as welding current, voltage, speed, gas flow, etc. These parameters can be set and adjusted according to different welding tasks and workpiece materials. When welding operations are required, the control system calls the corresponding welding parameters from this module to ensure welding quality.

[0064] The process design module selects the appropriate welding process according to the characteristics of the welding task and the workpiece material. For example, for thin plate welding, gas shielded welding is selected; for thick plate welding, submerged arc welding is selected, etc., to ensure that the selected process meets the requirements of welding quality and efficiency. The welding quality evaluation module evaluates the quality of the welded workpiece, including the appearance quality, internal quality, dimensional accuracy, etc. of the weld. The evaluation results are used to feedback and adjust the welding process parameters to improve the welding quality. The parameter dynamic adjustment module dynamically adjusts the welding parameters according to the real-time monitored welding parameters and workpiece status during the welding process. For example, when the welding current is found to be too large or too small, the current size is automatically adjusted; when the weld position is found to be offset, the robot's motion trajectory is automatically adjusted to ensure welding quality and efficiency. When a welding quality problem occurs, the quality problem analysis module analyzes the cause of the problem, finds out the root cause of the problem by analyzing the welding parameters, workpiece status, environmental factors, etc., and proposes corresponding solutions. At the same time, historical quality problems are statistically analyzed and analyzed to provide a reference for improving welding technology and improving quality.

[0065] The network communication stability module ensures that the network communication between the robot and the host computer and other devices is stable and reliable. It can use wired network or wireless network technology to achieve high-speed data transmission and remote monitoring. It has network fault detection and recovery functions to ensure timely restoration of communication when network problems occur. The serial communication connection module is used for serial communication with some specific devices, such as sensors, controllers, etc. It has good compatibility and stability, can communicate with different types of devices, and has data verification and error handling functions to ensure the accuracy of data transmission. The communication protocol conversion module is responsible for the conversion between different communication protocols. Since different devices may use different communication protocols, this module is required to perform protocol conversion to achieve interconnection between devices. It has efficient protocol conversion capabilities and good compatibility, and can support the conversion of multiple communication protocols. The human-machine interaction interface module provides a friendly human-machine interaction interface, which is convenient for operators to set parameters, monitor the robot's operating status, and other operations. It can use input devices such as touch screens, keyboards, and mice, as well as output devices such as display screens and indicator lights to achieve interaction between operators and robots. When the robot encounters an abnormal situation, the alarm information push module will promptly issue an audible and visual alarm signal and push the alarm information to the operator or other relevant personnel. It has the ability to respond quickly and accurately alarm to ensure timely discovery and handling of problems. The wireless communication control module provides wireless communication function to facilitate remote monitoring and operation. It can use wireless communication technologies such as Bluetooth, Wi-Fi, and ZigBee to achieve communication between robots and mobile devices. It has security encryption and authority management functions to ensure the security and reliability of communication.

[0066] The axis motion control module achieves high-precision motion control by controlling the motors of the robot's six axes. It has the characteristics of fast response, high precision and high stability. It can accurately control the position, speed and acceleration of the robot. At the same time, it has motion planning and trajectory tracking functions to ensure that the robot moves according to the predetermined trajectory. The trajectory planning module plans the robot's motion trajectory according to the requirements of the welding task, taking into account factors such as the shape, size, and position of the weld, as well as the robot's motion performance and constraints, to generate the optimal motion trajectory. At the same time, it has a trajectory optimization function to improve welding efficiency and quality. The speed curve setting module sets the robot's motion speed curve according to the requirements of the welding task, taking into account factors such as the shape, size, and position of the weld, as well as the robot's motion performance and constraints, to generate the optimal speed curve. At the same time, it has speed adjustment and optimization functions to improve welding efficiency and quality. The position feedback analysis module uses encoders and other position sensors to provide real-time feedback of the robot's position information, analyzes and processes the position feedback information to ensure the robot's movement accuracy and stability. At the same time, it has position error compensation and adjustment functions to improve welding accuracy. The motion coordination management module coordinates the movement of the robot's six axes to ensure that the robot can perform welding operations smoothly and accurately, taking into account the motion relationship and constraints between each axis to generate the optimal motion coordination plan. At the same time, it has motion conflict detection and resolution functions to ensure the safe operation of the robot.

[0067] The visual recognition and retrieval module consists of an image processing unit and a 3D reconstruction unit. The image processing unit processes the collected images, extracts key features, and provides basic data for weld identification and workpiece positioning. The 3D reconstruction unit reconstructs the 3D model of the workpiece based on images from multiple angles to provide more accurate information for welding path planning. The intelligent decision-making module automatically plans the welding path, selects appropriate welding process parameters, and generates welding procedures based on the information provided by the visual recognition module. It has powerful computing power and intelligent decision-making capabilities, and can make decisions quickly and accurately. The algorithm library contains path planning algorithms, process parameter optimization algorithms, etc. To achieve efficient and high-quality welding, it is necessary to continuously update and optimize algorithms to improve welding efficiency and quality. The learning module can continuously learn and optimize the welding process, improve the adaptability and stability of the system, and continuously improve welding processes and parameters through analysis and learning of historical welding data to adapt to different workpieces and welding tasks.

[0068] The axis motion control module can adopt Yaskawa servo drive, the trajectory planning module can adopt ABB trajectory planning software, the speed curve setting module can adopt Siemens motion control module, the position feedback analysis module can adopt Omron encoder, the motion coordination management module can adopt Kuka robot motion coordination system, the position sensor data acquisition module can adopt Pepperl+Fuchs encoder, the force sensor monitoring module can adopt Toledo force sensor, the temperature sensor control module can adopt Omron temperature sensor, the proximity sensor warning module can adopt Keyence proximity sensor, the collision sensor response module can adopt Balluff collision sensor, the high-definition image acquisition module can adopt Hikvision industrial camera, the image feature extraction module can adopt Halcon image processing software, the weld seam precision recognition module can adopt Cognex vision system, the workpiece 3D reconstruction module can adopt RealSense depth camera, the visual data processing module can adopt VisionPro image processing software, the visual system calibration module can adopt OptiTrack calibration system, the welding data module can adopt Panasonic welding parameter storage software, the process design module can adopt Lincoln welding process selection system, and the welding quality assessment module can adopt Olympus flaw detector, parameter dynamic adjustment module can adopt FANUC parameter adjustment system, quality problem analysis module can adopt QC analysis software, network communication stability module can adopt Cisco network equipment, serial communication connection module can adopt MOXA serial port server, wireless communication control module can adopt Huawei wireless communication module, communication protocol conversion module can adopt Anybus protocol converter, human-computer interaction interface module can adopt Weinun touch screen, alarm information push module can adopt sound and light alarm brand (such as Tianyi), power input voltage stabilization module can adopt Mean Well power supply, power distribution and scheduling module can adopt Phoenix power distributor, battery charge and discharge management module can adopt BYD battery management system, power monitoring and early warning module can adopt Fluke power monitor, energy-saving mode switching module can adopt Schneider energy-saving controller, power system maintenance module can adopt professional power maintenance tool brand (such as Fluke17B+ multimeter, etc.), visual recognition module (image processing unit, three-dimensional reconstruction unit) can adopt OpenCV open source library, autonomous decision-making system can adopt independently developed welding robot decision-making software, algorithm library can adopt commonly used machine learning algorithm library such as Scikit-learn, etc.

Claims

1. A teaching-free welding positioning control method, characterized in that: A teaching-free welding positioning control system is included, and the teaching-free welding positioning control system includes a PLC controller, a power management module, a sensor detection module, a visual recognition module, a communication interaction module, a motion trajectory module, a process quality module, a teaching-free module and a welding robot, wherein the PLC controller and the communication interaction module are electrically connected, and the power management module, the sensor detection module, the visual recognition module, the motion trajectory module, the process quality module, the teaching-free module and the welding robot are respectively connected to the PLC controller by signal; The communication interaction module includes a network communication stabilization module, a serial communication connection module, a communication protocol conversion module, a human-machine interaction interface module, an alarm information push module and a wireless communication control module. The network communication stabilization module is electrically connected to the PLC controller and the serial communication connection module is also electrically connected to the PLC controller. The wireless communication control module is signal-connected to the PLC controller. The communication protocol conversion module, the human-machine interaction interface module, the welding robot and the alarm information push module are respectively signal-connected to the PLC controller through the wireless communication control module. The sensor detection module includes a position sensor data acquisition module, a force sensor monitoring module, a temperature sensor control module, a proximity sensor warning module and a collision sensor response module; The visual recognition module includes a high-definition image acquisition module, an image feature extraction module, a weld precision recognition module, a workpiece three-dimensional reconstruction module, a visual data processing module and a visual system calibration module; The process quality module includes a welding data module, a process design module, a welding quality assessment module, a parameter dynamic adjustment module and a quality problem analysis module; The power management module includes a power input voltage stabilization module, a power distribution scheduling module, a battery charge and discharge management module, a power monitoring and early warning module, an energy-saving mode switching module and a power system maintenance module; The teaching-free module includes a visual recognition and retrieval module, an intelligent decision-making module, an algorithm library and a learning module; The visual recognition acquisition module is composed of an image processing unit and a three-dimensional reconstruction unit; The motion trajectory module includes an axis motion control module, a trajectory planning module, a speed curve setting module, a position feedback analysis module and a motion coordination management module; The teaching-free welding positioning control method comprises the following steps: Step 1: Power supply preparation: the power input voltage regulator module receives external power and converts it into a stable voltage output through the voltage regulator circuit and filter to provide a reliable power foundation for the system. The power distribution and scheduling module reasonably allocates power according to the needs of each module. Step 2: Battery management. If the system has a backup battery, the battery charge and discharge management module monitors the battery charge status, charges when needed, and automatically switches to battery power when the main power fails. At the same time, it reasonably controls the battery discharge process to extend the life; Step 3: Power monitoring and early warning. The power monitoring and early warning module monitors the power parameters in real time. Once an abnormal situation is found, it immediately sends out an early warning signal to notify the operator or other modules to take corresponding measures. Step 4: Sensor startup: the position sensor data acquisition module uses sensors to measure the position and posture of the robot in real time, converts the position information into electrical signals and transmits it to the control system. The force sensor monitoring module is installed on the welding tool or robot arm to detect the contact force during welding. The temperature sensor control module installs temperature sensors near the welding area and inside the robot to monitor the temperature in real time. The proximity sensor warning module detects the distance between the robot and the surrounding environment. The collision sensor response module detects collision signals at key parts of the robot. Step 5: Visual acquisition and processing. The high-definition image acquisition module obtains the image of the welding workpiece through the image acquisition device. The image feature extraction module processes the image and extracts key features. The weld seam precision recognition module uses image processing algorithms and machine learning technology to accurately identify the weld seam position, shape and size. The workpiece 3D reconstruction module reconstructs the workpiece 3D model. The visual data processing module processes and analyzes the image data to verify and optimize the weld seam recognition and workpiece positioning results. The visual system calibration module regularly calibrates the visual system. Step 6: Process parameter setting. The welding data module stores various welding process parameters, which are set and adjusted according to different welding tasks and workpiece materials. The process design module selects the appropriate welding process. Step 7: Quality assessment and adjustment. The welding quality assessment module assesses the quality of the workpiece after welding. The parameter dynamic adjustment module dynamically adjusts the parameters according to the real-time monitored welding parameters and workpiece status during the welding process. The quality problem analysis module analyzes the causes when welding quality problems occur, providing a reference for improving the process. Step 8: Communication establishment. The network communication stabilization module ensures that the network communication between the robot and the host computer and other devices is stable and reliable. It uses wired or wireless network technology to achieve high-speed data transmission and remote monitoring, and has network fault detection and recovery functions. The serial communication connection module is used for serial communication with specific devices, and has compatibility and stability as well as data verification and error handling functions. The communication protocol conversion module converts between different communication protocols to achieve interconnection between devices. Step 9: Human-computer interaction. The human-computer interaction interface module provides a friendly operation interface, which is convenient for operators to set parameters and monitor the operation status of the robot. The alarm information push module promptly sends out sound and light alarm signals and pushes information when the robot encounters abnormal conditions. The wireless communication control module provides wireless communication function, which is convenient for remote monitoring and operation. Step 10: Motion control and trajectory planning. The axis motion control module achieves high-precision motion control by controlling the motors of the robot's six axes, and has motion planning and trajectory tracking functions. The trajectory planning module plans the robot's motion trajectory according to the welding task requirements, considering the weld shape, size, position, robot motion performance and constraints, generates the optimal trajectory and optimizes it. The speed curve setting module sets the robot's motion speed curve, and also considers multiple factors for optimization. The position feedback analysis module uses the encoder to feedback the robot's position information in real time, performs error compensation and adjustment, and the motion coordination management module coordinates the movement of the six axes to ensure that the robot performs welding operations smoothly and accurately, and has motion conflict detection and resolution functions. At the same time, the visual recognition retrieval module, intelligent decision-making module, algorithm library and learning module in the teaching-free module automatically plan the welding path, select process parameters and generate programs based on visual information, continuously learn and optimize the welding process, and realize the teaching-free function.

2. The teaching-free welding positioning control method according to claim 1, characterized in that: The position sensor data acquisition module, the force sensor monitoring module, the temperature sensor management and control module, the proximity sensor early warning module, and the collision sensor response module are respectively connected to the PLC controller signal through the wireless communication control module.

3. The teaching-free welding positioning control method according to claim 2, characterized in that: The high-definition image acquisition module, the image feature extraction module, the weld precision identification module, the workpiece three-dimensional reconstruction module, the visual data processing module, and the visual system calibration module are respectively connected to the PLC controller signal through the wireless communication control module.

4. The teaching-free welding positioning control method according to claim 3 is characterized in that: The welding data module, the process design module, the welding quality assessment module, the parameter dynamic adjustment module, and the quality problem analysis module are respectively connected to the PLC controller signal through the wireless communication control module.

5. The teaching-free welding positioning control method according to claim 4, characterized in that: The power input voltage stabilization module, the power distribution scheduling module, the battery charge and discharge management module, the power monitoring and early warning module, the energy-saving mode switching module, and the power system maintenance module are respectively connected to the PLC controller signal through the wireless communication control module.

6. The teaching-free welding positioning control method according to claim 5, characterized in that: The visual recognition retrieval module, the intelligent decision-making module, the algorithm library, and the learning module are respectively connected to the PLC controller signal through the wireless communication control module.

7. The teaching-free welding positioning control method according to claim 6, characterized in that: The image processing unit and the three-dimensional reconstruction unit are respectively connected to the PLC controller signal through a wireless communication control module.

8. According to the teaching-free welding positioning control method of claim 1, the axis motion control module, the trajectory planning module, the speed curve setting module, the position feedback analysis module and the motion coordination management module are respectively connected to the PLC controller signal through the wireless communication control module.

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