Dynamic adjusting method for arc multi-layer and multi-pass welding of industrial robot

Abstract

The invention discloses a dynamic adjusting method for arc multi-layer and multi-pass welding of an industrial robot. The method comprises the following steps that a real-time welding mode instruction is obtained according to real-time central angles in multiple layers and multiple channels of the arc; based on the real-time arc current, a manual control switch instruction, a left-right adjusting instruction and an up-down adjusting instruction of arc multi-layer and multi-pass welding of the industrial robot are obtained; and dynamic adjustment is conducted on arc multi-layer and multi-pass welding of the industrial robot through the control instruction. According to the invention, the problem of track deviation caused by assembly errors, roundness errors of the circular welding seam of the pipeline, bending deformation of the circular pipeline and welding wire bending errors in the welding process of the existing welding equipment in the welding construction operation of the circular welding seam is solved; and the real-time welding mode instruction is used for controlling the industrial robot to switch the welding mode among flat welding, overhead welding and vertical welding, so that the welding mode is more practical, and the welding accuracy is improved.

Description

Technical Field

[0001] The invention relates to the field of circular arc multi-layer multi-pass welding of industrial robots, and in particular to a dynamic adjustment method for circular arc multi-layer multi-pass welding of industrial robots. Background Art

[0002] In the welding operation of circular welds, the commonly used welding equipment mainly relies on rotating the weld to be welded to achieve relative rotation of the welding equipment, thereby completing the welding of the weld. When the weld to be welded is fixed, manual real-time observation is required. Due to the arc light and welding smoke, the operator's working environment is harsh, making it difficult to perform welding work accurately.

[0003] At present, industrial robots are often used to complete welding. The industrial robot first scans the weld along the pipeline, and then converts the scanned weld information to the robot coordinate system. The robot moves along the weld to weld. However, as the arc weld is welded, the weld is gradually filled until the weld is flat. However, due to the assembly error of the processing, the heights of the left and right ends of the weld are not equal. Therefore, when the industrial robot fills the weld, one end will be filled and the other end will have a surplus. The current collected by the arc tracking technology under this working condition will only detect the current change at one end. The current at the filled end is almost the same as the center current, resulting in the inability to identify the weld center. The industrial robot will also appear to be constantly looking for the weld center, causing it to deviate from the correct welding trajectory. In addition, the roundness error of the circular weld of the pipeline itself and the bending deformation of the circular pipeline will affect the accuracy of the industrial robot's arc multi-layer and multi-pass welding. Summary of the invention

[0004] In view of the above-mentioned deficiencies in the prior art, the present invention provides a dynamic adjustment method for circular arc multi-layer and multi-pass welding of an industrial robot.

[0005] In order to achieve the above-mentioned object of the invention, the technical solution adopted by the present invention is:

[0006] A dynamic adjustment method for arc multi-layer multi-pass welding of an industrial robot comprises the following steps:

[0007] S1, obtaining the real-time center angle of the arc in multiple layers and multiple channels, and obtaining the real-time welding mode instruction according to the real-time center angle of the arc in multiple layers and multiple channels;

[0008] S2, obtaining real-time arc current, and obtaining manual control switch instructions, left-right adjustment instructions, and up-down adjustment instructions of the industrial robot arc multi-layer multi-pass welding based on the real-time arc current;

[0009] S3. Based on the real-time welding mode instruction in step S1 and the manual control switch instruction, left and right adjustment instruction and up and down adjustment instruction of the industrial robot's circular arc multi-layer multi-pass welding in step S2, dynamically adjust the industrial robot's circular arc multi-layer multi-pass welding.

[0010] Further, in step S1, a real-time welding mode instruction is obtained according to the real-time center angle of the circular arc in multiple layers and multiple channels. The specific process is: determine whether the real-time center angle of the circular arc in multiple layers and multiple channels is in a first set angle range; if so, determine the welding mode as flat welding and generate a real-time flat welding instruction; otherwise, determine whether the real-time center angle of the circular arc in multiple layers and multiple channels is in a second set angle range; if so, determine the welding mode as vertical welding and generate a real-time vertical welding instruction; otherwise, determine the welding mode as overhead welding and generate a real-time overhead welding instruction to obtain a real-time welding mode instruction.

[0011] Further, in step S2, the manual control switch command of the industrial robot circular arc multi-layer and multi-pass welding is obtained based on the real-time arc current. The specific process is: based on the real-time arc current, it is determined whether the current value at the left end of the swing welding or the current value at the right end of the swing welding is equal to the reference current at the center of the weld; if so, a manual control on command is generated, otherwise a manual control off command is generated to obtain the manual control switch command of the industrial robot circular arc multi-layer and multi-pass welding.

[0012] Further, the reference current at the center of the weld is set to an average current value at the center of the weld between the start of sampling and the current sampling period.

[0013] Furthermore, manual control, the specific process is: use the programmable logic controller input point to connect the up, down, left, and right control buttons, when the manual control start command is generated, the industrial robot's arc multi-layer and multi-pass welding is manually controlled through the up, down, left, and right control buttons.

[0014] Further, in step S2, obtaining left and right adjustment instructions for circular arc multi-layer multi-pass welding of the industrial robot based on the real-time arc current includes the following steps:

[0015] A1. Based on the real-time arc current, determine whether the current value at the left end of the swing welding is equal to the current value at the right end of the swing welding; if so, do not generate the left and right adjustment instruction of the industrial robot arc multi-layer multi-pass welding, otherwise go to step A2;

[0016] A2. Determine whether the current value at the left end of the swing welding is greater than the current value at the right end of the swing welding; if so, generate a right adjustment instruction for the industrial robot circular arc multi-layer multi-pass welding; otherwise, generate a left adjustment instruction for the industrial robot circular arc multi-layer multi-pass welding.

[0017] Further, in step S2, the up and down adjustment instructions of the industrial robot arc multi-layer multi-pass welding are obtained based on the real-time arc current, including the following steps:

[0018] B1. Based on the real-time arc current, determine whether the current at the center of the weld is equal to the reference current at the center of the weld; if so, do not generate the up and down adjustment instructions for the industrial robot circular arc multi-layer multi-pass welding, otherwise proceed to step B2;

[0019] B2. Determine whether the current at the center of the weld is greater than the reference current at the center of the weld; if so, generate an upward adjustment instruction for the industrial robot's circular arc multi-layer multi-pass welding; otherwise, generate a downward adjustment instruction for the industrial robot's circular arc multi-layer multi-pass welding.

[0020] Further, in step S3, the manual control switch instruction of the industrial robot's circular arc multi-layer and multi-pass welding is set as the first priority instruction, the real-time welding mode instruction is set as the second priority instruction, the left and right adjustment instruction of the industrial robot's circular arc multi-layer and multi-pass welding is set as the third priority instruction, and the up and down adjustment instruction of the industrial robot's circular arc multi-layer and multi-pass welding is set as the fourth priority instruction.

[0021] The present invention has the following beneficial effects:

[0022] (1) The present invention takes into account the actual situation of multiple layers and multiple channels of circular arcs, obtains the real-time center angle of the circular arcs in multiple layers and multiple channels, and obtains the real-time welding mode instruction according to the real-time center angle of the circular arcs in multiple layers and multiple channels, and uses the real-time welding mode instruction to control the industrial robot to switch the welding mode among flat welding, overhead welding and vertical welding, so that the welding mode is more in line with reality, thereby improving the accuracy of welding;

[0023] (2) The present invention obtains manual control switch instructions, left and right adjustment instructions and up and down adjustment instructions of the industrial robot's circular arc multi-layer and multi-pass welding according to the real-time arc current, so as to dynamically adjust the industrial robot's circular arc multi-layer and multi-pass welding, thereby solving the problem of trajectory deviation caused by errors in the welding process of circular welds, roundness errors of the circular welds of the pipes themselves, bending deformation of the circular pipes and bending errors of the welding wires in the welding construction operations of circular welds. BRIEF DESCRIPTION OF THE DRAWINGS

[0024] Figure 1 A schematic flow chart of a dynamic adjustment method for arc multi-layer and multi-pass welding of an industrial robot;

[0025] Figure 2 This is a schematic diagram of arc weld welding;

[0026] Figure 3 This is a schematic diagram of the current changes at the left and right ends and the center of the weaving welding process;

[0027] Figure 4 This is the current waveform diagram when the welding wire deviates to the right end of the groove during welding;

[0028] Figure 5 Schematic diagram of current change after compensation of industrial robot arc multi-layer and multi-pass welding in the up and down directions. DETAILED DESCRIPTION

[0029] The specific implementation modes of the present invention are described below so that those skilled in the art can understand the present invention. However, it should be clear that the present invention is not limited to the scope of the specific implementation modes. For those of ordinary skill in the art, as long as various changes are within the spirit and scope of the present invention as defined and determined by the attached claims, these changes are obvious, and all inventions and creations utilizing the concept of the present invention are protected.

[0030] like Figure 1 As shown, a dynamic adjustment method for arc multi-layer multi-pass welding of an industrial robot includes steps S1-S3, which are specifically as follows:

[0031] S1. Obtain the real-time center angle of the arc in multiple layers and multiple channels, and obtain the real-time welding mode instruction according to the real-time center angle of the arc in multiple layers and multiple channels.

[0032] In an optional embodiment of the present invention, the present invention obtains real-time welding mode instructions based on the real-time center angle of the circular arc multi-layer and multi-channel. The specific process is: determine whether the real-time center angle of the circular arc multi-layer and multi-channel is in a first set angle range; if so, determine the welding mode as flat welding and generate real-time flat welding instructions, otherwise determine whether the real-time center angle of the circular arc multi-layer and multi-channel is in a second set angle range, if so, determine the welding mode as vertical welding and generate real-time vertical welding instructions, otherwise determine the welding mode as overhead welding and generate real-time overhead welding instructions to obtain real-time welding mode instructions.

[0033] The present invention welds the circular weld of a circular pipe. When welding two pipes, two welding robots are used, and one robot welder can move 180 degrees. Before welding, the present invention sets an initial welding mode according to the central angle of the pipe. The first set angle interval and the second set angle interval in the present invention are set according to welding data in actual operation.

[0034] S2. Acquire real-time arc current, and acquire manual control switch instructions, left-right adjustment instructions, and up-down adjustment instructions of the industrial robot arc multi-layer and multi-pass welding based on the real-time arc current.

[0035] In an optional embodiment of the present invention, the present invention obtains manual control switch instructions for circular arc multi-layer and multi-pass welding of an industrial robot based on real-time arc current. The specific process is: based on the real-time arc current, determine whether the current value at the left end of the swing welding or the current value at the right end of the swing welding is equal to the reference current at the center of the weld; if so, generate a manual control on instruction, otherwise generate a manual control off instruction to obtain the manual control switch instructions for circular arc multi-layer and multi-pass welding of the industrial robot.

[0036] The present invention sets the reference current of the weld center as the average current of the weld center between the start of sampling and the current sampling cycle.

[0037] The manual control in the present invention specifically comprises the following steps: using the programmable logic controller input point to connect the up, down, left, and right control buttons, when a manual control start instruction is generated, the industrial robot's arc multi-layer and multi-pass welding is manually controlled by the up, down, left, and right control buttons.

[0038] The present invention obtains left and right adjustment instructions of circular arc multi-layer multi-pass welding of an industrial robot based on real-time arc current, and includes the following steps:

[0039] A1. Based on the real-time arc current, determine whether the current value at the left end of the swing welding is equal to the current value at the right end of the swing welding; if so, do not generate the left and right adjustment instructions for the industrial robot's arc multi-layer and multi-pass welding, otherwise go to step A2.

[0040] like Figure 2 As shown, when the present invention uses swing welding to perform V-groove welding in arc weld welding, the distance between the front end of the welding wire and the weld will change, and the current will also change with the swing of the welding wire.

[0041] like Figure 3 As shown in the figure, when the welding wire passes through the left and right ends of the arc V-shaped groove, the distance between the welding wire and the weld becomes shorter, and when it is in the center of the weld, the distance between the welding wire and the weld becomes longer, so the current flowing through the left and right ends is larger than the current flowing through the center. However, when the welding wire deviates from the center of the arc V-shaped groove, the distance between the welding wire and the weld becomes shorter at the deviated ends due to the structure of the weld, and the current also becomes larger due to the shortening of the welding wire. Figure 4 As shown in the figure, when the welding wire deviates to the right end, the current on the left and right sides of the weaving welding is different.

[0042] Therefore, the present invention determines whether to generate left and right adjustment instructions for circular arc multi-layer multi-pass welding of the industrial robot by judging whether the current value at the left end of the swing welding is equal to the current value at the right end of the swing welding.

[0043] The adjustment instruction generated in the present invention is used for the next swing welding cycle, and the adjustment amplitude is set to a fixed amount based on actual operating experience.

[0044] A2. Determine whether the current value at the left end of the swing welding is greater than the current value at the right end of the swing welding; if so, generate a right adjustment instruction for the industrial robot circular arc multi-layer multi-pass welding; otherwise, generate a left adjustment instruction for the industrial robot circular arc multi-layer multi-pass welding.

[0045] The present invention obtains the up and down adjustment instructions of the circular arc multi-layer multi-pass welding of the industrial robot based on the real-time arc current, and comprises the following steps:

[0046] B1. Based on the real-time arc current, determine whether the current at the center of the weld is equal to the reference current at the center of the weld; if so, do not generate the up and down adjustment instructions for the industrial robot's arc multi-layer and multi-pass welding, otherwise go to step B2.

[0047] When the distance between the welding wire and the workpiece becomes shorter, the current flowing becomes larger, and when the distance between the welding wire and the workpiece becomes longer, the current flowing becomes smaller. Therefore, the present invention determines whether to generate up and down adjustment instructions for the industrial robot's arc multi-layer and multi-pass welding by judging whether the current at the center of the weld is equal to the reference current at the center of the weld.

[0048] B2. Determine whether the current at the center of the weld is greater than the reference current at the center of the weld; if so, generate an upward adjustment instruction for the industrial robot's circular arc multi-layer multi-pass welding; otherwise, generate a downward adjustment instruction for the industrial robot's circular arc multi-layer multi-pass welding.

[0049] When the current at the center of the weld is greater than the reference current at the center of the weld, an upper adjustment instruction for the industrial robot's circular arc multi-layer and multi-pass welding is generated to control the industrial robot to make corresponding adjustments to raise the welding torch; when the current at the center of the weld is less than the reference current at the center of the weld, a lower adjustment instruction for the industrial robot's circular arc multi-layer and multi-pass welding is generated to control the industrial robot to make corresponding adjustments to lower the welding torch.

[0050] like Figure 5 As shown, the present invention compensates the circular arc multi-layer and multi-pass welding of the industrial robot in the upper and lower directions through the upper adjustment instruction and the lower adjustment instruction, thereby maintaining a stable welding current.

[0051] S3. Based on the real-time welding mode instruction in step S1 and the manual control switch instruction, left and right adjustment instruction and up and down adjustment instruction of the industrial robot's circular arc multi-layer multi-pass welding in step S2, the industrial robot's circular arc multi-layer multi-pass welding is dynamically adjusted.

[0052] In an optional embodiment of the present invention, the present invention sets the manual control switch instruction of the industrial robot's circular arc multi-layer and multi-pass welding as the first priority instruction, sets the real-time welding mode instruction as the second priority instruction, sets the left and right adjustment instruction of the industrial robot's circular arc multi-layer and multi-pass welding as the third priority instruction, and sets the up and down adjustment instruction of the industrial robot's circular arc multi-layer and multi-pass welding as the fourth priority instruction.

[0053] The present invention is described with reference to flowcharts and / or block diagrams of methods, devices (systems), and computer program products according to embodiments of the present invention. It should be understood that each process and / or block in the flowchart and / or block diagram, as well as the combination of processes and / or blocks in the flowchart and / or block diagram, can be implemented by computer program instructions. These computer program instructions can be provided to a processor of a general-purpose computer, a special-purpose computer, an embedded processor, or other programmable data processing device to produce a machine, so that the instructions executed by the processor of the computer or other programmable data processing device generate instructions for implementing the processes in the flowchart and / or block diagram. Figure 1 A process or multiple processes and / or boxes Figure 1 A device that provides the functions specified in a block or multiple blocks.

[0054] These computer program instructions may also be stored in a computer-readable memory capable of directing a computer or other programmable data processing device to operate in a specific manner, so that the instructions stored in the computer-readable memory produce an article of manufacture comprising an instruction device, which implements the process Figure 1 A process or multiple processes and / or boxes Figure 1 A function specified in one or more boxes.

[0055] These computer program instructions can also be loaded onto a computer or other programmable data processing device so that a series of operating steps are executed on the computer or other programmable device to produce a computer-implemented process, thereby providing instructions for implementing the process. Figure 1 A process or multiple processes and / or boxes Figure 1 The steps for the functions specified in one or more boxes.

[0056] The present invention uses specific embodiments to illustrate the principles and implementation methods of the present invention. The description of the above embodiments is only used to help understand the method of the present invention and its core idea. At the same time, for those skilled in the art, according to the idea of ​​the present invention, there will be changes in the specific implementation methods and application scope. In summary, the content of this specification should not be understood as a limitation on the present invention.

[0057] Those skilled in the art will appreciate that the embodiments described herein are intended to help readers understand the principles of the present invention, and should be understood that the protection scope of the present invention is not limited to such specific statements and embodiments. Those skilled in the art can make various other specific variations and combinations that do not deviate from the essence of the present invention based on the technical revelations disclosed by the present invention, and these variations and combinations are still within the protection scope of the present invention.

Claims

1. A dynamic adjustment method for arc multi-layer and multi-pass welding of an industrial robot, characterized in that: The following steps are involved: S1, obtaining the real-time center angle of the arc in multiple layers and multiple channels, and obtaining the real-time welding mode instruction according to the real-time center angle of the arc in multiple layers and multiple channels; S2, obtaining real-time arc current, and obtaining manual control switch instructions, left-right adjustment instructions, and up-down adjustment instructions of the industrial robot arc multi-layer multi-pass welding based on the real-time arc current; S3. Based on the real-time welding mode instruction in step S1 and the manual control switch instruction, left and right adjustment instruction and up and down adjustment instruction of the industrial robot's circular arc multi-layer multi-pass welding in step S2, the industrial robot's circular arc multi-layer multi-pass welding is dynamically adjusted.

2. The dynamic adjustment method for circular arc multi-layer multi-pass welding of an industrial robot according to claim 1, characterized in that: In step S1, a real-time welding mode instruction is obtained according to the real-time center angle of the circular arc in multiple layers and multiple channels. The specific process is: determine whether the real-time center angle of the circular arc in multiple layers and multiple channels is in a first set angle range; if so, determine the welding mode as flat welding and generate a real-time flat welding instruction; otherwise, determine whether the real-time center angle of the circular arc in multiple layers and multiple channels is in a second set angle range; if so, determine the welding mode as vertical welding and generate a real-time vertical welding instruction; otherwise, determine the welding mode as overhead welding and generate a real-time overhead welding instruction to obtain a real-time welding mode instruction.

3. The dynamic adjustment method for circular arc multi-layer and multi-pass welding of an industrial robot according to claim 1, characterized in that: In step S2, the manual control switch command of the industrial robot circular arc multi-layer and multi-pass welding is obtained based on the real-time arc current. The specific process is: based on the real-time arc current, it is determined whether the current value at the left end of the swing welding or the current value at the right end of the swing welding is equal to the reference current at the center of the weld; if so, a manual control on command is generated, otherwise a manual control off command is generated to obtain the manual control switch command of the industrial robot circular arc multi-layer and multi-pass welding.

4. The dynamic adjustment method for arc multi-layer and multi-pass welding of an industrial robot according to claim 3, characterized in that: The reference current of the weld center is set to the average current of the weld center between the start of sampling and the current sampling cycle.

5. The dynamic adjustment method for circular arc multi-layer and multi-pass welding of an industrial robot according to claim 3, characterized in that: Manual control, the specific process is: use the programmable logic controller input point to connect the up, down, left, and right control buttons. When the manual control start command is generated, the industrial robot's arc multi-layer and multi-pass welding is manually controlled through the up, down, left, and right control buttons.

6. The dynamic adjustment method for arc multi-layer and multi-pass welding of an industrial robot according to claim 1, characterized in that: In step S2, the left and right adjustment instructions of the industrial robot arc multi-layer multi-pass welding are obtained based on the real-time arc current, including the following steps: A1. Based on the real-time arc current, determine whether the current value at the left end of the swing welding is equal to the current value at the right end of the swing welding; if so, do not generate the left and right adjustment instruction of the industrial robot arc multi-layer multi-pass welding, otherwise go to step A2; A2. Determine whether the current value at the left end of the swing welding is greater than the current value at the right end of the swing welding; if so, generate a right adjustment instruction for the industrial robot circular arc multi-layer multi-pass welding; otherwise, generate a left adjustment instruction for the industrial robot circular arc multi-layer multi-pass welding.

7. The dynamic adjustment method for arc multi-layer and multi-pass welding of an industrial robot according to claim 1, characterized in that: In step S2, the up and down adjustment instructions of the industrial robot arc multi-layer multi-pass welding are obtained based on the real-time arc current, including the following steps: B1. Based on the real-time arc current, determine whether the current at the center of the weld is equal to the reference current at the center of the weld; if so, do not generate the up and down adjustment instructions for the industrial robot circular arc multi-layer multi-pass welding, otherwise proceed to step B2; B2. Determine whether the current at the center of the weld is greater than the reference current at the center of the weld; if so, generate an upward adjustment instruction for the industrial robot's circular arc multi-layer multi-pass welding; otherwise, generate a downward adjustment instruction for the industrial robot's circular arc multi-layer multi-pass welding.

8. The dynamic adjustment method for arc multi-layer and multi-pass welding of an industrial robot according to claim 1, characterized in that: In step S3, the manual control switch instruction of the industrial robot's circular arc multi-layer and multi-pass welding is set as the first priority instruction, the real-time welding mode instruction is set as the second priority instruction, the left and right adjustment instruction of the industrial robot's circular arc multi-layer and multi-pass welding is set as the third priority instruction, and the up and down adjustment instruction of the industrial robot's circular arc multi-layer and multi-pass welding is set as the fourth priority instruction.

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