Automatic spraying robot for steel surface of ship and working method of automatic spraying robot

Abstract

The invention discloses an automatic spraying robot for a steel surface of a ship and a working method of the automatic spraying robot. The robot is suitable for surface treatment and coating of a large steel structure in the ship building and repairing industry. The robot is mainly composed of a tail end execution device and a straight arm robot vehicle body part. The tail end execution device comprises two small spraying mechanical arms and a 2m * 3m spraying area sliding rail mechanism. The straight-arm robot vehicle body part comprises a front-end mechanical arm unit, a front-section straight arm, a middle-section straight arm, a tail-end straight arm, a robot rotating joint, a vehicle body mechanism, a supporting arm hydraulic cylinder mechanism, a bottom table mechanism, a laser radar device 2, a display warning lamp, an angle sensor and the like. According to the spraying robot, automatic identification and intelligent spraying of the complex steel surface can be achieved. Compared with traditional ship spraying operation, about 60% of operation manpower is saved, the spraying efficiency is improved by 11%, the spraying quality is remarkably improved, and the labor cost is reduced.

Description

Technical Field

[0001] The invention relates to an automatic spraying robot for a ship steel surface and a working method thereof, belonging to the technical field of the shipbuilding industry. Background Art

[0002] The steel hull and outfitting of ships are susceptible to corrosion from the atmosphere and marine environment. Corrosion causes serious damage to ships, easily reduces the strength of the ship structure, and affects navigation safety. When steel ships are corroded to a certain extent, the structural strength of the hull is not enough to withstand the impact of ocean waves, leading to shipwrecks. In order to reduce the damage of corrosion to the outer plate of the hull, the outer plate of the ship needs to be sprayed with anti-rust paint before launching. In addition, in addition to anti-rust paint, the bottom part of the ship also needs to be sprayed with anti-fouling paint to prevent marine organisms such as oysters and anemones from attaching to the bottom of the ship and increasing navigation resistance. In the traditional shipbuilding process, the spraying of the steel surface of the ship usually relies on manual operation, which is not only inefficient, but also labor-intensive and easily affected by human factors, resulting in unstable spraying quality. In addition, due to the complex structure of the hull, it is often difficult to effectively spray in high and difficult-to-reach places, which affects the quality and life of the overall coating. Although the existing aerial work machinery can solve the height problem to a certain extent, it lacks professional design for steel surface spraying and cannot meet the needs of efficient, precise and automated spraying. Therefore, developing a robot mechanism specifically for spraying steel surfaces has important practical significance and market value. Summary of the invention

[0003] In view of the problems existing in the above-mentioned prior art, the present invention provides an automatic spraying robot for ship steel surface and a working method thereof, thereby solving the above-mentioned technical problems.

[0004] In order to achieve the above-mentioned object, the technical solution adopted by the present invention is: an automatic spraying robot for ship steel surface, comprising an end effector and a straight-arm robot body;

[0005] The end effector comprises: an upper spraying mechanical arm, a lower spraying mechanical arm and a spraying area slide rail mechanism; the spraying area slide rail mechanism comprises laser sensor 1, laser sensor 2, laser sensor 3, laser sensor 4, a truss support mechanism, a transverse slide rail 1, a transverse slide rail 2, a longitudinal slide rail 1, a longitudinal slide rail 2, a transverse slide rail left drive motor, a transverse slide rail right drive motor, a longitudinal slide rail left drive motor, and a longitudinal slide rail right drive motor;

[0006] The truss support mechanism is connected to the end of the straight arm robot body; the transverse slide rail 1 and the transverse slide rail 2 are installed on the truss support mechanism in a transverse arrangement, and the distance between the two is 2m; the longitudinal slide rail 1 and the longitudinal slide rail 2 are installed on the truss support mechanism in a longitudinal arrangement, and the distance between the two is 3m;

[0007] The left drive motor of the transverse slide rail and the right drive motor of the transverse slide rail are respectively installed on the transverse slide rail 1 and the transverse slide rail 2, and are respectively used to drive the upper position spraying mechanical arm and the lower position spraying mechanical arm to perform transverse displacement spraying; the left drive motor of the longitudinal slide rail and the right drive motor of the longitudinal slide rail are respectively installed on the longitudinal slide rail 1 and the longitudinal slide rail 2, and are respectively used to drive the transverse slide rail 1 and the transverse slide rail 2 to perform longitudinal displacement to drive the upper position spraying mechanical arm and the lower position spraying mechanical arm to perform longitudinal spraying displacement;

[0008] The laser sensor 1, laser sensor 2, laser sensor 3 and laser sensor 4 are respectively installed at the four top corner edges of the end effector for positioning the front end of the robot; the upper spraying mechanical arm is installed on the transverse slide rail 1, and the lower spraying mechanical arm is installed on the transverse slide rail 2; the two spraying mechanical arms carry spray guns respectively, and the front ends of the spray guns are installed with positioning sensor 1 and positioning sensor 2 for positioning the end of the spray gun;

[0009] The straight-arm robot body includes a front-end mechanical arm unit, a front straight arm, a middle straight arm, a terminal straight arm, a robot rotary joint, a body mechanism, a support arm hydraulic cylinder mechanism, and a base mechanism;

[0010] The front-end mechanical arm unit includes a swing cylinder mechanism for adjusting the angle, a telescopic mechanism for adjusting the distance, and a laser radar device; the swing cylinder mechanism is respectively installed at the front and rear ends of the front-end mechanical arm unit, and is respectively connected to the front straight arm and the truss support mechanism; the telescopic mechanism is arranged in the middle of the front-end mechanical arm unit; the laser radar device is installed at the bottom of the front-end mechanical arm unit, and is used for positioning the end of the straight arm; the front straight arm, the middle straight arm, and the end straight arm are connected in sequence to adjust the length of the telescopic arm; the robot rotation joint, the support arm hydraulic cylinder mechanism, and the base mechanism are respectively installed on the body mechanism;

[0011] The body mechanism includes the robot main structure and power system, connecting the robot's terminal straight arm and the base mechanism; the base mechanism is connected to the body mechanism through a turntable, on which an angle sensor is installed for rotation angle control, and four tires are installed at the bottom to drive the robot as a whole to move on the ground; a laser radar device 2 is installed at the front end of the base mechanism for base positioning and side elevation direction angle measurement; a display alarm light is installed at the upper end of the body mechanism for displaying the overall working status of the robot, and different colors are used to distinguish the status.

[0012] A working method of an automatic spraying robot for a ship steel surface comprises the following steps:

[0013] Step S1: The ground staff starts the robot spraying operation and sets the operation instructions; controls the robot to move to the designated workstation, connects the air pipe and paint pipe, stirs the paint and feeds it to the ground paint pump, evacuates the pipeline gas, and starts the spray pump or other paint supply equipment;

[0014] Step S2: The robot detection unit performs spatial positioning of the spraying position and the working height, the robot straight arm part is driven to extend and retract, and the end effector is positioned near the initial spraying point to complete the robot operation preparation work;

[0015] Step S3: Start the robot automatic positioning program, the straight arm robot body moves, and the end effector is kept horizontal during the process; the straight arm robot body is equipped with a laser radar to detect the distance between the robot body and the ship outer plate, and determine whether the distance is ≤3m. If it is ≤3m, proceed to the next program step; if it is >3m, the front and rear drive wheels of the body move a distance d x Adjust and re-test the radar distance;

[0016] Step S4: The four laser distance measuring sensors carried by the end effector of the automatic spraying robot detect whether the distance to the hull is [L min ,L max ] range, if yes, then proceed to the next process, if not, the front end robot arm unit will perform a distance d y Adjustment, while automatically moving to adjust the relative angle between the end effector and the wall, and re-entering the sensor detection step after adjustment;

[0017] Step S5: The end effector of the automatic spraying robot detects the horizontal inclination angle of the position through the sensor and feeds it back to the body part of the straight-arm robot. Through the above-mentioned linear displacement and angle adjustment, it is ensured that the end effector is parallel to the hull outer plate and the distance meets the preset distance value, completing the unit small area positioning process;

[0018] Step S6: Start the robot automatic spraying program, and the upper position spraying robot arm carried by the end effector performs adaptive adjustment according to the signal detected by the positioning sensor until the distance between the spray gun mouth and the ship outer plate is guaranteed to be 400mm;

[0019] Step S7: The end effector slide drives the robot arm to hold the spray gun and traverse and move the spray gun within the 2m×3m area to spray. While ensuring the uniform spraying effect and uniform paint film thickness within the 2m×3m area, the robot arm simulates the manual gun swinging action to make the paint film thickness at the edge of the area uniform. When the robot arm sprays to the edge, the spray head rotates 45° to ensure uniform overlap transition between unit areas.

[0020] Step S8: After spraying the 2m×3m area, the robot arm automatically descends vertically to the next unit area. The sensor detects whether there is a deviation during the descent process. If there is a deviation, the front-end robot arm unit compensates the distance d. y ', complete the position self-correction, if there is no deviation, complete the lifting operation in the next operating area;

[0021] Step S9: The system determines whether the preset column spraying task is completed. If not, the above action is repeated, and the spraying positioning is re-performed according to the preset column reciprocating spraying. If it is completed, a single column vertical area spraying is set, and then the next step is entered;

[0022] Step S10: Set a movement instruction for the robot to move horizontally by 3m, automatically correct the position, and start working after entering the next row;

[0023] Step S11: Check whether all the required columns have been sprayed and whether there are any omissions. If all are completed, the task is terminated. If not, the reciprocating spraying task is re-entered, and the spraying positioning is re-performed and reciprocating spraying is performed according to the preset columns until the task is completed.

[0024] Furthermore, the system includes a robot spraying end effector control unit, a straight-arm robot body control unit, an automated linkage control unit, a robot detection unit, a robot integrated control system, and an interface signal device.

[0025] Furthermore, the control unit of the straight-arm robot body part includes: robot automatic compensation control, robot straight-arm descending drive control, robot straight-arm ascending drive control, and robot front and rear drive control; the control unit is mainly used to control the movement and lifting of the robot to realize automatic correction of position deviation during the spraying process.

[0026] Furthermore, the control unit of the robot spraying end effector includes: an automatic spraying control system, a power supply and communication management component, a spraying robot and a slide rail mechanism collaborative control component, a distance sensing and data processing module, and a spraying control and status monitoring component; the control unit is mainly responsible for the power supply of the system and the communication between the modules, obtains distance information through sensors, coordinates the movement of the spraying robot and the slide rail, and ensures the accuracy of the spraying path.

[0027] Furthermore, the automatic linkage control unit includes: automatic positioning drive control for robot lateral spraying, robot straight arm lifting and execution end drive control, and robot overall emergency stop control; this unit controls the lifting and lowering of the robot straight arm and the movement of the spray execution end, and adjusts the lateral position of the spray head to adapt to different surfaces and spraying requirements to ensure uniform spraying. At the same time, in abnormal situations, all actions of the robot can be stopped immediately to ensure safe operation and prevent equipment damage and personal injury.

[0028] Furthermore, the robot detection unit includes: angle, pressure sensors, laser rangefinder sensors, laser radar, wheel speed meter, IMU sensor, etc.; this unit is used to detect changes in the robot's straight arm part, body part and surrounding environment during operation. It provides timely and accurate data on the robot's joint running speed, robot moving distance, etc. for real-time feedback, helping the robot control system to make dynamic adjustments.

[0029] Furthermore, the robot integrated control system and interface signal equipment include: a control panel, a display interface, digital and analog input and output units, a power interface, a sensor interface, a communication protocol interface, etc.; they are responsible for the coordination and control of the overall system to ensure effective communication and collaboration between modules. The communication protocol is developed based on the CAN bus and includes all the data required for robot control and status response.

[0030] Furthermore, the spraying position change process can be expressed as:

[0031] P k+1 =P k +δ(p t -P k ) (1)

[0032] Where k represents the time variation step (k = 1, 2, ..., n), P k represents the position of the spraying robot at time step k, P t It is represented as the target position of spraying, and δ represents a scalar parameter of control step length. When the robot completes a vertical spraying task and moves to the next area, this control process is used to gradually adjust the spraying position of the robot, so that it gradually approaches and reaches the preset spraying target position, and controls the speed and stability of position update.

[0033] The beneficial effects of the present invention are as follows: under normal spraying state, the maximum operating height of the robot can reach 26m, the spraying efficiency is about 500㎡ / h, and the maximum radius of the spraying surface is 6m. Compared with the existing manual spraying method, the robot requires 1 worker, while the traditional spraying operation requires 3 workers, saving about 60% of manpower. Compared with the traditional spraying method that requires 1 person for high-altitude spraying, the number of people required for high-altitude operations is 0, and the robot replaces manual spraying to avoid workers being poisoned by paint mist and falling from high altitude. Compared with the existing manual spraying of about 450㎡ / h, the spraying efficiency is improved by 11%. BRIEF DESCRIPTION OF THE DRAWINGS

[0034] Figure 1 This is the overall structure diagram of an automatic spraying robot for ship steel surface of the present invention

[0035] Figure 2This is a structural diagram of the terminal actuator of a ship steel surface automatic spraying robot of the present invention.

[0036] Figure 3 This is a structural diagram of the body of a straight-arm robot for an automatic spraying robot for a ship's steel surface according to the present invention.

[0037] Figure 4 This is a control diagram of a robot system for automatically spraying steel surfaces on ships according to the present invention.

[0038] Figure 5 This is a flow chart of an automatic spraying robot for ship steel surface and its working method of the present invention

[0039] Figure 6 This is a motor synchronous control structure diagram of a ship steel surface automatic spraying robot of the present invention

[0040] Figure 7 This is a distribution diagram of the movement rate of the spray gun of a ship steel surface automatic spraying robot of the present invention

[0041] Figure 8 This is a ship steel surface automatic spraying robot ship surface spraying trajectory diagram of the present invention

[0042] Fig. 9 This is a simulation diagram of the motor operation of a ship steel surface automatic spraying robot of the present invention.

[0043] In the figure: 1, upper area spraying robot arm; 1a, positioning sensor 1; 2, lower area spraying robot arm; 2a, positioning sensor 2; 3, spraying area slide rail mechanism; 3a, laser sensor 1; 3b, laser sensor 2; 3c, laser sensor 3; 3d, laser sensor 4; 3e, longitudinal slide rail 1; 3f, longitudinal slide rail 2; 3g, transverse slide rail 1; 3h, transverse slide rail 2; 3i, transverse slide rail left drive motor; 3j, longitudinal slide rail right drive motor; 3k, transverse slide rail right drive motor; 3l, longitudinal slide rail left drive motor; 3m, truss support mechanism; 4, front end robot arm unit; 4a, laser radar device 1; 5a, front section straight arm; 5b, middle section straight arm; 5c, end straight arm; 6, robot rotation joint; 7, body mechanism; 7a, laser radar device 2; 7b, display alarm light; 7c, angle sensor; 8, support arm hydraulic cylinder; 9, base mechanism. DETAILED DESCRIPTION

[0044] In order to make the purpose, technical solution and advantages of the present invention more clear, the present invention is further described in detail below through the accompanying drawings and embodiments. However, it should be understood that the specific embodiments described herein are only used to explain the present invention and are not intended to limit the scope of the present invention.

[0045] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by technicians in the technical field to which the present invention belongs. The terms used in the specification of the present invention are only for the purpose of describing specific embodiments and are not intended to limit the present invention.

[0046] like Figure 1 , Figure 2 and Figure 3 As shown, an automatic spraying robot for ship steel surface includes an end effector and a straight-arm robot body;

[0047] The end effector comprises: an upper spraying mechanical arm (1), a lower spraying mechanical arm (2) and a spraying area slide rail mechanism (3); the spraying area slide rail mechanism (3) comprises a laser sensor 1 (3a), a laser sensor 2 (3b), a laser sensor 3 (3c), a laser sensor 4 (3d), a truss support mechanism (3m), a transverse slide rail 1 (3g), a transverse slide rail 2 (3h), a longitudinal slide rail 1 (3e), a longitudinal slide rail 2 (3f), a transverse slide rail left drive motor (3i), a transverse slide rail right drive motor (3k), a longitudinal slide rail left drive motor (3l), and a longitudinal slide rail right drive motor (3j);

[0048] The truss support mechanism (3m) is connected to the end of the straight arm robot body; the transverse slide rail 1 (3g) and the transverse slide rail 2 (3h) are installed on the truss support mechanism (3m) in a transverse arrangement, and the distance between the two is 2m; the longitudinal slide rail 1 (3e) and the longitudinal slide rail 2 (3f) are installed on the truss support mechanism (3m) in a longitudinal arrangement, and the distance between the two is 3m;

[0049] The left drive motor (3i) of the transverse slide rail and the right drive motor (3k) of the transverse slide rail are respectively installed on the transverse slide rail 1 (3g) and the transverse slide rail 2 (3h), and are respectively used to drive the upper spraying mechanical arm (1) and the lower spraying mechanical arm (2) to perform transverse displacement spraying; the left drive motor (3l) of the longitudinal slide rail and the right drive motor (3j) of the longitudinal slide rail are respectively installed on the longitudinal slide rail 1 (3e) and the longitudinal slide rail 2 (3f), and are respectively used to drive the transverse slide rail 1 (3g) and the transverse slide rail 2 (3h) to perform longitudinal displacement to drive the upper spraying mechanical arm (1) and the lower spraying mechanical arm (2) to perform longitudinal spraying displacement;

[0050] The laser sensor 1 (3a), laser sensor 2 (3b), laser sensor 3 (3c), and laser sensor 4 (3d) are respectively installed at the four top corner edges of the end effector for positioning the front end of the robot; the upper spraying robot arm (1) is installed on the transverse slide rail 1 (3g), and the lower spraying robot arm (2) is installed on the transverse slide rail 2 (3h); the two spraying robot arms respectively carry a spray gun, and the front end of the spray gun is installed with a positioning sensor 1 (1a) and a positioning sensor 2 (2a) for positioning the end of the spray gun;

[0051] The straight-arm robot body comprises a front-end mechanical arm unit (4), a front straight arm (5a), a middle straight arm (5b), a terminal straight arm (5c), a robot rotary joint (6), a body mechanism (7), a support arm hydraulic cylinder mechanism (8), and a base mechanism (9);

[0052] The front-end mechanical arm unit (4) comprises a swing cylinder mechanism for adjusting the angle, a telescopic mechanism for adjusting the distance, and a laser radar device (4a); the swing cylinder mechanism is respectively installed at the front and rear ends of the front-end mechanical arm unit (4), and is respectively connected to the front straight arm (5a) and the truss support mechanism (3m); the telescopic mechanism is arranged in the middle of the front-end mechanical arm unit (4); the laser radar device (4a) is installed at the bottom of the front-end mechanical arm unit (4) and is used for positioning the end of the straight arm; the front straight arm (5a), the middle straight arm (5b), and the end straight arm (5c) are connected in sequence and are used to adjust the length of the telescopic arm; the robot rotary joint (6), the support arm hydraulic cylinder mechanism (8), and the base mechanism (9) are respectively installed on the body mechanism (7);

[0053] The body mechanism (7) comprises a robot main body structure and a power system, and connects the robot's terminal straight arm (5c) and a base mechanism (9); the base mechanism (9) is connected to the body mechanism (7) via a turntable, and is provided with an angle sensor (7c) for controlling the rotation angle, and is provided with four tires at the bottom to drive the robot as a whole to move on the ground; a laser radar device (7a) is provided at the front end of the base mechanism (9) for base positioning and side elevation direction angle measurement; a display alarm light (7b) is provided at the upper end of the body mechanism (7) for displaying the overall working status of the robot, and different states are distinguished by different colors.

[0054] Reference Figure 5 , a working method of an automatic spraying robot for a ship steel surface, comprising the following steps:

[0055] Step S1: The ground staff starts the robot spraying operation and sets the operation instructions; controls the robot to move to the designated workstation, connects the air pipe and paint pipe, stirs the paint and feeds it to the ground paint pump, evacuates the pipeline gas, and starts the spray pump or other paint supply equipment;

[0056] Step S2: The robot detection unit performs spatial positioning of the spraying position and the working height, the robot straight arm part is driven to extend and retract, and the end effector is positioned near the initial spraying point to complete the robot operation preparation work;

[0057] Step S3: Start the robot automatic positioning program, the straight arm robot body moves, and the end effector is kept horizontal during the process; the straight arm robot body is equipped with a laser radar to detect the distance between the robot body and the ship outer plate, and determine whether the distance is ≤3m. If it is ≤3m, proceed to the next program step; if it is >3m, the front and rear drive wheels of the body move a distance d x Adjust and re-test the radar distance;

[0058] Step S4: The four laser distance measuring sensors carried by the end effector of the automatic spraying robot detect whether the distance to the hull is [L min ,L max ] range, if yes, then proceed to the next process, if not, the front end robot arm unit will perform a distance d y Adjustment, while automatically moving to adjust the relative angle between the end effector and the wall, and re-entering the sensor detection step after adjustment;

[0059] Step S5: The end effector of the automatic spraying robot detects the horizontal inclination angle of the position through the sensor and feeds it back to the body part of the straight-arm robot. Through the above-mentioned linear displacement and angle adjustment, it is ensured that the end effector is parallel to the hull outer plate and the distance meets the preset distance value, completing the unit small area positioning process;

[0060] Step S6: Start the robot automatic spraying program, and the upper area spraying robot arm 2 carried by the end effector performs adaptive adjustment according to the signal detected by the positioning sensor until the distance between the spray gun mouth and the outer plate of the ship is guaranteed to be 400mm;

[0061] Step S7: The end effector slide drives the robot arm to hold the spray gun and traverse and move the spray gun within the 2m×3m area to spray. While ensuring the uniform spraying effect and uniform paint film thickness within the 2m×3m area, the robot arm simulates the manual gun swinging action to make the paint film thickness at the edge of the area uniform. When the robot arm sprays to the edge, the spray head rotates 45° to ensure uniform overlap transition between unit areas.

[0062] Step S8: After spraying the 2m×3m area, the robot arm automatically descends vertically to the next unit area. The sensor detects whether there is a deviation during the descent process. If there is a deviation, the front-end robot arm unit compensates the distance d. y ', complete the position self-correction, if there is no deviation, complete the lifting operation in the next operating area;

[0063] Step S9: The system determines whether the preset column spraying task is completed. If not, the above action is repeated, and the spraying positioning is re-performed according to the preset column reciprocating spraying. If it is completed, a single column vertical area spraying is set, and then the next step is entered;

[0064] Step S10: Set a movement instruction for the robot to move horizontally by 3m, automatically correct the position, and start working after entering the next row;

[0065] Step S11: Check whether all the required columns have been sprayed and whether there are any omissions. If all are completed, the task is terminated. If not, the reciprocating spraying task is re-entered, and the spraying positioning is re-performed and reciprocating spraying is performed according to the preset columns until the task is completed.

[0066] In this embodiment, refer to Figure 4 The system includes a robot spraying end effector control unit, a straight-arm robot body control unit, an automated linkage control unit, a robot detection unit, a robot integrated control system, and interface signal equipment.

[0067] In this embodiment, refer to Figure 4 The control unit of the straight-arm robot body part includes: robot automatic compensation control, robot straight-arm descending drive control, robot straight-arm ascending drive control, and robot front and rear drive control; the control unit is mainly used to control the movement and lifting of the robot to realize automatic correction of position deviation during spraying.

[0068] In this embodiment, refer to Figure 4 The control unit of the robot spraying end effector includes: automatic spraying control system, power supply and communication management components, spraying robot and slide mechanism collaborative control components, distance perception and data processing modules, spraying control and status monitoring components; the control unit is mainly responsible for the power supply of the system and the communication between the modules, obtains distance information through sensors, coordinates the movement of the spraying robot and the slide rail, and ensures the accuracy of the spraying path.

[0069] In this embodiment, refer to Figure 4 The automatic linkage control unit includes: automatic positioning drive control for robot lateral spraying, robot straight arm lifting and execution end drive control, and robot overall emergency stop control; this unit controls the lifting and lowering of the robot straight arm and the movement of the spray execution end, and adjusts the lateral position of the spray head to adapt to different surfaces and spraying requirements to ensure uniform spraying. At the same time, in abnormal situations, all movements of the robot can be stopped immediately to ensure safe operation and prevent equipment damage and personal injury.

[0070] In this embodiment, refer to Figure 4The robot detection unit includes: angle, pressure sensor, laser distance sensor, laser radar, wheel speed meter, IMU sensor, etc. This unit is used to detect changes in the robot's straight arm, body and surrounding environment during operation. It provides timely and accurate data on the robot's joint speed, robot movement distance, etc. for real-time feedback, helping the robot control system to make dynamic adjustments.

[0071] In this embodiment, refer to Figure 4 , robot integrated control system and interface signal equipment, including: control panel, display interface, digital and analog input and output units, power interface, sensor interface, communication protocol interface, etc.; responsible for the coordination and control of the overall system to ensure effective communication and collaboration between modules. The communication protocol is developed based on the CAN bus and includes all the data required for robot control and status response.

[0072] In this embodiment, the spraying position change process can be expressed as:

[0073] P k+1 =P k +δ(p t -P k ) (1)

[0074] Where k represents the time variation step (k = 1, 2, ..., n), P k represents the position of the spraying robot at time step k, P t It is represented as the target position of spraying, and δ represents a scalar parameter of control step length. When the robot completes a vertical spraying task and moves to the next area, this control process is used to gradually adjust the spraying position of the robot, so that it gradually approaches and reaches the preset spraying target position, and controls the speed and stability of position update.

[0075] Reference Figure 6 The present invention provides a motor synchronous control structure for a ship steel surface automatic spraying robot, including but not limited to the following steps:

[0076] First, the spraying position instruction of the end effector is set. The system calculates the spraying path parameters required by the upper spraying robot arm and the lower spraying machine based on the sensor data, and specifies the speed of the drive motor and other data. The left drive motor of the longitudinal slide, the right drive motor of the longitudinal slide, the left drive motor of the transverse slide, and the right drive motor of the transverse slide are controlled by their respective controllers to ensure the achievement of the preset goals. The positioning sensor installed on the slide mechanism of the spraying area is used to detect the trajectory point. According to the movement result of the slide, the PID controller is used to ensure that the deviation of the two small mechanical arms is kept within a reasonable range during the operation, and real-time adjustment is performed. At the same time, the four controllers output the control information of the motor to manage the movement of the slide position. Considering that the inertial force generated by high-speed moving parts may cause the robot to shake, the spraying movement of the end effector is specially designed. The moving speed of the end of the slide is controlled by installing a distance sensor to reduce the shaking caused by high-speed operation. Furthermore, two small robotic arms are arranged symmetrically, dividing the spraying area into two parts, upper and lower. Each nozzle is responsible for spraying an area, and the robotic arm holding the nozzle maintains the opposite direction of horizontal movement during the spraying process, thereby offsetting part of the inertial force caused by the movement and reducing disturbances. For persistent disturbances, the four motor circuits are coordinated and compensated according to different conditions to improve system stability. The control system establishes a closed-loop feedback mechanism to collect data such as motor speed in real time, and transmits the feedback data to the four controllers for adaptive adjustment to optimize the spraying effect. Finally, after the drive control is completed, the motor speed drops to zero. The specific working path is as follows:

[0077] Control loop ①: The control end issues a spray positioning command; the lateral slide controller 1 receives the command and transmits it to the motor speed controller 1; the motor speed controller 1 adjusts the motor speed ω according to the command 1 ; The motor drive circuit 1 receives the signal from the motor speed controller 1, supplies power to the motor and controls its movement direction; the transverse slide drive motor 1 is started, so that the transverse slide moves to the specified position (x 1 ,y 1 ); Distance detector 1 monitors the distance between the horizontal rail and the rail boundary in real time and maintains [u1 min ,u1 max ] and sends the data back to the control end; the control end makes necessary adjustments or corrections based on the feedback information from the distance detector 1 to ensure accurate positioning of the paint spraying.

[0078] Control loop ②: The control end issues a spray positioning command; the longitudinal slide controller 2 receives the command and transmits it to the motor speed controller 2; the motor speed controller 2 adjusts the motor speed ω according to the command 2; The motor drive circuit 2 receives the signal from the motor speed controller 2, supplies power to the motor and controls its movement direction; the longitudinal slide drive motor 1 is started, so that the longitudinal slide moves to the specified position (x 2 ,y 2 ); The distance detector 2 monitors the distance between the longitudinal rail and the rail boundary in real time and maintains [u2 min ,u2 max ] and returns the data to the control end; the control end makes necessary adjustments or corrections based on the feedback information from the distance detector 2 to ensure accurate positioning of the paint spraying.

[0079] Control loop ③: The control end issues a spray positioning command; the lateral slide controller 3 receives the command and transmits it to the motor speed controller 3; the motor speed controller 3 adjusts the motor speed ω according to the command 3 ; The motor drive circuit 3 receives the signal from the motor speed controller 3, supplies power to the motor and controls its movement direction; the transverse slide drive motor 2 is started, so that the transverse slide moves to the specified position (x 3 ,y 3 ); The distance detector 3 monitors the distance between the horizontal rail and the rail boundary in real time and is maintained at [u3 min ,u3 max ] and sends the data back to the control end; the control end makes necessary adjustments or corrections based on the feedback information of the distance detector 3 to ensure that the paint spraying positioning is accurate.

[0080] Control loop ④: The control end issues a spray positioning command; the longitudinal slide controller 4 receives the command and transmits it to the motor speed controller 4; the motor speed controller 4 adjusts the motor speed ω according to the command 4 ; The motor drive circuit 4 receives the signal from the motor speed controller 4, supplies power to the motor and controls its movement direction; the longitudinal slide drive motor 2 is started, so that the longitudinal slide moves to the specified position (x 4 ,y 4 ); The distance detector 4 monitors the distance between the longitudinal rail and the rail boundary in real time and is maintained at [u4 min ,u4 max ] and returns the data to the control end; the control end makes necessary adjustments or corrections based on the feedback information from the distance detector 4 to ensure accurate positioning of the paint spraying.

[0081] Reference Figure 7 The present invention provides a ship steel surface automatic spraying robot spray gun movement rate distribution, including but not limited to the following steps:

[0082] In order to ensure the spraying effect and consistency of the paint film thickness during the spraying process, the two small spraying mechanical arms on the end effector need to spray the thickness of the edge of the area less than the thickness of the middle area, and set the corresponding spraying movement speed according to different operating positions. In an automatic spraying robot for ship steel surface, the upper spraying mechanical arm starts from the upper right of the end effector and sprays from the XO direction, and the lower spraying mechanical arm starts from the lower left of the end effector and sprays from the OX direction. The spraying movement speeds of the two are V and V respectively. 1 、V 2 、V 3 、V 3 、V 2 、V 1 , where V 1 >V 2 >V 3 ; The velocity distribution design controls the distribution of spray paint film thickness and meets the spray thickness requirements, ensuring uniform transition at the edge of the spray area.

[0083] Reference Figure 8 The present invention provides a ship steel surface automatic spraying robot ship surface spraying trajectory, including but not limited to the following steps:

[0084] The spraying robot moves along a horizontal “bow”-shaped line to spray. The robot first completes the first 2m×3m small area spraying task, then performs adaptive adjustment positioning of distance and accuracy, and descends to spray the second 2m×3m area. The spraying action is repeated until the spraying task of one vertical column is completed. The robot moves horizontally to the second vertical column to spray the upward reciprocating area, and finally reaches the predetermined target.

[0085] Reference Fig. 9 The present invention provides a motor operation simulation of a ship steel surface automatic spraying robot, including but not limited to the following steps:

[0086] The motor of the end effector was set for experimental simulation test. The motor simulation curve rose rapidly in the initial stage of time, indicating that the motor responded very quickly to the control signal and could reach a speed close to the set speed in a short time. After about 0.02 seconds, the speed quickly stabilized and finally reached about 1500 rpm. This shows that the motor can maintain a stable operating state after reaching the target speed, reflecting the good control performance of the system.

[0087] The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Any modification, equivalent substitution or improvement made within the spirit and principle of the present invention should be included in the protection scope of the present invention.

Claims

1. An automatic spraying robot for ship steel surface, characterized in that: It includes an end effector and a straight-arm robot body; The end effector comprises: an upper spraying mechanical arm (1), a lower spraying mechanical arm (2) and a spraying area slide rail mechanism (3); the spraying area slide rail mechanism (3) comprises a laser sensor 1 (3a), a laser sensor 2 (3b), a laser sensor 3 (3c), a laser sensor 4 (3d), a truss support mechanism (3m), a transverse slide rail 1 (3g), a transverse slide rail 2 (3h), a longitudinal slide rail 1 (3e), a longitudinal slide rail 2 (3f), a transverse slide rail left drive motor (3i), a transverse slide rail right drive motor (3k), a longitudinal slide rail left drive motor (3l), and a longitudinal slide rail right drive motor (3j); The truss support mechanism (3m) is connected to the end of the straight arm robot body; the transverse slide rail 1 (3g) and the transverse slide rail 2 (3h) are installed on the truss support mechanism (3m) in a transverse arrangement, and the distance between the two is 2m; the longitudinal slide rail 1 (3e) and the longitudinal slide rail 2 (3f) are installed on the truss support mechanism (3m) in a longitudinal arrangement, and the distance between the two is 3m; The left drive motor (3i) of the transverse slide rail and the right drive motor (3k) of the transverse slide rail are respectively installed on the transverse slide rail 1 (3g) and the transverse slide rail 2 (3h), and are respectively used to drive the upper spraying mechanical arm (1) and the lower spraying mechanical arm (2) to perform transverse displacement spraying; the left drive motor (3l) of the longitudinal slide rail and the right drive motor (3j) of the longitudinal slide rail are respectively installed on the longitudinal slide rail 1 (3e) and the longitudinal slide rail 2 (3f), and are respectively used to drive the transverse slide rail 1 (3g) and the transverse slide rail 2 (3h) to perform longitudinal displacement to drive the upper spraying mechanical arm (1) and the lower spraying mechanical arm (2) to perform longitudinal spraying displacement; The laser sensor 1 (3a), laser sensor 2 (3b), laser sensor 3 (3c), and laser sensor 4 (3d) are respectively installed at the four top corner edges of the end effector for positioning the front end of the robot; the upper spraying robot arm (1) is installed on the transverse slide rail 1 (3g), and the lower spraying robot arm (2) is installed on the transverse slide rail 2 (3h); the two spraying robot arms respectively carry a spray gun, and the front end of the spray gun is installed with a positioning sensor 1 (1a) and a positioning sensor 2 (2a) for positioning the end of the spray gun; The straight-arm robot body comprises a front-end mechanical arm unit (4), a front straight arm (5a), a middle straight arm (5b), a terminal straight arm (5c), a robot rotary joint (6), a body mechanism (7), a support arm hydraulic cylinder mechanism (8), and a base mechanism (9); The front-end mechanical arm unit (4) comprises a swing cylinder mechanism for adjusting the angle, a telescopic mechanism for adjusting the distance, and a laser radar device (4a); the swing cylinder mechanism is respectively installed at the front and rear ends of the front-end mechanical arm unit (4), and is respectively connected to the front straight arm (5a) and the truss support mechanism (3m); the telescopic mechanism is arranged in the middle of the front-end mechanical arm unit (4); the laser radar device (4a) is installed at the bottom of the front-end mechanical arm unit (4) and is used for positioning the end of the straight arm; the front straight arm (5a), the middle straight arm (5b), and the end straight arm (5c) are connected in sequence and are used to adjust the length of the telescopic arm; the robot rotary joint (6), the support arm hydraulic cylinder mechanism (8), and the base mechanism (9) are respectively installed on the body mechanism (7); The body mechanism (7) comprises a robot main body structure and a power system, and connects the robot's terminal straight arm (5c) and a base mechanism (9); the base mechanism (9) is connected to the body mechanism (7) via a turntable, and is provided with an angle sensor (7c) for controlling the rotation angle, and is provided with four tires at the bottom to drive the robot as a whole to move on the ground; a laser radar device (7a) is provided at the front end of the base mechanism (9) for base positioning and side elevation direction angle measurement; a display alarm light (7b) is provided at the upper end of the body mechanism (7) for displaying the overall working status of the robot, and different states are distinguished by different colors.

2. A working method of an automatic spraying robot for a ship steel surface, characterized in that: The steps include: Step S1: The ground staff starts the robot spraying operation and sets the operation instructions; controls the robot to move to the designated workstation, connects the air pipe and paint pipe, stirs the paint and feeds it to the ground paint pump, evacuates the pipeline gas, and starts the spray pump or other paint supply equipment; Step S2: The robot detection unit performs spatial positioning of the spraying position and the working height, the robot straight arm part is driven to extend and retract, and the end effector is positioned near the initial spraying point to complete the robot operation preparation work; Step S3: Start the robot automatic positioning program, the straight arm robot body moves, and the end effector is kept horizontal during the process; the straight arm robot body is equipped with a laser radar to detect the distance between the robot body and the ship outer plate, and determine whether the distance is ≤3m. If it is ≤3m, proceed to the next program step; if it is >3m, the front and rear drive wheels of the body move a distance d x Adjust and re-test the radar distance; Step S4: The four laser distance measuring sensors carried by the end effector of the automatic spraying robot detect whether the distance to the hull is [L min ,L max ] range, if yes, then proceed to the next process, if not, the front end robot arm unit will perform a distance d y Adjustment, while automatically moving to adjust the relative angle between the end effector and the wall, and re-entering the sensor detection step after adjustment; Step S5: The end effector of the automatic spraying robot detects the horizontal inclination angle of the position through the sensor and feeds it back to the body part of the straight-arm robot. Through the above-mentioned linear displacement and angle adjustment, it is ensured that the end effector is parallel to the hull outer plate and the distance meets the preset distance value, completing the unit small area positioning process; Step S6: Start the robot automatic spraying program, and the upper area spraying robot arm 2 carried by the end effector performs adaptive adjustment according to the signal detected by the positioning sensor until the distance between the spray gun mouth and the outer plate of the ship is guaranteed to be 400mm; Step S7: The end effector slide drives the robot arm to hold the spray gun and traverse and move the spray gun within the 2m×3m area to spray. While ensuring the uniform spraying effect and uniform paint film thickness within the 2m×3m area, the robot arm simulates the manual gun swinging action to make the paint film thickness at the edge of the area uniform. When the robot arm sprays to the edge, the spray head rotates 45° to ensure uniform overlap transition between unit areas. Step S8: After spraying the 2m×3m area, the robot arm automatically descends vertically to the next unit area. The sensor detects whether there is a deviation during the descent process. If there is a deviation, the front-end robot arm unit compensates the distance d. y ', complete the position self-correction, if there is no deviation, complete the lifting operation in the next operating area; Step S9: The system determines whether the preset column spraying task is completed. If not, the above action is repeated, and the spraying positioning is re-performed according to the preset column reciprocating spraying. If it is completed, a single column vertical area spraying is set, and then the next step is entered; Step S10: Set a movement instruction for the robot to move horizontally by 3m, automatically correct the position, and start working after entering the next row; Step S11: Check whether all the required columns have been sprayed and whether there are any omissions. If all are completed, the task is terminated. If not, the reciprocating spraying task is re-entered, and the spraying positioning is re-performed and reciprocating spraying is performed according to the preset columns until the task is completed.

3. The working method of the automatic spraying robot for ship steel surface according to claim 2 is characterized in that: The system includes a robot spraying end effector control unit, a straight-arm robot body control unit, an automated linkage control unit, a robot detection unit, a robot integrated control system, and interface signal equipment.

4. The working method of the automatic spraying robot for ship steel surface according to claim 3 is characterized in that: The control unit of the straight-arm robot body part includes: robot automatic compensation control, robot straight-arm descending drive control, robot straight-arm ascending drive control, and robot front and rear drive control; the control unit is mainly used to control the movement and lifting action of the robot to realize automatic correction of position deviation during spraying.

5. The working method of the automatic spraying robot for ship steel surface according to claim 3 is characterized in that: The control unit of the robot spraying end effector includes: an automatic spraying control system, a power supply and communication management component, a spraying robot and a slide rail mechanism collaborative control component, a distance sensing and data processing module, and a spraying control and status monitoring component; the control unit is mainly responsible for the power supply of the system and the communication between the modules, obtains distance information through sensors, coordinates the movement of the spraying robot and the slide rail, and ensures the accuracy of the spraying path.

6. The working method of the automatic spraying robot for ship steel surface according to claim 3 is characterized in that: The automatic linkage control unit includes: automatic positioning drive control for robot lateral spraying, robot straight arm lifting and execution end drive control, and robot overall emergency stop control; this unit controls the lifting and lowering of the robot straight arm and the movement of the spray execution end, and adjusts the lateral position of the spray head to adapt to different surfaces and spraying requirements to ensure uniform spraying. At the same time, in abnormal situations, all actions of the robot can be stopped immediately to ensure safe operation and prevent equipment damage and personal injury.

7. The working method of the automatic spraying robot for ship steel surface according to claim 3 is characterized in that: The robot detection unit includes: angle, pressure sensor, laser distance sensor, laser radar, wheel speed meter, IMU sensor, etc. This unit is used to detect changes in the robot's straight arm, body and surrounding environment during operation. It provides timely and accurate data on the robot's joint speed, robot movement distance, etc. for real-time feedback, helping the robot control system to make dynamic adjustments.

8. The working method of the automatic spraying robot for ship steel surface according to claim 3 is characterized in that: The robot integrated control system and interface signal equipment include: control panel, display interface, digital and analog input and output units, power interface, sensor interface, communication protocol interface, etc.; they are responsible for the coordination and control of the overall system to ensure effective communication and collaboration between modules. The communication protocol is developed based on the CAN bus and includes all the data required for robot control and status response.

9. The working method of the automatic spraying robot for ship steel surface according to claim 2 is characterized in that: The spraying position change process can be expressed as: P k+1 =P k +δ(P t -P k ) (1) Where k represents the time variation step (k = 1, 2, ..., n), P k represents the position of the spraying robot at time step k, P t It is represented as the target position of spraying, and δ represents a scalar parameter of control step length. When the robot completes a vertical spraying task and moves to the next area, this control process is used to gradually adjust the spraying position of the robot, so that it gradually approaches and reaches the preset spraying target position, and controls the speed and stability of position update.

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