A ship painting robot hull leveling control system and its working method

Abstract

This invention discloses a ship painting robot's outer hull leveling control system and its operating method, comprising: a signal acquisition unit, a signal processing unit, a control center, and an execution mechanism. The system utilizes multiple control loops to achieve collaborative operation among multiple mechanisms to complete set actions. Specifically, the boom control loop controls the horizontal distance between the boom and the outer hull; the spraying bracket rotation mechanism control loop controls the parallelism between the bracket and the ground; the bracket horizontal adjustment mechanism control loop controls the equal horizontal distance between the four sides of the square bracket and the outer hull; the robotic arm control loop controls the horizontal distance between the spray gun and the outer hull; and the paint mist protection mechanism control loop controls the start and stop of the protection mechanism. The system of this invention uses a CAN bus to transmit the acquired signals to the control center in real time. Leveling of the device is achieved through the cooperation of the multi-angle bracket adjustment mechanism, the slide table movement mechanism, and the end effector robotic arm, ensuring that the paint nozzle is within a certain range in both the vertical and horizontal directions from the ship's outer hull.

Description

Technical Field

[0001] This invention belongs to the field of automatic control technology, specifically relating to a ship painting robot's outer plate painting and leveling control system and its working method. Background Technology

[0002] Ship painting plays a crucial role in ship construction and maintenance. Traditional ship painting operations involve manual hand-held spray guns, which not only suffers from low automation, high engineering costs, significant safety risks associated with working at heights, and severe environmental pollution, but also suffers from the fact that the painting quality is directly affected by the worker's experience. Furthermore, in rainy and humid environments, workers cannot maintain the original work efficiency when using this method, which seriously hinders the development of intelligent shipbuilding.

[0003] With the innovation and development of ship coating design technology and the needs of application scenarios, various spraying methods have emerged in the market, such as high-flow-rate low-pressure atomization spraying, automatic spraying, and multi-group spraying. These technologies cannot maintain horizontal and continuous spraying operations during the spraying process, resulting in poor consistency of paint overlap film thickness and making it impossible to operate in adverse weather conditions or high wind speeds. In view of the current situation of spraying control, there is an urgent need for new technologies, new processes, and new equipment to replace the existing spraying operation methods.

[0004] This invention employs an automatic leveling control system for ship hull painting. The system transmits collected signals to the control center in real time via a CAN bus. The device is leveled through the cooperation of a multi-angle bracket adjustment mechanism, a sliding table movement mechanism, and an end-effector, ensuring that the paint nozzles are within a certain range from the ship's hull in both vertical and horizontal directions. This achieves a uniform paint thickness on the hull, improves painting efficiency, and reduces manual labor.

[0005] Existing leveling systems and devices suffer from limitations such as a small horizontal adjustment range, limited system functionality, and poor applicability to ship hull painting operations. For example, patent CN108112293A provides a hydraulic leveling device. Other existing patents, such as CN218323996U, describe a positioning and leveling device for prefabricated walls. This device includes wall positioning columns, comprising a left positioning column and a right positioning column, with the left positioning column located next to the right positioning column. A support base is fixedly installed on the lower surface of each wall positioning column. A first connecting telescopic column is fixedly installed on one side of the support base's outer surface. A limiting groove is formed on one side of the wall positioning column's outer surface, and a limiting block is movably installed inside the limiting groove. A limiting connecting plate is fixedly installed on one side of the limiting block's outer surface, and an electric telescopic column is fixedly installed on the other side of the limiting connecting plate's outer surface. While this device solves the problems of wall positioning and ground leveling, its limited horizontal adjustment range and limited system functionality result in poor applicability to ship hull painting operations. Summary of the Invention

[0006] Purpose of the invention: In order to overcome the shortcomings of the prior art, the present invention provides a ship painting robot outer plate painting and leveling control system and its working method.

[0007] Technical solution: A ship painting robot outer plate painting and leveling control system, including: a signal acquisition unit, a signal processing unit, a control center and actuators; the system uses a CAN bus to transmit the information processed by the signal processing unit to the control center, and then the system performs device drive calculations based on the data and sends instructions to each actuator to complete the painting operation;

[0008] The signal acquisition unit comprises a first laser rangefinder, a second laser rangefinder, a first rangefinder panoramic camera, a second rangefinder panoramic camera, a third rangefinder panoramic camera, a fourth rangefinder panoramic camera, and a gyroscope. The system uses the first laser rangefinder and the second laser rangefinder to calculate the horizontal distance between the spray gun and the ship's outer plate, uses the first rangefinder panoramic camera, the second rangefinder panoramic camera, the third rangefinder panoramic camera, and the fourth rangefinder panoramic camera to assist in the leveling calculation of the device support, and uses the gyroscope to calculate the horizontal distance between the device support and the ground.

[0009] In the device drive calculation process, point O is set as the origin of the device boom, c1 is the horizontal distance between the device boom and the outer plate of the ship, θL is the angle between the boom and the vertical distance, and points A, B, and C are the three spraying points in the spraying actuator. The boom performs horizontal spraying from points A, B, and C respectively. At point A, the horizontal distance between the front end of the support and the spray gun on the outer plate of the ship is m1, and the horizontal distance between the spray gun and the outer plate is L1. The system maintains the stability of the mechanism by controlling the horizontal distance c1 between the boom and the outer plate of the ship, the angle θL between the boom and the vertical distance, and the horizontal distance m1 between the front end of the support and the spray gun on the outer plate of the ship.

[0010] The horizontal control process between the support frame and the ship's outer plate includes: setting Q' as the support frame origin, A1B1C1D1 as the initial position of the support frame, and A2B2C2D2 as the adjusted position of the support frame. After adjustment, the horizontal distances of A2, B2, C2, and D2 from the outer plate are l1, l2, l3, and l4, respectively. The support frame rotation mechanism rotates to a horizontal angle of T. The drive coefficients of the four servo motors are F_drive1, F_drive2, F_drive3, and F_drive4, respectively, and the drive coefficient of the rotary motor is Fz. The system coordinates the control of the four servo motors F_drive1, F_drive2, F_drive3, and F_drive4 with the rotary motor Fz. When the following conditions are met: l1≈l2≈l3≈l4, and the error value α∈[αmin, αmax], and the horizontal angle value is T (T=X°), the support frame and the ship's outer plate remain horizontal.

[0011] The system motor synchronization control includes: to ensure that the speeds of the motors tend to be synchronized and to eliminate speed deviations and overshoot, a coupled synchronization control system is used for the coordinated control of multiple motors in each loop, wherein the speed of the i-th motor in each loop satisfies:

[0012] V i =kV i+1 (1)

[0013] In the formula, Vi is the speed of the i-th motor, Vi+1 is the speed of the (i+1)-th motor, k is the motor speed synchronization coefficient, and the speed deviation is e;

[0014] During the spraying process, the four motors in the control loop of the bracket horizontal adjustment mechanism must meet the system synchronization requirements. The system periodically collects the motor speed. At time t0, when e≠0, the system motors Vi and Vi+1 are not synchronized. The synchronization control compensation circuit adopts PID control, and the control algorithm is as follows:

[0015]

[0016] K d =K P ×T d (3)

[0017]

[0018] In the formula, K P K is the proportionality coefficient. d K is the differential time constant. I The integral time constant;

[0019] Among them, the larger the proportional coefficient value, the greater the motor acceleration, and speed overshoot is avoided by correcting the signal derivative time constant;

[0020] The incremental algorithm is as follows:

[0021] K p [e(k)-e(k-1)]+K I e(k)+K D [e(k)-2e(k-1)+e(k-2)](5)

[0022] The system has parameters K P K d K I Online adjustments are made, and the control loop is directly controlled in a closed loop.

[0023] As an optimization: the control center mainly consists of a signal converter, CPU, memory and input / output interface. The data collected by the system is adjusted by the controller algorithm to realize the device's real-time perception of the environment and multi-point coordinated control between various mechanisms to complete the continuous horizontal spraying operation.

[0024] As an optimization: the actuator comprises a spraying boom mechanism, a spraying support rotation mechanism, a support leveling adjustment mechanism, a support slide moving mechanism, a spraying robotic arm, a spray gun, and a paint mist protection mechanism. The spraying boom mechanism is integrated with the straight boom overhead vehicle and placed on the ground. The spraying support rotation mechanism and the support leveling adjustment mechanism are connected and suspended in the air via a rotary bearing. The support slide moving mechanism is connected to the support leveling adjustment mechanism and embedded on the outside of the support. The spraying robotic arm, the spray gun, and the paint mist protection mechanism are integrated and connected to the support slide moving mechanism via a slider.

[0025] As an optimization: the spraying bracket rotation mechanism includes: a left connecting rod, a gyroscope storage cover, a gyroscope, a right connecting rod, a rotation mechanism connector, and a rotation bearing. The left and right connecting rods horizontally fix the rotation mechanism at the center of the bracket. The front rotation mechanism connector is connected to the rotation bearing and embedded in the bracket groove. The gyroscope storage cover is horizontally placed at the top center of the rotation mechanism, and the gyroscope is embedded inside the storage cover.

[0026] As an optimization: the bracket horizontal adjustment mechanism includes a first movable bracket and a second movable bracket, wherein the bracket slide moving mechanism is located on the first movable bracket, four panoramic cameras are placed at the four corners of the top of the first movable bracket, two drive stepper motors are installed at the bottom of the bracket, located at the bottom left and the top right respectively, and two horizontal brackets are connected to the outside of the bracket and connected to the bottom through two vertical moving sliders.

[0027] As an optimization: the horizontal support is equipped with a driving stepper motor on its side and a horizontal moving slider on its top. The second movable support is equipped with four sets of support driving components on its side, which are placed on the sides of the two supports through front and rear connecting parts. The support driving component has an external driving servo motor and an internal screw. The driving slider is mounted on the screw and directly connected to the first one.

[0028] As an optimization: the spraying robot arm is located on the support slide moving mechanism and is connected to the support slide moving mechanism through a horizontal moving slider. The spraying robot arm is integrated with the spray gun and the paint mist protection mechanism.

[0029] As an optimization: the paint mist protection mechanism is located at the bottom of the spray gun, and the mechanism includes: a base and a top plate of the paint mist protection mechanism. A quartz material protective cover is installed on the right side of the base, and a servo motor is installed at the bottom of the protective cover, which is connected to the base. A drive motor is installed at the top left end of the base, a cleaning nozzle is installed at the top middle end, and a bearing washer is installed at the right end. A rotatable brush at the bottom end is connected to the base of the paint mist protection mechanism.

[0030] As an optimization, the system control loop principle includes: a boom truck control loop, a support rotation mechanism control loop, a support horizontal adjustment mechanism control loop, a support slide table moving mechanism control loop, a robotic arm control loop, and a paint mist protection mechanism control loop.

[0031] The system controls the horizontal distance between the boom truck and the outer panel through the boom truck control circuit, the spraying bracket rotation mechanism control circuit controls the parallelism between the bracket and the ground, the bracket horizontal adjustment mechanism control circuit controls the equal horizontal distance between the four sides of the square bracket and the outer panel, the robotic arm control circuit controls the horizontal distance between the spray gun and the outer panel, and the paint mist protection mechanism control circuit controls the start and stop of the protection.

[0032] A method for operating a ship painting robot's outer hull painting and leveling control system, wherein the system's control flow includes the following steps:

[0033] S1: The system is a ship outer plate spraying and leveling control system. Workers drive the straight boom overhead truck to the initial starting position according to the system's preset initial position.

[0034] S2: The signal acquisition unit starts working, and the four sets of ranging panoramic cameras randomly sample the data, and the system performs distance detection;

[0035] S3: The overhead boom begins to move toward the outer plating of the ship, and the system monitors the distance between the support and the outer plating in real time.

[0036] S4: If the distance between the support and the outer plate of the ship satisfies L1∈[Lmin, Lmax], L2∈[Lmin, Lmax], L3∈[Lmin, Lmax], L4∈[Lmin, Lmax], then the system controls the overhead boom to stop moving. Similarly, if the distance between the support and the outer plate of the ship does not satisfy the above conditions, then the overhead boom continues to move forward or backward.

[0037] S5: The system signal acquisition unit activates the built-in gyroscope to collect the bracket position information in real time and transmit it to the control center;

[0038] S6: The control center receives the signal from the signal acquisition unit and issues a command to the built-in rotating shaft motor of the bracket rotation mechanism to drive the rotating shaft to the designated position;

[0039] S7: When the bracket rotation mechanism rotates to the horizontal angle value T (T=X°), the drive motor stops rotating, and the bracket horizontal adjustment mechanism starts to work;

[0040] S8: The control center performs numerical comparison and analysis on the collected signals and calculates the electromechanical control relationship of the four motors of the horizontal adjustment mechanism;

[0041] S9: The control center sends a command to the motor driver, and the bracket drives motors 1, 2, 3, and 4 to start running;

[0042] S10: When the system collects ranging values ​​L1≈L2≈L3≈L4 and the error range α∈[αmin, αmax], start the support slide moving mechanism;

[0043] S11: The slide bracket motor drives the slider to move to the designated position according to the system's planned route;

[0044] S12: The laser ranging sensor in the signal acquisition unit activates laser ranging, and the system controls the robotic arm to move in coordination.

[0045] S13: When the system receives laser ranging values ​​M1∈[Mmin, Mmax] and M2∈[Mmin, Mmax], the arm drive motor stops running, and the paint mist protection device is activated at this time.

[0046] S14: The built-in drive motor of the paint mist protection device starts to operate, the spray gun sprays, and the straight boom lift truck starts to move.

[0047] Beneficial effects: The system of the present invention uses a CAN bus to transmit the collected signals to the control center in real time. The device is leveled by the cooperation of the multi-angle bracket adjustment mechanism, the slide table moving mechanism and the end robotic arm, so as to ensure that the paint nozzle is within a certain range from the ship's outer plate in both vertical and horizontal directions, thereby achieving a uniform paint thickness on the outer plate, improving spraying efficiency and reducing manual input. Attached Figure Description

[0048] Figure 1 This is a schematic diagram of the overall structure of the ship outer plate spraying leveling control device of the present invention;

[0049] Figure 2 This is a schematic diagram of the ship outer plate spraying leveling control device of the present invention;

[0050] Figure 3 This is a schematic diagram of the side structure of the paint mist protection mechanism of the present invention;

[0051] Figure 4 This is a schematic diagram of the paint mist protection mechanism of the present invention;

[0052] Figure 5 This is a schematic diagram of the support horizontal adjustment mechanism of the present invention;

[0053] Figure 6 This is a schematic diagram of the first movable support structure of the present invention;

[0054] Figure 7 This is a schematic diagram of the second movable support structure of the present invention;

[0055] Figure 8 This is a schematic diagram of the ship outer plate spraying leveling control device system of the present invention;

[0056] Figure 9 This is a schematic diagram of the working structure of the ship outer plate spraying leveling control device of the present invention;

[0057] Figure 10 This is a schematic diagram of the horizontal adjustment structure of the ship outer plate spraying leveling control device of the present invention;

[0058] Figure 11 This is a flowchart of the system control loop structure of the present invention;

[0059] Figure 12 This is a system control flowchart of the ship outer plate spraying leveling control device of the present invention.

[0060] In the diagram: 1. First paint mist protection mechanism; 2. Second paint mist protection mechanism; 2a. First laser rangefinder; 2b. Rotatable brush; 2c. Quartz material protective cover; 2d. Base of paint mist protection mechanism; 2e. Protective cover drive servo motor; 2f. Bearing gasket; 2g. Cleaning nozzle; 2h. Brush drive servo motor; 2i. Top plate of paint mist protection mechanism; 3. Second spraying execution mechanism; 3a. Second spray gun; 3b. Second spraying robotic arm; 4. First spraying execution mechanism; 4a. First spray gun; 4b. First spray... 5. Spraying robotic arm; 5a. Spraying bracket rotation mechanism; 5b. Left connecting rod; 5c. Gyroscope storage cover; 5d. Gyroscope; 5e. Right connecting rod; 5f. Rotation mechanism connector; 5f. Rotary bearing; 6. First movable bracket; 6a. Second ranging panoramic camera; 6b. Second horizontal bracket vertical drive stepper motor; 6c. Second horizontal bracket; 6d. Horizontal moving slider; 6e. Third ranging panoramic camera; 6f. Second horizontal bracket horizontal drive stepper motor; 6g. Vertical moving slider; 6h. Second vertical bracket 6i, Fourth ranging panoramic camera; 6j, Second vertical bracket vertical drive stepper motor; 6k, First ranging panoramic camera; 6l, First horizontal bracket; 6m, First horizontal bracket horizontal drive stepper motor; 6n, First vertical bracket; 7, Second movable bracket; 7a, Third bracket drive slider; 7b, Third connector at the front end of the bracket; 7c, Third track screw; 7d, Third connector at the rear end of the bracket; 7e, Third bracket drive servo motor; 7f, Second bracket drive slider; 7g, Second connector at the front end of the bracket; 7h 7i, Second track screw; 7j, Second support rear end connector; 7k, Second support drive servo motor; 7l, First support drive slider; 7m, First track screw; 7n, First support rear end connector; 7o, First support drive servo motor; 7p, Fourth support drive slider; 7q, Fourth support front end connector; 7r, Fourth track screw; 7s, Fourth support rear end connector; 7t, Fourth support drive servo motor; 8, Spray painting boom truck mechanism; 9, Ship outer plate; 10, Straight boom overhead truck. Detailed Implementation

[0061] The technical solutions in the embodiments of the present invention will be clearly and completely described below, so that those skilled in the art can better understand the advantages and features of the present invention, thereby making a clearer definition of the scope of protection of the present invention. The embodiments described in this invention are only some embodiments of the present invention, not all embodiments. All other embodiments obtained by those skilled in the art based on the embodiments of the present invention without creative effort are within the scope of protection of the present invention.

[0062] Example

[0063] like Figure 1-2 As shown, a diagram of the overall structure of a ship outer plate spraying leveling control device is provided. The device mainly consists of a spraying arm mechanism 8, a spraying bracket rotation mechanism 5, a bracket horizontal adjustment mechanism, a bracket slide moving mechanism, a spraying robotic arm, a spray gun, and a paint mist protection mechanism. The system utilizes the control loops between the various mechanisms to achieve corresponding actions.

[0064] like Figure 3-7 As shown, the spraying boom vehicle mechanism 8 is integrated with the straight boom overhead vehicle 10 and placed on the ground. The spraying bracket rotation mechanism 5 and the bracket horizontal adjustment mechanism are connected and suspended in the air through a rotary bearing 5f. The bracket slide moving mechanism is connected to the bracket horizontal adjustment mechanism and embedded on the outside of the bracket. The spraying robotic arm, spray gun and paint mist protection mechanism are integrated and connected to the bracket slide moving mechanism through a slider.

[0065] The spraying bracket rotation mechanism 5 comprises: a left connecting rod 5a, a gyroscope housing 5b, a gyroscope 5c, a right connecting rod 5d, a rotation mechanism connector 5e, and a rotation bearing 5f. The left connecting rod 5a and the right connecting rod 5d horizontally fix the rotation mechanism at the center of the bracket. The front rotation mechanism connector is connected to the rotation bearing 5f and embedded in the bracket groove. The gyroscope housing 5b is horizontally positioned at the top center of the rotation mechanism, housing the gyroscope within it.

[0066] The horizontal adjustment mechanism of the support includes a first movable support 6 and a second movable support 7. The support slide mechanism is located on the first movable support. Four panoramic cameras are positioned at the four corners of the top of the first movable support. Two drive stepper motors are mounted on the bottom of the support, located at the bottom left and top right respectively. Two horizontal supports are connected to the outer side of the support via two vertical sliding blocks 6g. Each horizontal support has a drive stepper motor on its side and a horizontal sliding block 6d on its top. The second movable support has four sets of support drive components on its side, positioned on the sides of the two supports via front and rear connecting parts. Each support drive component has an external drive servo motor and an internal screw. The drive slider is mounted on the screw and directly connected to the first support.

[0067] The spraying robot arm is located on the support slide moving mechanism and is connected to the support slide moving mechanism through the horizontal moving slider 6d. The spraying robot arm is integrated with the spray gun and the paint mist protection mechanism.

[0068] The paint mist protection mechanism is located at the bottom of the spray gun. The mechanism consists of a paint mist protection mechanism base 2d and a paint mist protection mechanism top plate 2i. A quartz material protective cover 2c is installed on the right side of the base. A servo motor is installed at the bottom of the protective cover and connected to the base. A drive motor is installed at the top left end of the base. A cleaning nozzle 2g is installed at the top middle end. A bearing washer 2f is installed at the right end. A rotatable brush 2b at the bottom end is connected to the paint mist protection mechanism base.

[0069] like Figure 8 The diagram shows the structural principle of a ship outer plating spraying and leveling control device system. The system consists of a signal acquisition unit, a signal processing unit, a control center, and actuators. The information processed by the signal processing unit is transmitted to the control center via a CAN bus. After the system performs device drive calculations based on the data, it sends instructions to each actuator to complete the spraying operation.

[0070] The acquisition unit comprises a first laser rangefinder 2a, a second laser rangefinder, a first rangefinder panoramic camera 6k, a second rangefinder panoramic camera 6a, a third rangefinder panoramic camera 6e, a fourth rangefinder panoramic camera 6i, and a gyroscope. The system uses the first laser rangefinder and the second laser rangefinder to calculate the horizontal distance between the spray gun and the outer plate 9 of the ship. The first rangefinder panoramic camera 6k, the second rangefinder panoramic camera 6a, the third rangefinder panoramic camera 6e, and the fourth rangefinder panoramic camera assist in the leveling calculation of the device support. The gyroscope is used to calculate the horizontal distance between the device support and the ground.

[0071] like Figure 9 The diagram illustrates the operation of a ship's outer plating spraying and leveling control device. The system calculation process includes: setting point O as the origin of the device's boom trolley, c1 as the horizontal distance between the boom trolley and the ship's outer plating, and θL as the angle between the boom trolley's upper arm and the vertical distance. Points A, B, and C are three spraying points within the spraying actuator. The boom trolley performs horizontal spraying from points A, B, and C. Taking point A as an example, the horizontal distance between the front end of the support frame and the ship's outer spray gun is m1, and the horizontal distance between the spray gun and the outer plating is L1. The system maintains stability by controlling the horizontal distance c1 between the boom trolley and the ship's outer plating, the angle θL between the boom trolley's upper arm and the vertical distance, and the horizontal distance m1 between the front end of the support frame and the ship's outer spray gun.

[0072] like Figure 10 The diagram shows a horizontal adjustment schematic of a ship hull coating leveling control device, comprising:

[0073] Let Q' be the origin of the support, A1B1C1D1 be the initial position of the support, and A2B2C2D2 be the adjusted position of the support. After adjustment, the horizontal distances of A2, B2, C2, and D2 from the outer plate are l1, l2, l3, and l4, respectively. The horizontal angle value of the support rotation mechanism is T. The drive coefficients of the four servo motors are F drive 1, F drive 2, F drive 3, and F drive 4, respectively, and the drive coefficient of the rotary motor is Fz.

[0074] The system coordinates the control of four servo motors F1, F2, F3 and F4 with the rotary motor Fz. When the following conditions are met: l1≈l2≈l3≈l4, and the error value α∈[αmin, αmax], and the horizontal angle value T (T=X°), the bracket and the outer plate of the ship remain horizontal.

[0075] like Figure 11 The system control loop structure flowchart shown is characterized by the following: the control loop consists of a boom control loop, a support rotation mechanism control loop, a support horizontal adjustment mechanism control loop, a support slide table movement mechanism control loop, a robotic arm control loop, and a paint mist protection mechanism control loop.

[0076] The system uses a boom control circuit to control the horizontal distance between the boom and the outer panel, a spraying bracket rotation mechanism 5 control circuit to control the parallelism between the bracket and the ground, a bracket horizontal adjustment mechanism control circuit to control the equal horizontal distance between the four sides of the square bracket and the outer panel, a robotic arm control circuit to control the horizontal distance between the spray gun and the outer panel, and a paint mist protection mechanism control circuit to control the start and stop of the protection.

[0077] The characteristics of the system's motor synchronization control principle include: to ensure that the speeds of the motors tend to be synchronized and to eliminate speed deviations and overshoot, a coupled synchronization control system is used to coordinate the control of multiple motors in each loop, wherein the speed of the i-th motor in each loop satisfies:

[0078] V i =kV i+1 (1)

[0079] In the formula, Vi is the speed of the i-th motor, Vi+1 is the speed of the (i+1)-th motor, k is the motor speed synchronization coefficient, and the speed deviation is e.

[0080] During the spraying process, the four motors in the control loop of the bracket horizontal adjustment mechanism must meet the system synchronization requirements. The system periodically collects the motor speed. At time t0, when e≠0, the system motors Vi and Vi+1 are not synchronized. The synchronization control compensation circuit adopts PID control, and the control algorithm is as follows:

[0081]

[0082] K d =K P ×T d (3)

[0083]

[0084] In the formula, KP is the proportionality coefficient, Kd is the differential time constant, and KI is the integral time constant.

[0085] The larger the proportional coefficient value, the greater the motor acceleration. Speed ​​overshoot is avoided by correcting the signal differential time constant.

[0086] The incremental algorithm is as follows:

[0087] K p [e(k)-e(k-1)]+K I e(k)+K D [e(k)-2e(k-1)+e(k-2)](5)

[0088] The system adjusts parameters KP, Kd, ​​and KI online and uses the control system to directly perform closed-loop control of the control loop.

[0089] like Figure 12 The diagram shown is a control flowchart of a ship outer plating spraying and leveling control device system. The process includes:

[0090] S1: The system is a ship outer plate spraying and leveling control system. Workers drive the straight boom overhead truck to the initial starting position according to the system's preset initial position.

[0091] S2: The signal acquisition unit starts working, and the four sets of ranging panoramic cameras randomly sample the data, and the system performs distance detection;

[0092] S3: The overhead boom begins to move toward the outer plating of the ship, and the system monitors the distance between the support and the outer plating in real time.

[0093] S4: If the distance between the support and the outer plate of the ship satisfies L1∈[Lmin, Lmax], L2∈[Lmin, Lmax], L3∈[Lmin, Lmax], L4∈[Lmin, Lmax], then the system controls the overhead boom to stop moving. Similarly, if the distance between the support and the outer plate of the ship does not satisfy the above conditions, then the overhead boom continues to move forward or backward.

[0094] S5: The system signal acquisition unit activates the built-in gyroscope to collect the bracket position information in real time and transmit it to the control center;

[0095] S6: The control center receives the signal from the signal acquisition unit and issues a command to the built-in rotating shaft motor of the bracket rotation mechanism to drive the rotating shaft to the designated position;

[0096] S7: When the bracket rotation mechanism rotates to the horizontal angle value T (T=X°), the drive motor stops rotating, and the bracket horizontal adjustment mechanism starts to work;

[0097] S8: The control center performs numerical comparison and analysis on the collected signals and calculates the electromechanical control relationship of the four motors of the horizontal adjustment mechanism;

[0098] S9: The control center sends a command to the motor driver, and the bracket drives motors 1, 2, 3, and 4 to start running;

[0099] S10: When the system collects ranging values ​​L1≈L2≈L3≈L4 and the error range α∈[αmin, αmax], start the support slide moving mechanism;

[0100] S11: The slide bracket motor drives the slider to move to the designated position according to the system's planned route;

[0101] S12: The laser ranging sensor in the signal acquisition unit activates laser ranging, and the system controls the robotic arm to move in coordination.

[0102] S13: When the system receives laser ranging values ​​M1∈[Mmin, Mmax] and M2∈[Mmin, Mmax], the arm drive motor stops running, and the paint mist protection device is activated at this time.

[0103] S14: The built-in drive motor of the paint mist protection device starts to operate, the spray gun sprays, and the straight boom lift truck starts to move.

Claims

1. A ship painting robot outer hull painting leveling control system, characterized in that: include: The system consists of a signal acquisition unit, a signal processing unit, a control center, and actuators. The system uses a CAN bus to transmit the information processed by the signal processing unit to the control center. The system then performs device drive calculations based on the data and sends instructions to each actuator to complete the spraying operation. The signal acquisition unit includes: a first laser rangefinder, a second laser rangefinder, a first rangefinder panoramic camera, a second rangefinder panoramic camera, a third rangefinder panoramic camera, a fourth rangefinder panoramic camera, and a gyroscope; the system uses the first and second laser rangefinders to calculate the horizontal distance between the spray gun and the ship's outer plate, uses the first, second, third, and fourth rangefinder panoramic cameras to assist in leveling the device support, and uses the gyroscope to calculate the horizontal distance between the device support and the ground; In the device drive calculation process, point O is set as the origin of the device boom, c1 is the horizontal distance between the device boom and the outer plate of the ship, θL is the angle between the boom and the vertical distance, and points A, B, and C are the three spraying points in the spraying actuator. The boom performs horizontal spraying from points A, B, and C respectively. At point A, the horizontal distance between the front end of the support and the spray gun on the outer plate of the ship is m1, and the horizontal distance between the spray gun and the outer plate is L1. The system maintains the stability of the mechanism by controlling the horizontal distance c1 between the boom and the outer plate of the ship, the angle θL between the boom and the vertical distance, and the horizontal distance m1 between the front end of the support and the spray gun on the outer plate of the ship. The horizontal control process between the support frame and the ship's outer plate includes: setting Q' as the support frame origin, A1B1C1D1 as the initial position of the support frame, and A2B2C2D2 as the adjusted position of the support frame. After adjustment, the horizontal distances of A2, B2, C2, and D2 from the outer plate are l1, l2, l3, and l4, respectively. The support frame rotation mechanism rotates to a horizontal angle of T. The drive coefficients of the four servo motors are F_drive1, F_drive2, F_drive3, and F_drive4, respectively, and the drive coefficient of the rotary motor is Fz. The system coordinates the control of the four servo motors F_drive1, F_drive2, F_drive3, and F_drive4 with the rotary motor Fz. When the following conditions are met: l1≈l2≈l3≈l4, and the error value α∈[αmin, αmax], and the preset horizontal angle value T is reached, the support frame and the ship's outer plate remain horizontal. The system's motor synchronization control includes: to ensure that the speeds of the motors tend to be synchronized and to eliminate speed deviations and overshoot, a coupled synchronization control system is used for the coordinated control of multiple motors in each loop, wherein the speed of the i-th motor in each loop satisfies: ； In the formula, Vi is the speed of the i-th motor, Vi+1 is the speed of the (i+1)-th motor, k is the motor speed synchronization coefficient, and the speed deviation is e; During the spraying process, the four motors in the control loop of the bracket horizontal adjustment mechanism must meet the system synchronization requirements. The system periodically collects the motor speed. At time t0, when e≠0, the system motors Vi and Vi+1 are not synchronized. The synchronization control compensation circuit adopts PID control, and the control algorithm is as follows: ； ； ； In the formula, For controller output; The difference in speed between two adjacent motors at the current moment is the system error signal. and Same meaning; This is the proportionality coefficient; The integral time constant; The differential time constant; This is the differential gain; For integral gain; For the first Error value per sampling period; For the first Error value per sampling period; For the first The error value of each sampling period is used to calculate the second-order difference of the error to approximate the differential term; Among them, the larger the proportional coefficient value, the greater the motor acceleration, and speed overshoot is avoided by correcting the signal derivative time constant; The incremental algorithm is as follows: ； In the formula, For the first The control output increment for each control cycle. For differential gain, and The system has the same parameters. , , Online adjustments are made, and the control loop is directly controlled in a closed loop.

2. The ship painting robot outer hull painting and leveling control system according to claim 1, characterized in that: The control center mainly includes a signal converter, CPU, memory and input / output interface. The data collected by the system is adjusted by the controller algorithm to realize the device's real-time perception of the environment and multi-point coordinated control between various mechanisms to complete the continuous horizontal spraying operation.

3. The ship painting robot outer hull painting and leveling control system according to claim 1, characterized in that: The actuators include: a spraying boom mechanism, a spraying support rotation mechanism, a support leveling adjustment mechanism, a support slide moving mechanism, a spraying robotic arm, a spray gun, and a paint mist protection mechanism. The spraying boom mechanism is integrated with the straight boom overhead vehicle and placed on the ground. The spraying support rotation mechanism and the support leveling adjustment mechanism are connected and suspended in the air via a rotary bearing. The support slide moving mechanism is connected to the support leveling adjustment mechanism and embedded on the outside of the support. The spraying robotic arm, the spray gun, and the paint mist protection mechanism are integrated and connected to the support slide moving mechanism via a slider.

4. The ship painting robot outer hull painting and leveling control system according to claim 3, characterized in that: The spraying bracket rotation mechanism includes: a left connecting rod, a gyroscope storage cover, a gyroscope, a right connecting rod, a rotation mechanism connector, and a rotation bearing. The left and right connecting rods horizontally fix the rotation mechanism at the center of the bracket. The front rotation mechanism connector is connected to the rotation bearing and embedded in the bracket groove. The gyroscope storage cover is horizontally placed at the top center of the rotation mechanism, and the gyroscope is embedded inside the storage cover.

5. The ship painting robot outer plate painting and leveling control system according to claim 3, characterized in that: The spraying robot arm is located on the support slide moving mechanism and is connected to the support slide moving mechanism through a horizontal moving slider. The spraying robot arm is integrated with the spray gun and the paint mist protection mechanism.

6. The ship painting robot outer hull painting and leveling control system according to claim 3, characterized in that: The paint mist protection mechanism is located at the bottom of the spray gun. The mechanism includes a paint mist protection mechanism base and a paint mist protection mechanism top plate. A quartz material protective cover is installed on the right side of the base. A servo motor is installed at the bottom of the protective cover. A drive motor is installed at the top left end of the base. A cleaning nozzle is installed at the top middle of the base. A bearing washer is installed at the right end of the base. A rotatable brush at the bottom end is connected to the paint mist protection mechanism base.

7. The ship painting robot outer hull painting and leveling control system according to claim 1, characterized in that: The system control loop includes: boom control loop, support rotation mechanism control loop, support horizontal adjustment mechanism control loop, support slide table moving mechanism control loop, robotic arm control loop, and paint mist protection mechanism control loop; The system controls the horizontal distance between the boom truck and the outer panel through the boom truck control circuit, the spraying bracket rotation mechanism control circuit controls the parallelism between the bracket and the ground, the bracket horizontal adjustment mechanism control circuit controls the equal horizontal distance between the four sides of the square bracket and the outer panel, the robotic arm control circuit controls the horizontal distance between the spray gun and the outer panel, and the paint mist protection mechanism control circuit controls the start and stop of the protection.

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