Intelligent welding robot system for deepwater jacket reinforcing ring

Abstract

The invention discloses an intelligent welding robot system for a deepwater jacket reinforcing ring, which belongs to the technical field of robot welding and comprises a roller carrier positioner for clamping and driving a workpiece to rotate, a photoelectric switch is arranged on the roller carrier positioner, and the photoelectric switch measures the rotating distance of the workpiece. Two sets of three-axis movement mechanisms and robot modules are arranged on the two sides of the roller carrier positioner, the robot modules are installed on the three-axis movement mechanisms so that the three-axis movement mechanisms can drive the robot modules to linearly move in the X-axis direction, the Y-axis direction and the Z-axis direction, and welding gun modules are arranged on the robot modules and comprise two welding guns and laser tracking sensors; the laser tracking sensor achieves real-time tracking and locating of the welding seam and adapts to welding seam deformation in the welding process. Accurate linkage matching of the robot module and the roller carrier positioner is achieved through the control module, so that double-face double-arc simultaneous bottom sealing welding of the reinforcing ring is achieved, the back gouging procedure of a conventional welding method is omitted, double-face four-wire simultaneous filling is adopted, and the welding efficiency is improved.

Description

Technical Field

[0001] The invention belongs to the technical field of robot welding, and in particular relates to an intelligent welding robot system for a deepwater jacket reinforcement ring. Background Art

[0002] At present, the traditional welding of the jacket pipe of the offshore oil platform is mainly done by manual welding, and the weld quality and welding efficiency are difficult to guarantee. In addition, since the jacket pipe is a semi-enclosed structure, there is a lot of smoke and high temperature during welding, and the working environment of the workers is poor. Robots are gradually being used for the welding of the inner annular seam of the jacket pipe. The jacket pipe is placed horizontally on the roller frame, the welding gun reaches the welding position, and the roller frame drives the workpiece to rotate to complete the welding of the inner annular weld of the pipe.

[0003] The existing robot welding system adopts a repeated teaching method. However, due to the heavy weight of the catheter and the small space inside the tube, the teaching is difficult and wastes a lot of time. When the existing roller frame is used, the workpiece is rotated by friction. Due to the uncertainty of slippage and movement, the error of each rotation is different, resulting in poor welding quality. As a result, the existing robot welding system cannot be applied to the welding of the annular seam inside the catheter frame pipe.

[0004] Therefore, it is urgent to design an intelligent welding robot system for deepwater jacket reinforcement rings to solve the above-mentioned problem of poor welding quality due to the uncertainty of slippage and movement and the rotation error of the workpiece. Summary of the invention

[0005] In order to solve the technical problem mentioned in the background technology that the workpiece has a rotation error, resulting in poor welding quality, an intelligent welding robot system for a deep-water conductor frame reinforcement ring is provided to solve the above problem, that is, the conductor is placed axially and horizontally on a roller frame, a 45° K-shaped groove is opened on the reinforcing ring body, and the reinforcing ring is fixed to the inside of the guide channel; two robot modules respectively deliver two welding guns to the horizontal welding position from both sides of the conductor and keep the posture unchanged, and obtain the surface morphology of the weld through a laser tracking sensor, and the roller frame drives the workpiece to rotate to complete the double-sided welding of the annular weld in the pipe.

[0006] To achieve the above objectives, the specific technical solution of the intelligent welding robot system for the reinforcement ring of the deepwater jacket frame of the present invention is as follows:

[0007] An intelligent welding robot system for a deepwater jacket reinforcement ring comprises a roller frame positioner for clamping and driving a workpiece to rotate, a photoelectric switch is arranged on the roller frame positioner, and the photoelectric switch measures the rotation distance of the workpiece, three-axis motion mechanisms and robot modules are arranged on both sides of the roller frame positioner, and the robot module is installed on the three-axis motion mechanism so that the three-axis motion mechanism drives the robot module to move linearly along the XYZ axis direction, and a welding gun module is arranged on the robot module, including two welding guns and a laser tracking sensor, and the laser tracking sensor realizes the positioning of the weld and corrects the trajectory deviation caused by welding deformation.

[0008] Furthermore, the control module realizes precise linkage between the roller frame positioner and the robot, realizes weld tracking and correction through laser tracking sensors, has the function of detecting workpiece anti-movement and sliding compensation, and corrects the position in real time, thereby realizing double-sided double-arc robot bottom welding and double-sided four-wire filling welding.

[0009] Furthermore, the global vision sensor realizes automatic positioning of the workpiece and guides the welding robot to autonomously move to the circumferential seam welding position.

[0010] Furthermore, during the welding process, the welding wire feeding speed is intelligently adjusted according to the assembly status of the workpieces to adapt to automatic bottom sealing under different gap conditions.

[0011] Furthermore, automatic filling of multi-layer and multi-pass welding of thick plates can be achieved.

[0012] Furthermore, the roller frame positioner includes a positioner base, an axial track is fixedly installed on the positioner base, and a tube length adjustment mechanism is connected to the axial track so as to adapt to the length of the workpiece by adjusting the tube length adjustment mechanism.

[0013] Furthermore, the tube length adjustment mechanism includes a fixed end and a movable end, the fixed end is fixedly connected to one end of the axial track, and the movable end is slidably connected to the axial track.

[0014] Furthermore, radial tracks are installed on both the fixed end and the movable end, and roller groups are slidably connected to the radial tracks to adapt to the diameter of the workpiece through the roller groups.

[0015] Furthermore, the roller group includes a driving wheel and a driven wheel, both of which are slidably connected to the radial track, and both of which are connected to a lead screw, which is connected to a coupling, and which is connected to a servo motor and a reducer, and the servo motor and the reducer drive the driving wheel and the driven wheel to move toward or away from each other.

[0016] Furthermore, a grounding pole lifting device for grounding the workpiece is installed on the positioner base, and the grounding pole lifting device is located on the inner side of the driving wheel and the driven wheel.

[0017] Furthermore, the grounding pole lifting device includes a fixed bracket, which is fixedly connected to the positioner base, and a pneumatic cylinder is connected to the fixed bracket, and a linear bearing is connected to the pneumatic cylinder. A linear guide rod is slidably connected in the linear bearing to guide the movement direction of the pneumatic cylinder. A copper contact is fixedly connected to the top of the pneumatic cylinder, and the copper contact contacts the workpiece, thereby grounding the workpiece.

[0018] Furthermore, a pipe end stop wheel bracket is fixedly connected to the positioner base, and a stop wheel is connected to the pipe end stop wheel bracket. The stop wheel is located outside the driving wheel and the driven wheel to limit the axial direction of the workpiece rotation. The stop wheel is wrapped with rubber to cushion the collision between the workpiece and the stop wheel. The photoelectric switch is horizontally installed on the pipe end stop wheel bracket.

[0019] Furthermore, the three-axis motion mechanism includes an X-axis crossbar, a Z-axis vertical rod is slidably connected to the X-axis crossbar, a slide groove is provided on the Z-axis vertical rod, a slider is slidably connected in the slide groove, a Y-axis crossbar is slidably connected to the slider, a robot module is fixedly connected to the Y-axis crossbar, and a global vision sensor is fixedly connected to the slider to scan the workpiece data.

[0020] Furthermore, a wire feeder is fixedly connected to the Y-axis crossbar to provide welding wire.

[0021] The intelligent welding robot system for the deepwater jacket reinforcement ring of the present invention has the following advantages:

[0022] The present invention realizes intelligent welding through the precise coordination of the robot module and the roller frame positioner, reduces manual intervention and operation difficulty, and the application of the global visual sensor ensures the accuracy of the welding position and posture, avoiding the collision between the robot and the conduit when entering the welding position in the pipe. The pipe length adjustment mechanism and the roller group can be automatically adjusted according to the different sizes of the workpiece to adapt to various working conditions, reduce the harm of welding smoke and high temperature to operators, and improve the working environment. BRIEF DESCRIPTION OF THE DRAWINGS

[0023] Figure 1 It is a front view of the intelligent welding robot system of the deepwater jacket reinforcement ring of the present invention.

[0024] Figure 2 It is a structural schematic diagram of the roller rack positioner of the present invention.

[0025] Figure 3 It is a schematic diagram of the driving wheel structure of the present invention.

[0026] Figure 4 It is a schematic structural diagram of the grounding electrode lifting device of the present invention.

[0027] Figure 5 It is a schematic diagram of the pipe end stop wheel bracket and the stop wheel structure of the present invention.

[0028] Figure 6 It is a schematic diagram of the three-axis motion mechanism of the present invention.

[0029] Figure 7 The figure is a schematic diagram of the overall structure of the intelligent welding robot system for the reinforcement ring of the deepwater jacket according to the present invention.

[0030] Explanation of the markings in the figure: 1. Roller rack positioner; 101. Positioner base; 102. Axial track; 103. Tube length adjustment mechanism; 1031. Fixed end; 1032. Moving end; 104. Radial track; 105. Roller assembly; 1051. Driving wheel; 1052. Driven wheel; 1053. Lead screw; 106. Grounding pole lifting device; 1061. Fixed bracket; 1062. Pneumatic cylinder; 1063. Linear bearing; 1064. Linear guide rod; 1065. Copper Contact; 107, pipe end stop wheel bracket; 108, stop wheel; 2, photoelectric switch; 3, three-axis motion mechanism; 301, X-axis crossbar; 302, Z-axis vertical rod; 303, Y-axis crossbar; 304, slide; 305, slider; 306, global vision sensor; 307, wire feeder; 4, robot module; 5, welding gun; 6, laser tracking sensor; 7, welding power supply; 100, steel roller; 200, roller bearing; 300, rubber pad; 400, mounting bracket. DETAILED DESCRIPTION

[0031] In order to make the purpose, technical solution and advantages of the embodiments of the present invention clearer, the technical solution in the embodiments of the present invention will be clearly and completely described below in conjunction with the drawings in the embodiments of the present invention. Obviously, the described embodiments are part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative work are within the scope of protection of the present invention.

[0032] Those skilled in the art will appreciate that, although some embodiments herein include certain features included in other embodiments but not other features, the combination of features of different embodiments is meant to be within the scope of the present invention and form different embodiments. For example, in the claims, any one of the claimed embodiments may be used in any combination.

[0033] Please refer to the attached Figure 1 To Attachment Figure 7 The invention describes an intelligent welding robot system for a deepwater jacket reinforcement ring.

[0034] The existing robot welding system adopts a repeated teaching method. However, due to the heavy weight of the catheter and the small space inside the tube, the teaching is difficult and wastes a lot of time. When the existing roller rack is used, the workpiece contacts the roller surface and relies on friction to make the workpiece rotate. Due to the uncertainty of slippage and movement, the error of each rotation is different, resulting in poor welding quality. As a result, the existing robot welding system cannot be applied to the welding of the annular seam inside the catheter rack.

[0035] Therefore, the present invention provides an intelligent welding robot system for a deepwater jacket reinforcement ring, such as Figure 1 As shown, it includes a roller frame positioner 1 for clamping and driving the workpiece to rotate. The roller frame positioner 1 is provided with a photoelectric switch 2, which measures the rotation distance of the workpiece. Three-axis motion mechanisms 3 and robot modules 4 are provided on both sides of the roller frame positioner 1. The robot module 4 is installed on the three-axis motion mechanism 3 so that the motion mechanism drives the robot module 4 to move linearly along the XYZ axis direction. A welding gun module 5 is provided on the robot module 4. The welding gun module 5 includes two welding guns, and the interval between the welding guns is 15 mm to reduce interference between arcs.

[0036] The robot module 4 is provided with a laser tracking sensor 6 to locate the weld and correct weld deformation during the welding process.

[0037] Specifically, by installing the laser tracking sensor 6 on the welding gun module 5, the weld is located and the weld deformation during the welding process is corrected. When the welding gun module 5 reaches the welding starting position with the path planned by offline programming, the weld positioning is started, and the welding gun module 5 posture is adjusted to reach the ideal arc starting point to start welding. During the welding process, the characteristic points of the weld are scanned to correct the deviation of the welding gun module 5. The actual distance of one rotation of the workpiece is fed back through the photoelectric switch 2, reducing the cumulative error of multiple rotations, thereby solving the problem of rotation error of the workpiece resulting in poor welding quality.

[0038] The roller frame positioner 1 comprises a positioner base 101 , on which an axial rail 102 is fixedly mounted, and a tube length adjustment mechanism 103 is connected to the axial rail 102 , so that the tube length adjustment mechanism 103 can be adjusted to adapt to the length of the workpiece.

[0039] Preferably, the tube length adjustment mechanism 103 includes a fixed end 1031 and a movable end 1032, the fixed end 1031 is fixedly connected to one end of the axial rail 102, and the movable end 1032 is slidably connected to the axial rail 102. Specifically, the positioner base 101 is equipped with a rack and an axial rail 102, and the movable end 1032 is installed on the two axial rails 102 of the positioner base 101. The servo motor is connected to the gear through a coupling, and the gear and the rack of the positioner base 101 move relative to each other, thereby adjusting the distance between the fixed end 1031 and the movable end 1032 to adapt to workpieces of different lengths.

[0040] The fixed end 1031 and the movable end 1032 are both installed with radial tracks 104 , and a roller group 105 is slidably connected to the radial track 104 so as to adapt to the diameter of the workpiece through the roller group 105 .

[0041] Preferably, the roller group 105 includes a driving wheel 1051 and a driven wheel 1052, both of which are slidably connected to the radial track 104, and are connected to a lead screw 1053, the lead screw 1053 is connected to a coupling, and the coupling is connected to a servo motor and a reducer, and the servo motor and the reducer drive the driving wheel 1051 and the driven wheel 1052 to move toward or away from each other, so as to adjust the center distance between the driving wheel 1051 and the driven wheel 1052 to adapt to catheters of different diameters, wherein the centers of the rollers on the same side of the fixed end 1031 and the movable end 1032 are always kept on the same axis to ensure that the welding center axis is horizontal.

[0042] Optional, such as Figure 3 As shown, the driving wheel 1051 and the driven wheel 1052 are both provided with a steel roller 100, a roller bearing 200, a rubber pad 300 and a mounting bracket 400. The driving wheel 1051 also includes a servo motor, a reducer and a transmission shaft for driving. The two ends of the reducer are respectively connected to the roller and the output shaft of the servo motor. The welding speed can be adjusted by adjusting the speed of the servo motor.

[0043] like Figure 2 As shown, a grounding pole lifting device 106 for grounding the workpiece is installed on the positioner base 101 , and the grounding pole lifting device 106 is located inside the driving wheel 1051 and the driven wheel 1052 .

[0044] As a preferred example, Figure 4As shown, the grounding pole lifting device 106 includes a fixed bracket 1061, which is fixedly connected to the positioner base 101, and a pneumatic cylinder 1062 is connected to the fixed bracket 1061, and a linear bearing 1063 is connected to the pneumatic cylinder 1062. A linear guide rod 1064 is slidably connected in the linear bearing 1063 to guide the movement direction of the pneumatic cylinder 1062. A copper contact 1065 is fixedly connected to the top of the pneumatic cylinder 1062, and the copper contact 1065 is in contact with the workpiece, thereby grounding the workpiece.

[0045] As a preferred example, Figure 5 As shown, a pipe end stopping wheel bracket 107 is fixedly connected to the positioner base 101, and a stopping wheel 108 is connected to the pipe end stopping wheel bracket 107. The stopping wheel 108 is located outside the driving wheel 1051 and the driven wheel 1052 to limit the axial direction of the workpiece rotation. The stopping wheel 108 is wrapped with rubber to buffer the collision between the workpiece and the stopping wheel 108. The photoelectric switch 2 is horizontally installed on the pipe end stopping wheel bracket 107. When the workpiece rotates, due to the axial movement of the workpiece, the stopping wheel 108 will contact the pipe end of the workpiece, so that the stopping wheel 108 rotates tangentially along the rotation of the workpiece and buffers the collision between the workpiece and the stopping wheel 108.

[0046] like Figure 6 and Figure 7 As shown, the three-axis motion mechanism 3 includes an X-axis crossbar 301, a Z-axis vertical rod 302 is slidably connected to the X-axis crossbar 301, a slide 304 is provided on the Z-axis vertical rod 302, a slider 305 is slidably connected in the slide 304, a Y-axis crossbar 303 is slidably connected to the slider 305, a robot module 4 is fixedly connected to the Y-axis crossbar 303, and a global vision sensor 306 is fixedly connected to the slider 305 to scan the workpiece data. The global vision sensor 306 can scan the workpiece from multiple positions and generate a three-dimensional model of the workpiece to obtain the actual position and posture of the workpiece, so as to correct the motion path planned by offline programming to match it with the actual workpiece posture. A wire feeder 307 is fixedly connected to the Y-axis crossbar 303 to provide welding wire.

[0047] Preferably, the robot is linked to the welding power source 7 via Device-Net. The robot activates the welding program corresponding to the welding machine by retrieving the program number. The robot calls the program number corresponding to the process parameters, which includes process parameters such as welding current and arc closure time. During welding, the preset program number on the welding machine is activated to call the welding parameters. The equipment is controlled by the robot throughout the process.

[0048] As a preferred embodiment, the present invention adopts an electrical integrated control module, which is composed of a robot system, a positioner system and a welding system. The communication interface is used to communicate with each other and link related actions to jointly complete the welding of the workpiece. The integrated control module is equipped with a sensor capable of automatically detecting faults and reporting fault codes. The welding system is integrated with the host system and directly displayed on the industrial computer corresponding to the welding system to achieve association with the production task. At the same time, the welding should be able to interconnect with the system through the interface, and the specific communication format is negotiated by both parties.

[0049] For conduits of different lengths, diameters, and wall thicknesses, the roller spacing of the roller positioner 1, the spacing between the fixed end 1031 and the movable end 1032 of the tube length adjustment mechanism 103, and the roller rotation speed are all different, and need to be precisely coordinated with the robot welding system through algorithms.

[0050] The operation process of the present invention is as follows:

[0051] The operator hoists the workpiece onto the roller positioner 1, and magnetically attracts the marker to the bottom of the workpiece, and determines the rotation starting point through the feedback signal of the photoelectric switch 2. The global visual sensor 306 scans the actual clamping posture of the workpiece, adjusts the offline programming planning path, the three-axis motion mechanism 3 and the robot module 4 move, the welding gun module 5 reaches the welding starting position, the roller positioner 1 rotates at a predetermined rotation speed, and the laser tracking sensor 6 starts scanning the weld to obtain the weld height, gap, groove angle data and groove center point. After completing a round of groove scanning, the host computer performs multi-layer and multi-channel planning and matches the corresponding welding process parameter program number based on the acquired weld scanning data.

[0052] Then the weld seam positioning is turned on, the welding gun module 5 reaches the arc starting point of the weld bead planning, and welding begins. After welding one layer, the laser tracking sensor 6 returns to the welding starting point and rescans the weld seam data. The host computer adjusts the weld bead position and welding process parameters according to the scanning results. The welding gun continues to weld the next layer until the welding of the entire groove is completed. Finally, the robot module 4 is reset, and the operator unloads the workpiece and loads the new workpiece onto the roller frame positioner 1.

[0053] The present invention realizes automated welding through the precise coordination of the robot module 4 and the roller frame positioner 1, reduces manual intervention and operation difficulty, and has a high degree of automation. The application of the global vision sensor 306 ensures the accuracy of the welding position and posture, improves the welding quality, and the pipe length adjustment mechanism 103 and the roller group 105 can be automatically adjusted according to the different sizes of the workpiece to adapt to various working conditions, reduce the harm of welding smoke and high temperature to operators, and improve the working environment.

[0054] Obviously, the above embodiments of the present invention are merely examples for clearly illustrating the present invention, and are not intended to limit the embodiments of the present invention. For those skilled in the art, other different forms of changes or modifications can be made based on the above description. It is not necessary and impossible to list all the embodiments here. Any modifications, equivalent substitutions and improvements made within the spirit and principles of the present invention should be included in the protection scope of the claims of the present invention.

Claims

1. An intelligent welding robot system for a deepwater jacket reinforcement ring, characterized in that: It includes a roller frame positioner for clamping and driving the workpiece to rotate. The roller frame positioner is provided with a photoelectric switch, which measures the rotation distance of the workpiece. Three-axis motion mechanisms and robot modules are provided on both sides of the roller frame positioner. The robot module is installed on the three-axis motion mechanism so that the three-axis motion mechanism drives the robot module to move linearly along the XYZ axis. A welding gun module is provided on the robot module, including two welding guns and a laser tracking sensor. The laser tracking sensor realizes the positioning of the weld and corrects the trajectory deviation caused by welding deformation.

2. The intelligent welding robot system for deepwater jacket reinforcement ring according to claim 1 is characterized in that: The control module realizes precise linkage between the roller frame positioner and the robot, realizes weld tracking and correction through laser tracking sensors, has the functions of detecting workpiece anti-movement and sliding compensation, and corrects the position in real time, thereby realizing double-sided double-arc robot bottom welding and double-sided four-wire filling welding.

3. The intelligent welding robot system for deepwater jacket reinforcement ring according to claim 1 is characterized in that: The global vision sensor realizes automatic positioning of the workpiece and guides the welding robot to autonomously move to the circumferential seam welding position.

4. The intelligent welding robot system for the reinforcement ring of a deepwater jacket according to claim 1 is characterized in that: During the welding process, the welding wire feeding speed is intelligently adjusted according to the assembly status of the workpieces to adapt to automatic bottom sealing under different gap conditions.

5. The intelligent welding robot system for deepwater jacket reinforcement ring according to claim 1 is characterized in that: It can realize automatic filling of multi-layer and multi-pass welding of thick plates.

6. The intelligent welding robot system for the reinforcement ring of a deepwater jacket according to claim 1 is characterized in that: The roller frame positioner comprises a positioner base, an axial track is fixedly installed on the positioner base, and a pipe length adjustment mechanism is connected to the axial track so as to adapt to the length of the workpiece by adjusting the pipe length adjustment mechanism.

7. The intelligent welding robot system for the reinforcement ring of a deepwater jacket according to claim 6 is characterized in that: The tube length adjustment mechanism comprises a fixed end and a movable end, wherein the fixed end is fixedly connected to one end of the axial track, and the movable end is slidably connected to the axial track.

8. The intelligent welding robot system for the reinforcement ring of a deepwater jacket according to claim 7 is characterized in that: The fixed end and the movable end are both provided with radial tracks, and roller groups are slidably connected to the radial tracks so as to adapt to the diameter of the workpiece through the roller groups.

9. The intelligent welding robot system for the reinforcement ring of a deepwater jacket according to claim 8, characterized in that: The roller group includes a driving wheel and a driven wheel, both of which are slidably connected to the radial track, and both of which are connected to a lead screw, which is connected to a coupling, and which is connected to a servo motor and a reducer. The servo motor and the reducer drive the driving wheel and the driven wheel to move toward or away from each other.

10. The intelligent welding robot system for the reinforcement ring of a deepwater jacket according to claim 9, characterized in that: A grounding pole lifting device for grounding the workpiece is installed on the positioner base, and the grounding pole lifting device is located on the inner side of the driving wheel and the driven wheel.

11. The intelligent welding robot system for the reinforcement ring of a deepwater jacket according to claim 10, characterized in that: The grounding pole lifting device includes a fixed bracket, which is fixedly connected to the positioner base, a pneumatic cylinder is connected to the fixed bracket, a linear bearing is connected to the pneumatic cylinder, a linear guide rod is slidably connected in the linear bearing to guide the movement direction of the pneumatic cylinder, and a copper contact is fixedly connected to the top of the pneumatic cylinder, which contacts the workpiece to ground the workpiece.

12. The intelligent welding robot system for deepwater jacket reinforcement ring according to claim 9, characterized in that: A pipe end stop wheel bracket is fixedly connected to the positioner base, and a stop wheel is connected to the pipe end stop wheel bracket. The stop wheel is located outside the driving wheel and the driven wheel to limit the axial direction of the workpiece rotation. The stop wheel is wrapped with rubber to cushion the collision between the workpiece and the stop wheel. The photoelectric switch is horizontally installed on the pipe end stop wheel bracket.

13. The intelligent welding robot system for deepwater jacket reinforcement ring according to claim 12, characterized in that: The three-axis motion mechanism includes an X-axis crossbar, a Z-axis vertical rod is slidably connected to the X-axis crossbar, a slide groove is provided on the Z-axis vertical rod, a slider is slidably connected in the slide groove, a Y-axis crossbar is slidably connected to the slider, a robot module is fixedly connected to the Y-axis crossbar, and a global vision sensor is fixedly connected to the slider to scan workpiece data.

14. The intelligent welding robot system for deepwater jacket reinforcement ring according to claim 13, characterized in that: A wire feeder is fixedly connected to the Y-axis crossbar to provide welding wire.

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