Intelligent manufacturing method and system for complex special-shaped guardrail stand column

Abstract

The invention discloses an intelligent manufacturing method and system for a complex special-shaped guardrail stand column. Advanced equipment and processes such as numerical control laser blanking, digital bending, portable machining, a special groove assembling tool, laser derusting, robot welding, mechanical hydraulic assembling and splicing, a correcting device and an informatization platform are used; the geometric dimension of the complex special-shaped guardrail stand column is controllable, weld joints and overall appearance forming are excellent, the problem of streamlined manufacturing of complex special-shaped guardrail stand column steel structure machining is successfully solved, and the overall intelligent manufacturing level of steel guardrails is also improved through design and use of digital, mechanical and exclusive equipment and tools. And the welding path of the welding robot is optimized through AI scanning and a locating tracking algorithm, accurate welding is conducted on a welding seam, after welding is completed, the welding surplus height is obtained through a laser scanner, a polishing robot is controlled to conduct surplus height polishing through a PID control algorithm, and the welding and polishing efficiency and precision can be effectively improved.

Description

Technical Field

[0001] The present invention relates to the technical field of guardrail post manufacturing, and in particular to an intelligent manufacturing method and system for complex special-shaped guardrail posts. Background Art

[0002] With the rapid development of modern transportation infrastructure, bridge engineering has been widely used at home and abroad. As an important part of the bridge, the bridge guardrail not only plays a protective role, but also affects the overall appearance and safety of the bridge. In recent years, with the continuous innovation of bridge design and technological advancement, the guardrail structure has become more and more complex, especially the special-shaped and multi-jointed guardrail columns, the manufacturing difficulty has increased significantly. The traditional guardrail column manufacturing method can no longer meet the current engineering requirements for precision and quality. Therefore, it is particularly important to develop an efficient intelligent manufacturing method for complex special-shaped guardrail columns.

[0003] At present, the manufacturing of the main structural plate units of bridge steel structures has gradually achieved factoryization, standardization, automation and intelligence, especially in major engineering projects such as the Hong Kong-Zhuhai-Macao Bridge, the Shenzhen-Zhongshan Link, and the Huangmaohai Cross-sea Channel, and has achieved remarkable results. However, the manufacturing level of steel guardrails, which are auxiliary structures of the bridge deck, still remains at the stage of traditional manual operations. The existing technology mainly relies on manual operation, and there are a large number of manual marking, manual cutting and welding processes in the production process, resulting in low production efficiency and unstable product quality. In addition, traditional manufacturing methods are difficult to accurately control the geometric dimensions of complex special-shaped guardrail columns, especially in structures with multiple joints and inward folding, where welding deformation and dimensional deviation are particularly prominent.

[0004] The shortcomings of the existing technology are mainly reflected in the following aspects: first, the traditional manufacturing method has a low degree of automation and low production efficiency, which makes it difficult to meet the requirements of large-scale production and high quality; second, human errors are prone to occur during manual operation, resulting in unstable product quality, especially for guardrail columns with complex and special-shaped structures, the geometric dimensional accuracy is difficult to guarantee; third, the existing technology lacks effective information management means, and production data is difficult to monitor and adjust in real time, which is not conducive to the optimization and improvement of the production process. These problems have seriously restricted the further development of the steel guardrail manufacturing industry. Summary of the invention

[0005] In view of the above defects or improvement needs of the prior art, the purpose of the present invention is to provide a method and system for intelligent manufacturing of complex and special-shaped guardrail posts. By designing and building the first domestic assembly-line intelligent manufacturing system for guardrail posts, using advanced CNC laser cutting, digital bending, portable machining, special groove assembly tooling, laser rust removal, robot welding, mechanized hydraulic assembly, correction devices, information platform and other equipment and processes, the geometric dimensions of complex and special-shaped guardrail posts are controllable, and the welds and overall appearance are excellent. The problem of assembly-line manufacturing of complex and special-shaped guardrail posts steel structures has been successfully solved. The design and use of digital, mechanized and proprietary equipment and tooling have also improved the overall intelligent manufacturing level of steel guardrails, achieving stable and reliable product quality, greatly increased output, reduced costs, and the level of intelligence and informatization has entered a new stage.

[0006] According to a first aspect of the present invention, there is provided a method for intelligently manufacturing a complex and special-shaped guardrail column, comprising: S100, establishing a solid model of a complex special-shaped guardrail column and its components, and generating geometric dimensions of parts processing; the parts include a column shaft U-plate, a web, an inner stiffener, a bracket, a flange seat plate, and an outer stiffener; the column shaft U-plate includes an outer column shaft U-plate, an inner column shaft upper U-plate, and an inner column shaft lower U-plate; S200, accurately cutting and marking the column U-plate, web, inner stiffener, bracket and base plate, machining the column U-plate with a portable mobile groove equipment, and digitally bending the column U-plate and the bracket with a high-precision digital bending device; S300, designing a special positioning fixture to assemble the outer U-plate, the web and the inner stiffener of the column to form a first structure, and using a multi-axis welding robot to weld the first structure through AI scanning and position tracking algorithm, and using a digital hydraulic device to assemble the first structure with the inner upper U-plate and the inner lower U-plate of the column to form a second structure; S400, using a multi-axis welding robot to weld the column shaft U-plate butt weld on the second structure through AI scanning and position tracking algorithm, and using a special gantry workstation to grind the excess height of the column shaft U-plate butt weld on the second structure; S500. Design a special column assembly device to assemble the second structure with the flange seat plate and the bracket to form a third structure, and design a special 360° rotating displacement welding station to weld the column body and the flange plate weld on the third structure, use a digital hydraulic correction device to correct the angle between the column body and the flange on the third structure, and complete the column manufacturing.

[0007] Furthermore, the welding objective function of the AI ​​scanning and position tracking algorithm includes: In the formula, Represents the welding gun offset; Represents welding speed; Represents the welding gun angle; Represents the weight coefficient.

[0008] Furthermore, the method further includes: after the welding robot completes welding, collecting the weld excess height through a sensor, and using a PID control algorithm to control a grinding tool to grind the weld excess height.

[0009] Furthermore, the AI ​​scanning and position tracking algorithm also includes: in the welding or grinding process, real-time detection of the offset of the key matching parts, and adjustment of the position of the welding gun or grinding head according to the offset: In the formula, represents the adjustment factor; represents the position of the welding gun or grinding head at the i-th adjustment; Indicated in The position of the welding gun or grinding head during the first adjustment; Indicates the offset; Represents the actual position of the part detected by the sensor in real time at time t; Represents the ideal position that the expected part should be in at time t according to the design requirements and preset path.

[0010] Furthermore, the dedicated 360° rotating and variable position welding station constantly controls the motor rotation speed to ensure continuous welding of circumferential flat welds, optimizes the traditional welding method of "people rotating around objects" to a welding method of "objects rotating and people fixed" station, and adjusts the rotation speed to match the welding speed before welding, completing the welding of the column body and flange plate weld as the column rotates.

[0011] Furthermore, the design of a special column assembly device in step S500, assembling the second structure with the flange seat plate and the bracket to form a third structure includes: placing the bracket and the second structure column in a vertical state on a supporting platform having three baselines, namely, a horizontal baseline, a transverse baseline and a vertical baseline, and a bracket spiral positioning device for adjustment and assembly; based on the bracket spiral positioning device, the height of the bracket and the flange seat plate is adjusted through the horizontal baseline, the left and right of the bracket and the flange seat plate are adjusted through the vertical baseline, and the front and back of the bracket and the flange seat plate are adjusted through the transverse baseline.

[0012] According to the second aspect of the present invention, there is provided an intelligent manufacturing system for complex and special-shaped guardrail columns, which is used for the above-mentioned intelligent manufacturing method for complex and special-shaped guardrail columns, including: a control center, a material preparation area, a parts processing area, an assembly area, an intelligent welding area, a grinding area, a correction area and a semi-finished product area. The control center also includes a control system, through which the production data is mastered, the welding parameters are monitored and adjusted, real-time video monitoring and control of the production sites of other functional areas are performed, so as to realize dynamic management and control of the intelligent system for complex and special-shaped columns.

[0013] Furthermore, the dynamic control of the intelligent system for complex special-shaped columns includes: controlling the CNC laser cutting equipment to realize the cutting program, cutting statistics and process reporting; controlling the digital bending device to realize real-time adjustment of bending parameters, bending angles and dimensions; controlling the multi-axis welding robot to adaptively adjust and group-control the welding parameters according to the gap and programmed position; controlling the digital hydraulic correction device to realize the quantification of the correction pressure of the angle between the column body and the flange.

[0014] Furthermore, the control system also includes a visually assisted programming module, which is used to identify the weld by taking photos with an industrial camera provided on the multi-axis welding robot, quickly generate a welding program, and control the multi-axis welding robot to accurately complete welding; The control system also includes a laser positioning and tracking module, which is used to accurately measure, locate and track the weld through a high-precision laser profile sensor.

[0015] Furthermore, the control system also includes an error prediction module, which is used to collect real-time data of each functional area through sensors and generate an error vector: ; In the formula, represents the error vector of the ith measurement point; The guardrail post part design model representing the i-th measurement point; represents the actual processing data point cloud of the ith measurement point; represents the overall error vector.

[0016] Beneficial effects of the present invention: 1. The intelligent manufacturing method of complex special-shaped guardrail posts in the present invention is designed to build a streamlined guardrail post intelligent manufacturing system, using advanced CNC laser cutting, digital bending, portable machining, special groove assembly tooling, laser rust removal, robot welding, mechanized hydraulic assembly, correction device, information platform and other equipment and control algorithms to make the geometric dimensions of complex special-shaped guardrail posts controllable, and the welds and overall appearance are excellent. The problem of streamlined manufacturing of complex special-shaped guardrail post steel structure processing is successfully solved. The design and use of digital, mechanized, and proprietary equipment and tooling also improves the overall intelligent manufacturing level of steel guardrails, achieving stable and reliable product quality, greatly increased output, and reduced costs, and the level of intelligence and informatization has entered a new stage.

[0017] 2. The intelligent manufacturing method of complex special-shaped guardrail columns in the present invention uses a welding robot to optimize the welding path of the welding robot through AI scanning and position tracking algorithms, and accurately welds the welds. After welding is completed, the welding excess height is obtained through a laser scanner, and a PID control algorithm is used to control the grinding robot to perform excess height grinding, which can effectively improve the efficiency and accuracy of welding and grinding.

[0018] 3. The complex and special-shaped guardrail column intelligent manufacturing system in the present invention successfully solves the problem of streamlined manufacturing of complex and special-shaped guardrail column steel structure processing by integrating advanced CNC laser cutting, digital bending, portable machining, special groove assembly tooling, laser rust removal, robot welding, mechanized hydraulic assembly, correction devices and information platform equipment and processes. The system realizes the precise control of the geometric dimensions of the guardrail column and the excellent quality of the weld and the overall appearance, which greatly improves the intelligent manufacturing level of steel guardrails. The system uses AI scanning and position tracking algorithms to optimize the welding path, ensuring the accuracy and efficiency of welding, and realizes precise grinding of the weld excess height through the PID control algorithm. In addition, the system has established a feedback closed-loop system for real-time data acquisition and error prediction, and uses a recurrent neural network to optimize the processing path and process parameters in advance to ensure high precision of processing and welding. The vision-assisted programming module, laser positioning tracking module and welding process database included in the control system further enhance the flexibility and adaptability of the system, making product quality more stable and reliable, greatly improving production efficiency and significantly reducing costs, thus pushing the intelligence and informatization level of the steel guardrail manufacturing industry to a new stage.

[0019] Additional aspects and advantages of the present application will be partially given in the following description, which will become apparent from the following description, or will be understood through the practice of the present application. BRIEF DESCRIPTION OF THE DRAWINGS

[0020] The above and / or additional aspects and advantages of the present application will become apparent and easily understood from the following description of the embodiments in conjunction with the accompanying drawings, in which: Figure 1 This is a flow chart of the intelligent manufacturing method of complex special-shaped guardrail columns in an embodiment of the present invention; Figure 2 This is a schematic diagram of the structure of a complex special-shaped column in an embodiment of the present invention; Figure 3 Schematic diagram of laser precision cutting and scribing of parts in an embodiment of the present invention; Figure 4 Schematic diagram of groove processing of U-plate parts in an embodiment of the present invention; Figure 5 Schematic diagram of bending of U plate\bracket in an embodiment of the present invention; Figure 6 It is a schematic diagram of the assembly of a special positioning tool for a single groove type in an embodiment of the present invention; Figure 7 Schematic diagram of laser rust removal in a small space in an embodiment of the present invention; Figure 8 Schematic diagram of welding with a stiffened multi-position robot according to an embodiment of the present invention; Fig. 9 Schematic diagram of column assembly in an embodiment of the present invention; Fig.10 Schematic diagram of multi-axis robot welding in an embodiment of the present invention; Fig.11 Schematic diagram of welding seam grinding at a dedicated workstation in an embodiment of the present invention; Fig.12 It is a schematic diagram of the overall assembly station in an embodiment of the present invention; Fig.13 360° rotation displacement welding schematic diagram of the embodiment of the present invention; Fig.14 Schematic diagram of digital hydraulic correction angle in an embodiment of the present invention; Fig.15 It is a layout diagram of the intelligent manufacturing system for complex special-shaped guardrail columns in an embodiment of the present invention; Fig.16 Schematic diagram of laser positioning and tracking in an embodiment of the present invention. DETAILED DESCRIPTION

[0021] The present invention will be further described in detail below in conjunction with the accompanying drawings and embodiments. It is to be understood that the specific embodiments described herein are only used to explain the present invention, rather than to limit the present invention. It should also be noted that, for ease of description, only parts related to the present invention, rather than all structures, are shown in the accompanying drawings.

[0022] In the description of the present invention, unless otherwise clearly specified and limited, the terms "connected", "connected", and "fixed" should be understood in a broad sense, for example, it can be a fixed connection, a detachable connection, or an integral connection; it can be a mechanical connection or an electrical connection; it can be a direct connection or an indirect connection through an intermediate medium, it can be the internal connection of two elements or the interaction relationship between two elements. For ordinary technicians in this field, the specific meanings of the above terms in the present invention can be understood according to specific circumstances.

[0023] Those skilled in the art will appreciate that, unless otherwise stated, the singular forms "a", "an", "said" and "the" used herein may also include plural forms. It should be further understood that the term "comprising" used in the specification of the present application refers to the presence of the features, integers, steps, operations, elements and / or components, but does not exclude the presence or addition of one or more other features, integers, steps, operations, elements, components and / or combinations thereof.

[0024] It will be understood by those skilled in the art that, unless otherwise defined, all terms (including technical terms and scientific terms) used herein have the same meaning as the general understanding of those skilled in the art to which this application belongs. It should also be understood that terms such as those defined in general dictionaries should be understood to have the same meaning as in the context of the prior art, and will not be interpreted with an idealized or overly formal meaning unless specifically defined as in the embodiments of this application.

[0025] The present invention provides a method and system for intelligent manufacturing of complex and special-shaped guardrail posts. The method designs and builds the first domestic assembly-line intelligent manufacturing system for guardrail posts, and uses advanced CNC laser cutting, digital bending, portable machining, special groove assembly tooling, laser rust removal, robot welding, mechanized hydraulic assembly, correction devices, information platforms and other equipment and processes to make the geometric dimensions of complex and special-shaped guardrail posts controllable, and the welds and overall appearance are excellent. The method successfully solves the problem of assembly-line manufacturing of complex and special-shaped guardrail post steel structure processing. The design and use of digital, mechanized and proprietary equipment and tooling also improves the overall intelligent manufacturing level of steel guardrails, achieves stable and reliable product quality, greatly increases output, reduces costs, and enters a new stage of intelligence and informationization.

[0026] Embodiment 1: like Figure 1 As shown, an embodiment of the present invention provides an intelligent manufacturing method for complex special-shaped guardrail columns, comprising: S100, using digital modeling software to complete the solid modeling of the guardrail column and its components, and generate the geometric dimensions of the parts processing, the parts include the column body U plate, the web, the inner stiffener, the bracket and the flange seat plate, the outer stiffener, the column body U plate includes the column body outer side U plate, the column body inner side upper U plate and the column body inner side lower U plate; like Figure 2 As shown, firstly, digital modeling software is used to complete entity modeling, and the geometric dimensions of part processing are generated, and the process processing amount is accurately added to ensure the accuracy of the processing dimensions. The generated parts include: an outer U-plate 101 of the column body, an upper U-plate 102 on the inner side of the column body, and a lower U-plate 103 on the inner side of the column body; a web 201; internal stiffeners 301 to 305; a first bracket 401, a second bracket 402, a third bracket 403, and a fourth bracket 404; a flange seat plate 501; and an external stiffener 601.

[0027] S200, using CNC laser blanking equipment to accurately blank and mark the column U-plate, web, internal stiffener, bracket and base plate, then using portable mobile beveling equipment to machine the column U-plate, and finally using a high-precision digital bending device to digitally bend the column U-plate and the bracket; Specifically, Figure 3 As shown, the outer U plate 101 of the column body, the upper U plate 102 on the inner side of the column body, the lower U plate 103 on the inner side of the column body, the web 201, the first inner stiffener 301, the second inner stiffener 302, the third inner stiffener 303, the fourth inner stiffener 304 and the fifth inner stiffener 305, the first bracket 401, the second bracket 402, the third bracket 403, the fourth bracket 404 and the flange seat plate 501 are automatically programmed and added with the process cutting amount, and then directly imported into the most advanced CNC laser cutting equipment to complete precise cutting and marking, with high cutting efficiency, cutting and marking deviation accuracy of 0.5mm, good cutting surface and roughness, and the cutting workload statistics and work reporting can be completed in real time in the information system, reducing repeated cutting errors and improving the efficiency of manual statistics and manual reporting.

[0028] like Figure 4 As shown, the U-plate butt groove of the column body is machined using a portable mobile groove equipment. The equipment has a machining accuracy of 0.5mm, high efficiency, and small machining deformation, which solves the problem of difficulty in controlling thermal cutting groove deformation.

[0029] like Figure 5 As shown, after the groove processing of the U plate 101 on the outer side of the column body, the upper U plate 102 on the inner side of the column body and the lower U plate 103 on the inner side of the column body is completed, the first bracket 401, the second bracket 402, the third bracket 403 and the fourth bracket 404 are laser cut, cut and marked, and then a high-precision digital bending machine is used to quantitatively control the bending angle and bending size, so as to achieve precise control of the geometric dimensional accuracy for the subsequent column body splicing size and gap.

[0030] S300, designing a special positioning fixture to assemble the outer U-plate, the web and the inner stiffener of the column to form a first structure, and using a multi-axis welding robot to weld the first structure through AI scanning and position tracking algorithm, and finally using a digital hydraulic device to assemble the first structure with the inner upper U-plate and the inner lower U-plate of the column to form a second structure; The welding objective functions of the AI ​​scanning and positioning tracking algorithm include: In the formula, Represents the welding gun offset; Represents welding speed; Represents the welding gun angle; Represents the weight coefficient. After the welding robot completes welding, it is also necessary to collect the weld excess height through the sensor and use the PID control algorithm to control the grinding tool to grind the weld excess height.

[0031] Specifically, Figure 6 As shown, the U-plate 101 on the outside of the column, the web 201, the first internal stiffener 301, the second internal stiffener 302, the third internal stiffener 303, the fourth internal stiffener 304 and the fifth internal stiffener 305 are designed with a special positioning fixture for assembly. By using the fixed size of the column support and the positioning plate stiffener distance positioning reference, the assembly accuracy and efficiency are improved, and the deviation is controlled at 0.5mm to ensure the force requirements. Compared with the traditional marking and assembly process, the work efficiency is improved by 3 times.

[0032] like Figure 7 As shown, handheld laser rust removal equipment is used to complete the grinding of the welds of the column U plate 101, the web 201, the first internal stiffener 301, the second internal stiffener 302, the third internal stiffener 303, the fourth internal stiffener 304 and the fifth internal stiffener 305, thereby solving the problem that conventional grinding equipment in a confined small space cannot complete the rust removal of the welds. At the same time, the rust removal cleanliness quality is improved, and the rust removal efficiency is at least 2 times higher than that of ordinary manual work.

[0033] like Figure 8 As shown, the column U-plate 101, the web 201, the first internal stiffener 301, the second internal stiffener 302, the third internal stiffener 303, the fourth internal stiffener 304 and the fifth internal stiffener 305 are welded by a multi-axis robot. The multi-axis robot forms a welding path through AI scanning, and realizes a smooth transition of the horizontal and vertical welds 701 through laser positioning tracking. The weld leg size deviation is 1mm, the weld appearance is excellent, and the welding efficiency is increased by 1.5 times.

[0034] like Fig. 9As shown, after the column body U-plate 101 and the web 201, the first internal stiffener 301, the second internal stiffener 302, the third internal stiffener 303, the fourth internal stiffener 304 and the fifth internal stiffener 305 are welded together into a groove, a digital hydraulic device is designed for the column body assembly station to combine the completed primary groove with the column body U-plates 102 and 103 to form a hexagonal variable-section inward-folded column. The column body assembly angle is less than 0.1°, and the gap is controlled within 1 mm.

[0035] S400, using a multi-axis welding robot to weld the column shaft U-plate butt weld on the second structure through AI scanning and position tracking algorithm, and using a special gantry workstation to grind the excess height of the column shaft U-plate butt weld on the second structure; like Fig.10 As shown, the column U-plate butt weld 801 is welded by a multi-axis robot, and the welding is completed through AI scanning and positioning tracking. The penetration depth and weld leg size both reach a deviation of 1mm. The weld appearance has a high one-time flaw detection pass rate, and the welding efficiency is more than twice that of traditional manual welding.

[0036] like Fig.11 As shown in the figure, the 801 excess height of the U-plate weld of the column body is polished using a special gantry-type station. The grinding equipment is placed on the gantry and can be moved. The grinding is mechanized and 50 columns can be completed every day, which is more than 3 times more efficient than manual grinding and reduces labor intensity. The excess height deviation of the weld is as high as 0.2mm, and the six deformation arc parts are smooth and even, which is easy to paint and beautiful.

[0037] S500. Design a special column assembly device to assemble the second structure with the flange base plate and the bracket to form a third structure, and design a special 360° rotating displacement welding station to weld the column body and the flange plate weld on the third structure. Finally, use a digital hydraulic correction device to correct the angle between the column body and the flange on the third structure to complete the column production.

[0038] like Fig.12 As shown in the figure, a special column assembly equipment is designed to place the bracket and the column in a vertical state on a support platform with three types of reference lines. Among them, the horizontal baseline is used to control the height of the bracket hole and the flange bottom plate, the vertical baseline controls the left and right of the bracket and the flange, and the horizontal baseline is used to control the front and back of the bracket and the flange bottom plate; the height and front and back position relationship are controlled by the positioning rod 5, the rotating shaft 4 and the positioning shaft 6 at different positions. This equipment achieves a deviation of 1mm in angle, size and connection relationship, and the number of total columns assembled per day is increased by 2 times.

[0039] like Fig.13As shown, a special 360° rotating position welding station is designed for the weld 801 between the column body and the flange plate. The motor rotation speed is controlled at 6° / second to ensure continuous welding of the circumferential flat weld. The traditional welding method of "people rotating around objects" is optimized to a welding method of "objects rotating and people fixed". Before welding, the rotation speed of the position welding equipment is adjusted to match the welding speed, and a fixed welding station is set. The welding of the column and the flange weld is completed as the column rotates. The foot size deviation is 0.5mm, and the appearance is uniform, continuous and excellent.

[0040] like Fig.14 As shown, there is deformation in the weld between the column body and the flange base plate 501 after welding. A special digital hydraulic correction device is designed. According to the inclination angle and size deviation value, the hydraulic adjustment device is digitally controlled to ensure that the angle deviation between the seat plate and the column is controlled within 1mm.

[0041] Embodiment 2: like Fig.15 As shown, on the basis of Example 1, an embodiment of the present invention provides an intelligent manufacturing system for complex special-shaped guardrail columns, including: a control center, a material preparation area, a parts processing area, an assembly area, an intelligent welding area, a grinding area, a correction area and a semi-finished product area, the control center includes a control system, through which the production data is mastered, the welding parameters are monitored and adjusted, and real-time video monitoring and control of the production sites of other functional areas are performed, so as to realize dynamic control of the intelligent system of complex special-shaped columns, including: controlling the CNC laser blanking equipment to realize the blanking procedure, blanking statistics and process reporting; controlling the digital bending device to realize real-time adjustment of bending parameters, bending angles and dimensions; controlling the multi-axis welding robot to adaptively adjust and group-control the welding parameters according to the gap and programmed position; controlling the digital hydraulic correction device to realize quantification of the correction pressure of the angle between the column body and the flange.

[0042] Furthermore, the control system also includes a visually assisted programming module, which is used to identify welds by taking photos with an industrial camera installed on the multi-axis welding robot, quickly generate welding programs, and control the multi-axis welding robot to accurately complete welding. The visually assisted programming function is a function of quickly generating programs by taking photos with a camera to identify welds. The system consists of an industrial camera, a visual recognition module, and a program generation module. An industrial camera is used for taking photos. The camera is installed on the robot cantilever. The operator selects the weld position according to the photo results, completes the weld position identification, and then generates the welding program. Compared with traditional teaching programming, this function has the advantages of more convenient programming operation, less workload, and quick program generation; it is more suitable for small batch and multi-specification steel structure weld programming; and it is not affected by workshop light and workpiece surface conditions.

[0043] like Fig.16As shown, the control system also includes a laser positioning tracking module, which is used to accurately measure, locate and track the weld through a high-precision laser profile sensor. The laser module uses a high-precision laser profile sensor to accurately measure, locate and track the weld. The laser module has: high tracking accuracy, accuracy of ±0.5mm; good anti-interference performance, using a variety of filtering and reflection elimination methods, suitable for a variety of welds Surface grinding and processing status; the installation position of the laser can be changed arbitrarily to facilitate welding and avoid interference; and it has the advantages of multiple functions such as positioning and tracking.

[0044] Furthermore, the control system also includes an error prediction module, which is used to collect real-time data of each functional area through sensors and generate an error vector: ; In the formula, represents the error vector of the ith measurement point; The guardrail post part design model representing the i-th measurement point; represents the actual processing data point cloud of the ith measurement point; Represents the overall error vector. Finally, the error distribution of subsequent processes is predicted through a recurrent neural network, and the processing path and process parameters are optimized in advance.

[0045] Furthermore, the control system also includes a welding process package and a welding process database. The welding process package provides a complete welding process solution for the welding robot, including welding process, welding sequence, multi-layer multi-pass welding process parameter planning, welding gun posture, welding gun position, welding machine process mode, welding parameters at different positions, etc. The result of the welding decision is generated into a complete welding program, which is issued to the robot and the welding machine to control the precise execution of the welding program, adjust the welding process, welding gun posture, and welding gun position in real time, adapt to the real weld state, and achieve high-quality welding. The welding process database is the basis for realizing intelligent welding, and provides complete welding process parameters for welding decisions, including basic welding process parameters for standard welds of different specifications and welding process parameters for different weld errors. The welding process database in this system has a wide range of process parameters covering a variety of materials; suitable for a variety of joint forms; process parameters fully consider the workpiece structure, welded joint microstructure, mechanical properties, and internal quality; including multi-layer multi-pass welding process, automatic planning of welding layer number; support for pulse process mode, which can obtain lower heat input; and compatible with a large error range. The welding process library provides accurate welding process parameters for robot equipment to realize intelligent welding of target workpieces. The welding process library supports process calls of intelligent welding robots to realize welding of standard welds. It also supports adaptive welding functions and provides real-time process adjustment with an accuracy of 0.5mm.

[0046] Furthermore, the control system can also perform adaptive adjustment on the welding process. The adaptive adjustment of the welding process is to adjust the welding process parameters and the welding gun position in real time according to the actual situation such as irregular welding trajectory. In contrast, the trajectory, posture and welding process specifications of the traditional robot using teaching programming are too simple and cannot adapt to the changes in the weld. It is easy to produce process defects such as welding deviation, welding penetration, unwelded, and incomplete welding during welding. In order to adapt to the larger gap, the use of high current to cover brings about excessive heat input, resulting in a decrease in the mechanical properties of the joint.

[0047] It should be understood that, although the steps in the flowchart of the accompanying drawings are displayed in sequence as indicated by the arrows, these steps are not necessarily executed in sequence in the order indicated by the arrows. Unless otherwise specified herein, there is no strict order restriction on the execution of these steps, and they can be executed in other orders. Moreover, at least a part of the steps in the flowchart of the accompanying drawings may include multiple sub-steps or multiple stages, and these sub-steps or stages are not necessarily executed at the same time, but can be executed at different times, and their execution order is not necessarily sequential, but can be executed in turn or alternately with other steps or at least a part of the sub-steps or stages of other steps.

[0048] The above description is only a partial implementation method of the present application. It should be pointed out that for ordinary technicians in this technical field, several improvements and modifications can be made without departing from the principles of the present application. These improvements and modifications should also be regarded as the scope of protection of the present application.

Claims

1. A method for intelligent manufacturing of complex and special-shaped guardrail columns, characterized in that: include: S100, establishing a solid model of a complex special-shaped guardrail column and its components, and generating geometric dimensions of parts processing; the parts include a column shaft U-plate, a web, an inner stiffener, a bracket, a flange seat plate, and an outer stiffener; the column shaft U-plate includes an outer column shaft U-plate, an inner column shaft upper U-plate, and an inner column shaft lower U-plate; S200, accurately cutting and marking the column U-plate, web, inner stiffener, bracket and base plate, machining the column U-plate with a portable mobile groove equipment, and digitally bending the column U-plate and the bracket with a high-precision digital bending device; S300, designing a special positioning fixture to assemble the outer U-plate, the web and the inner stiffener of the column to form a first structure, and using a multi-axis welding robot to weld the first structure through AI scanning and position tracking algorithm, and using a digital hydraulic device to assemble the first structure with the inner upper U-plate and the inner lower U-plate of the column to form a second structure; S400, using a multi-axis welding robot to weld the column shaft U-plate butt weld on the second structure through AI scanning and position tracking algorithm, and using a special gantry workstation to grind the excess height of the column shaft U-plate butt weld on the second structure; S500. Design a special column assembly device to assemble the second structure with the flange seat plate and the bracket to form a third structure, and design a special 360° rotating displacement welding station to weld the column body and the flange plate weld on the third structure, use a digital hydraulic correction device to correct the angle between the column body and the flange on the third structure, and complete the column manufacturing.

2. According to claim 1, a complex and special-shaped guardrail column intelligent manufacturing method is characterized in that: The welding objective function of the AI ​​scanning and position tracking algorithm includes: In the formula, Represents the welding gun offset; Represents welding speed; Represents the welding gun angle; Represents the weight coefficient.

3. A method for intelligently manufacturing complex and special-shaped guardrail posts according to claim 2, characterized in that: Also includes: After the welding robot completes welding, the weld excess height is collected through the sensor, and the PID control algorithm is used to control the grinding tool to grind the weld excess height.

4. According to claim 2, a method for intelligently manufacturing complex and special-shaped guardrail columns is characterized in that: The AI ​​scanning and position tracking algorithm also includes: real-time detection of the offset of key matching parts during welding or grinding, and adjustment of the position of the welding gun or grinding head according to the offset: In the formula, represents the adjustment factor; represents the position of the welding gun or grinding head at the i-th adjustment; Indicated in The position of the welding gun or grinding head during the first adjustment; Indicates the offset; Represents the actual position of the part detected by the sensor in real time at time t; Represents the ideal position that the expected part should be in at time t according to the design requirements and preset path.

5. The intelligent manufacturing method of complex and special-shaped guardrail columns according to claim 1 is characterized in that: The special 360° rotating position welding station constantly controls the motor rotation speed to ensure continuous welding of circumferential flat welds, optimizes the traditional welding method of "people rotating around objects" to a welding method of "objects rotating and people fixed". Before welding, the rotation speed is adjusted to match the welding speed, and the welding of the column body and the flange plate weld is completed as the column rotates.

6. A method for intelligently manufacturing complex and special-shaped guardrail posts according to any one of claims 1 to 5, characterized in that: The special column assembly device designed in step S500 assembles the second structure with the flange seat plate and the bracket to form a third structure, including: placing the bracket and the second structure column in a vertical state on a supporting platform having three baselines, namely, a horizontal baseline, a transverse baseline and a vertical baseline, and a bracket spiral positioning device for adjustment and assembly; based on the bracket spiral positioning device, the height of the bracket and the flange seat plate is adjusted through the horizontal baseline, the left and right of the bracket and the flange seat plate are adjusted through the vertical baseline, and the front and back of the bracket and the flange seat plate are adjusted through the transverse baseline.

7. An intelligent manufacturing system for complex and special-shaped guardrail columns, used in an intelligent manufacturing method for complex and special-shaped guardrail columns according to any one of claims 1 to 6, characterized in that: It includes: control center, material preparation area, parts processing area, assembly area, intelligent welding area, grinding area, correction area and semi-finished product area. The control center also includes a control system, which can grasp production data, monitor and adjust welding parameters, conduct real-time video monitoring and control of production sites in other functional areas, and realize dynamic management and control of complex special-shaped column intelligent systems.

8. The complex and special-shaped guardrail column intelligent manufacturing system according to claim 7 is characterized in that: The dynamic control of the intelligent system for complex special-shaped columns includes: controlling the CNC laser cutting equipment to realize the cutting program, cutting statistics and process reporting; controlling the digital bending device to realize real-time adjustment of bending parameters, bending angles and dimensions; controlling the multi-axis welding robot to adaptively adjust and group-control the welding parameters according to the gap and programmed position; controlling the digital hydraulic correction device to realize the quantification of the correction pressure of the angle between the column body and the flange.

9. A complex and special-shaped guardrail column intelligent manufacturing system according to any one of claims 7 or 8, characterized in that: The control system also includes a visually assisted programming module for identifying welds by taking photos with an industrial camera provided on the multi-axis welding robot, quickly generating a welding program, and controlling the multi-axis welding robot to accurately complete welding; The control system also includes a laser positioning and tracking module, which is used to accurately measure, locate and track the weld through a high-precision laser profile sensor.

10. An intelligent manufacturing system for complex and special-shaped guardrail columns according to any one of claims 7 or 8, characterized in that: The control system also includes an error prediction module, which is used to collect real-time data of each functional area through sensors and generate an error vector: ； In the formula, represents the error vector of the ith measurement point; The guardrail post part design model representing the i-th measurement point; represents the actual processing data point cloud of the ith measurement point; represents the overall error vector.

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