Spraying positioning method for large surface space of steel structure of elevated spraying robot

Abstract

The invention discloses an elevated spraying robot steel structure large-surface space spraying positioning method, and belongs to the technical field of intelligent manufacturing and mechatronics. According to the method, a corresponding overhead spraying robot is selected according to operation requirements; ground advancing tracks of the spraying robots are set in the spraying area, and each spraying robot is provided with a corresponding ground auxiliary operation vehicle system; carrying out overhead spraying robot steel structure large surface space spraying positioning; a spraying path scheme is selected according to the actual operation space and process requirements of the dock; and spraying operation is conducted, and post-treatment work is completed. The method is suitable for large-surface space spraying of the steel structure, and can effectively solve the problems that during spraying operation in the dock, space positioning of a robot is difficult, and the efficiency of manually judging different tracks is low. And meanwhile, effective space positioning control over the robot is achieved, operation station distribution is reasonably planned, the operation quality of the elevated spraying robot is improved, and the equipment operation process is optimized.

Description

Technical Field

[0001] The invention relates to a method for spraying positioning on a large surface space of a steel structure of an elevated spraying robot, and belongs to the field of intelligent manufacturing and mechatronics. Background Art

[0002] The development of new quality productivity in the shipbuilding field is an important part of the digital transformation of the manufacturing industry. With the continuous deepening of the construction of my country's modern industrial system, relevant technical research on various industrial robots in the shipbuilding field has made corresponding progress. Because ships operate in high temperature and high salt environments for a long time, the outer plates are extremely susceptible to corrosion from seawater and atmosphere, as well as the attachment of marine organisms, which can affect the speed of the ship at the least, and damage the structural stability of the ship at the worst, reducing the service life of the ship. For this reason, it is necessary to spray protective paint on the outer plates of the ship, and at the same time ensure high-quality spraying. The existing spraying of the outer plates of ships is carried out manually. Workers use aerial work vehicles with spray guns to spray the outer plates. Multiple people are often required to work together during the operation. In addition, this method also has the risk of falling from high altitudes.

[0003] An overhead spraying robot is used to replace manual labor in spraying large-surface outer panels of ships, which reduces the risk of falling when humans participate in high-altitude operations, avoids direct contact between humans and toxic volatile gases, improves operating efficiency and reduces safety risks. Among them, the low degree of intelligence of spraying equipment, low efficiency of spraying equipment operation management, and high spraying rework rate are important factors restricting the efficiency of ship spraying. Secondly, considering that ship painting is a technical job that integrates chemical, mechanical, electrical, fluid power and other technologies, it has high requirements for the professional skills of operators. Therefore, multiple overhead spraying robots are used to work together to further optimize operating efficiency.

[0004] Controlling the robot to complete the spatial positioning of the steel surface of the hull and the planning of the operation trajectory in the dock is the key to using overhead spray robots to replace manual operations. Due to the limited space in the dock and the large size of the robot, safety hazards are prone to occur during the operation. In addition, the spraying process of the ship's outer plate is complicated, and the distance between the spray gun and the steel surface of the hull directly affects the quality of the paint film and the efficiency of the operation. Unlike manual operations, the spray robot needs to set a preset trajectory according to the painting requirements when operating to prevent paint leakage, repeated spraying, etc., which will delay the progress of the project and affect the economic efficiency of the shipyard. Summary of the invention

[0005] In response to the problems existing in the above-mentioned ship outer plate spraying operation process, the present invention provides a method for spatial spraying positioning of large surfaces of steel structures by an elevated spraying robot, which controls the robot to complete the spatial positioning of the steel surface of the hull and the planning of the operation trajectory in the dock, so as to effectively deal with the problems of difficulty in spatial positioning of the robot during spraying operations in the dock and low efficiency of manual judgment of different trajectories.

[0006] The technical solution adopted by the present invention is: a method for positioning large-surface space spraying of an elevated spraying robot steel structure, the method comprising the following steps: Step S1: Select the number of hulls and the outer surface operation area of ​​the hull that the spraying robot needs to perform the spraying operation. According to the operation needs in the dock, select the corresponding three overhead spraying robots, namely the first spraying robot, the second spraying robot, and the third spraying robot. The dock is divided into three main spraying areas, and each spraying robot corresponds to a different area. The three robots are used to complete the large surface spraying tasks from the flat side line of the hull to the top line of the bulwark on the left and right sides of the first ship to be sprayed and the second ship to be sprayed. The distance between the two ships to be sprayed is 5m, and other spraying equipment in the dock is used for supplementary spraying on the straight bottom part of the hull and the bow and stern frames.

[0007] Step S2: Set the travel trajectory of the spraying robot in different main spraying areas, and each spraying robot is equipped with a corresponding ground auxiliary work vehicle. Control the spraying robot body to enter the spraying area, and keep the distance between the robot body and the outer surface of the hull to be sprayed at 3m. Set the initial spraying position, and the robot runs along the ground walking trajectory, and the distance from the outer surface of the hull remains unchanged. The first spraying robot operates according to its preset ground walking trajectory within the operating range of the first main spraying area, the second spraying robot operates according to its preset ground walking trajectory within the operating range of the second main spraying area, and the third spraying robot operates according to its preset ground walking trajectory within the operating range of the third main spraying area. Each set of ground auxiliary work vehicles has functions such as paint supply and paint mist recovery. It is connected to the robot operation execution end through pipelines and can cooperate with the spraying robot in operations.

[0008] Step S3: Perform spray positioning of the large surface space of the steel structure of the overhead spray robot. The specific control steps are as follows: Step S3.1: issuing a spatial positioning instruction for the overhead spraying robot to start; Step S3.2: Ground positioning of the overhead spray painting robot body. In order to determine the working position of the bottom of the robot and avoid collisions during work, the ground position of the robot body needs to be confirmed. The laser radar installed on the robot body emits a laser beam and receives reflected light to complete the working environment detection. The front laser radar continuously scans the working surface ZOY facing the robot body, and feeds back the reflection of the laser point on the working surface. The rear laser radar continuously scans the working surface XOY facing the side of the robot body, and feeds back the reflection of the laser point on the XOY surface. Analyze the geometric changes between consecutive laser radar frames, perform real-time mileage and distance calculations, and use the distance from the base of the robot body to the XOY plane. R 1 express, R 1 The value range is between 3 and 3.5 m. The distance from the robot body base to the ZOY plane is expressed asR 2 express, R 2 The value range is [ L min , L max ], the ground coordinates of the overhead spraying robot body are expressed as P 底 ( R 2 ,0, R 1 ); Based on the position coordinates, the overhead spray robot system integrates the above multi-frame radar data to optimize the ground posture of the vehicle body, iterate the posture trajectory, and send real-time positioning information to the robot system.

[0009] Step S3.3: Numerical control of the end extension and retraction of the robot's arm mechanism. The arm mechanism includes a bottom arm and a front arm. In order to keep the nozzle and the wall surface of the robot's execution end within the optimal spraying range and avoid the situation where the spraying distance is too close and the film thickness is too thick, and the distance is too far and the film thickness is too thin, the end change numerical control is achieved by adjusting the rotation and extension amplitude and angle of each joint of the robot's arm mechanism. The bottom arm of the robot is driven to extend and retract. The bottom arm pull rope sensor is installed at the front joint of the robot to detect the extension length from the XOY plane. The sensor has a built-in arm rotary encoder connected to the pull rope reel. As the robot's arm extends and retracts, the reel rotates, and the encoder generates a corresponding pulse signal and transmits it to the robot control system, converting the signal into the extension length of the overhead spray robot's execution end from the XOY plane. or 1 , or 1 The value range is [ d 1min , d 1max ]; the front arm pull rope sensor is installed at the front joint of the robot arm to detect the telescopic length from the ZOX plane. The signal conversion is completed through the built-in arm rotary encoder and transmitted to the robot control system. The telescopic length from the execution end of the overhead spray robot to the ZOX plane is measured by or 2 express, or 2 The value range is [ d 2min , d 2max]; The end pull rope sensor is installed at the connection between the robot execution end and the forearm to detect the telescopic length between the ZOY plane. When the end motor drives the execution end to extend or retract, the moving part drives the pull rope, so that the pull rope is released or retracted from the reel inside the end pull rope sensor, and the pull rope displacement is converted into an electrical signal to complete the transmission. The telescopic length between the execution end of the overhead spray robot and the ZOY plane is measured by or 3 express, or 3 The value range is [ d 3min , d 3max ]between.

[0010] Step S3.4: Control of the angle variation of the robot's upper arm mechanism joints. The robot's lower arm is equipped with a lower swing cylinder, on which a first angle sensor is installed, which is positioned using the mounting boss of the first sensor to control the arm's amplitude variation; the front arm is equipped with a front swing cylinder, on which a second angle sensor is installed, which is positioned using the mounting boss of the second sensor to control the arm's angle variation; when the lower swing cylinder or the front swing cylinder is controlled to move, it drives the corresponding angle sensor to rotate, and the potentiometer inside the angle sensor generates a robot upper arm mechanism rotation voltage signal proportional to the rotation angle and transmits the signal, and the robot control system converts the original signal into a specific value of the rotation angle of the upper arm mechanism of the overhead spraying robot, and the rotation angle of the upper arm is i 1 , the arm rotation angle is i 2 .

[0011] Step S3.5: Establish the overall spatial positioning relationship of the overhead spraying robot. Complete the initialization setting and set the distance from the overhead spraying robot body base to the XOY plane. R 1 , the distance from the robot body base to the ZOY plane R 2 , import the ground coordinates of the overhead spraying robot body P 底 ( R 2 ,0, R 1 ), determine the target position of the robot when performing the hull spraying task in the dock, and establish the spatial positioning coordinates of the overhead spraying robot P G ( x G , y G , z G ),in: x G =R 2 +n 1 +M 1 cosθ 1 +M 2 cosθ 2 y G =h 2 +M 1 sinth 1 +M 2 sinth 2 z G =R 1 +n 3 R 1 It is expressed as the distance from the robot body base to the XOY plane, R 1 Between 3 and 3.5m; R 2 It is expressed as the distance from the robot body base to the ZOY plane, R 2 The value range is [ L min , L max ]between; or 1 Indicates the telescopic length between the execution end of the overhead spraying robot and the XOY plane. or 1 The value range is [ d 1min , d 1max ]between; or 2 It indicates the telescopic length between the execution end of the overhead spraying robot and the ZOX plane. or 2 The value range is [ d 2min , d 2max ]between; or 3 It indicates the telescopic length between the execution end of the overhead spraying robot and the ZOY plane. or 3 The value range is [ d 3min , d 3max ]between; i 1 Indicates the arm rotation angle, i 2 Indicates the rotation angle of the forearm. M 1 Indicates the length of the upper arm, M 2 Indicates the length of the forearm.

[0012] Step S4: The spraying robot starts to operate from the initial point, and sets the robot operation path according to the actual operation space of the dock and the spraying process requirements. The method includes: The method for setting the robot operation path plan according to the actual operation space of the dock and the spraying process requirements is: According to the occupied area A and the operating efficiency E of the robot operation path plan, the optimal operation path is selected in combination with the actual ground operation area range limit interval [n,m] of the dock; the optimal operation path plan occupies an area A i The following conditions are met: n≤A i ≤m, for each path plan, its plan benefit coefficient function is: , check whether the area occupied by each solution is within the restricted range. If only one solution meets the conditions, the solution that meets the conditions is the robot operation path; if there are multiple solutions that meet the conditions, the solution with the highest score is selected as the operation path solution; Scheme 1 is a large-area continuous spraying trajectory in the shape of a "horizontal bow". The spraying robot operates in the shape of a "horizontal bow". The execution end sprays horizontally on a large surface from the bow to the stern. After the execution end descends, it sprays horizontally on a large surface from the stern to the bow, and repeats this process until the spraying is completed. Solution 2 is a large-area continuous spraying trajectory in the shape of a "vertical bow". The spraying robot sprays from top to bottom in the shape of a "vertical bow". The elevated spraying robot moves sideways and then sprays from bottom to top, reciprocating from the bow to the stern until the spraying is completed. Solution 3 is a "vertical one" multi-area combined spraying trajectory. The spraying robot sprays from top to bottom in a "vertical one" shape. After the elevated spraying robot body moves horizontally, the robot's arm mechanism is lifted again, and then sprays from top to bottom, and repeats until the spraying is completed. Solution four is a "horizontal bow" multi-zone combined spraying trajectory, which divides the working area into more than two areas. In a single area, the spray robot operates in a "horizontal bow" shape, and the execution end sprays horizontally from one end of the large area to the other end. After the execution end descends, it returns to spray, and repeats this process until the spraying of a single area is completed. The body of the elevated spray robot moves horizontally to the next spraying area and re-executes the spraying operation in the single area until all single areas are sprayed.

[0013] The ground operator starts the control key, the robot starts working according to the trajectory, the feed pump in the ground auxiliary work vehicle starts, and begins to deliver the evenly stirred paint to the feed pipeline; the corresponding recovery hole is set at the robot operation execution end, and the toxic volatile gas overflowed by the spraying is recovered to the ground system through the paint mist recovery pipeline; Step S5: The three spraying robots complete the spraying operation of the large surface area of ​​the hull according to the predetermined trajectory and enter the post-spraying processing work. The first spraying robot and the third spraying robot leave the spraying area, and the second spraying robot turns 180° and drives to the left side of the second ship to be sprayed, 50~60cm away from the outer surface of the hull. Spray from the stern area to the bow area, repeat the process of the above step S3, and work until the task is completed. Beneficial effect: This method uses laser radar to scan the working environment in real time to ensure that the robot will not collide and provide accurate ground position information of the vehicle body; the pull rope sensor and the rotary encoder are used to accurately control the extension and angle of the big arm to maintain the optimal spraying distance between the nozzle and the wall, and the angle sensor is used to accurately adjust the angle of the big arm and the small arm to ensure flexibility and accuracy during the spraying process. This method is suitable for large-surface space spraying of steel structures, and controls the robot to complete the spatial positioning of the steel surface of the hull and the operation trajectory planning in the dock. It can effectively deal with the problems of difficult spatial positioning of robots and low efficiency of manual discrimination of different trajectories during spraying operations in the dock.

[0014] The present invention integrates laser radar and multiple sensors to control the distance between the spray gun and the steel surface of the hull to ensure the quality of the paint film and the operating efficiency; it improves the positioning accuracy, operating safety and spraying quality of the elevated spray robot, realizes integrated management from startup positioning to spatial positioning, improves the stability and reliability of the system, greatly improves the operating efficiency and quality, reduces operating costs, and promotes the development of new quality productivity in the shipbuilding industry. BRIEF DESCRIPTION OF THE DRAWINGS

[0015] Figure 1 This is a working area map of an elevated spraying robot in a dock provided by an example of the present invention.

[0016] Figure 2 A combination diagram of an overhead spraying robot system provided for an example of the present invention.

[0017] Figure 3This is a ground walking trajectory line diagram of the operating area of ​​an elevated spraying robot in a dock provided by an example of the present invention.

[0018] Figure 4 This is a structural diagram of the large-surface spatial spraying positioning of an elevated spraying robot steel structure provided in an example of the present invention.

[0019] Figure 5 A side view of an overhead spraying robot operating in a dock provided in an example of the present invention.

[0020] Figure 6 This is a flow chart of the operation of an elevated spraying robot in a dock provided by an example of the present invention.

[0021] Figure 7 The first example provided by the present invention is a large-area continuous spraying trajectory diagram of a "vertical bow character".

[0022] Figure 8 The second example provided by the present invention is a large-area continuous spraying trajectory diagram of the "horizontal bow character".

[0023] Figure 9 Case three "vertical line" multi-zone combined spraying trajectory diagram provided for the example of the present invention.

[0024] Figure 10 The present invention provides a case four "vertical bow" multi-zone combined spraying trajectory diagram.

[0025] In the figure: 1a, the first spraying robot; 1b, the second spraying robot; 1c, the third spraying robot; 1d, the elevated spraying robot body; 1e, the robot arm mechanism; 1f, the robot operation execution end; 1g, the feed recovery pipeline; 1h, the ground auxiliary operation vehicle; 2a, the first ship to be sprayed; 2b, the second ship to be sprayed; 2c, the first main spraying area; 2d, the second main spraying area; 2e, the third main spraying area; 3, the ground walking track of the spraying robot; 3a, the ground walking track of the first spraying robot; 3b, the ground walking track of the second spraying robot; 3c, the ground walking track of the third spraying robot; 3d, the hull boundary line; 4a, the initial spraying point of scheme one; 4b, the initial spraying small area of ​​scheme one; 4c, the second small spraying area of ​​Scheme 1; 4d, the first spraying trajectory of Scheme 1; 4e, the first spraying stop point of Scheme 1; 4f, the first robot downward movement trajectory of Scheme 1; 4g, the second spraying starting point of Scheme 1; 4h, the second spraying trajectory of Scheme 1; 4i, the second spraying stop point of Scheme 1; 4j, the second downward movement trajectory of the robot of Scheme 1; 4k, the third spraying starting point of Scheme 1; 4m, the third spraying trajectory of Scheme 1; 4n, the third downward movement trajectory of the robot of Scheme 1; 4o, the fourth spraying starting point of Scheme 1; 4p, the fourth spraying trajectory of Scheme 1; 5, flat edge line; 5a, the initial spraying point of Scheme 2; 5b, the initial spraying small area of ​​Scheme 2; 5c, the second small spraying area of ​​Scheme 2; 5d, the first spraying trajectory of Scheme 2; 5e, square The first spraying stop point of Scheme 2; 5f, the first lateral movement trajectory of the robot in Scheme 2; 5g, the second spraying starting point of Scheme 2; 5h, the second spraying trajectory of Scheme 2; 5i, the second spraying stop point of Scheme 2; 5j, the second lateral movement trajectory of the robot in Scheme 2; 5k, the third spraying starting point of Scheme 2; 5l, the third spraying trajectory of Scheme 2; 5m, the third spraying stop point of Scheme 2; 5n, the third lateral movement trajectory of the robot in Scheme 2; 5o, the fourth spraying starting point of Scheme 2; 5p, the fourth spraying trajectory of Scheme 2; 6a, the initial spraying point of Scheme 3; 6b, the initial spraying small area of ​​Scheme 3; 6c, the second spraying small area of ​​Scheme 3; 6d, the first vertical spraying trajectory of Scheme 3; 6e, the first spraying stop point of Scheme 3; 6f, the second spraying starting point of Scheme 3 ; 6g, the second vertical spraying trajectory of Scheme 3; 6h, the second spraying stop point of Scheme 3; 6i, the third spraying starting point of Scheme 3; 6j, the third vertical spraying trajectory of Scheme 3; 6k, the third spraying stop point of Scheme 3; 6l, the ground moving direction of the robot in Scheme 3; 6m, the fourth spraying starting point of Scheme 3; 6n, the fourth vertical spraying trajectory of Scheme 3; 6o, the fourth spraying stop point of Scheme 3; 7a, the initial spraying small area near the bow area of ​​Scheme 4; 7b, the initial spraying point near the bow area of ​​Scheme 4; 7c, the second small spraying area near the bow area of ​​Scheme 4; 7d, the first spraying trajectory near the bow area of ​​Scheme 4; 7e, the first spraying stop point near the bow area of ​​Scheme 4; 7f, the first descending trajectory of the spraying robot in Scheme 4;7g, Scheme 4, the second spraying starting point close to the bow area; 7h, Scheme 4, the second spraying trajectory close to the bow area; 7i, Scheme 4, the second spraying stop point close to the bow area; 7j, Scheme 4, the second descending trajectory of the spraying robot; 7k, Scheme 4, the third spraying starting point close to the bow area; 7l, Scheme 4, the third spraying trajectory close to the bow area; 7m, Scheme 4, the third spraying stop point close to the bow area; 7n, Scheme 4, the third descending trajectory of the spraying robot; 7o, Scheme 4, the fourth spraying starting point close to the bow area; 7p, Scheme 4, the fourth spraying trajectory close to the bow area; 8a, Scheme 4, the initial spraying small area close to the stern area; 8b, Scheme 4, the initial spraying point close to the stern area; 8c, Scheme 4, the second small spraying area close to the stern area ; 8d, the first spraying trajectory of the fourth scheme near the stern area; 8e, the first spraying stop point of the fourth scheme near the stern area; 8f, the fourth descending trajectory of the spraying robot of the fourth scheme; 8g, the second spraying starting point of the fourth scheme near the stern area; 8h, the second spraying trajectory of the fourth scheme near the stern area; 8i, the second spraying stop point of the fourth scheme near the stern area; 8j, the fifth descending trajectory of the spraying robot of the fourth scheme; 8k, the third spraying starting point of the fourth scheme near the stern area; 8l, the third spraying trajectory of the fourth scheme near the stern area; 8m, the third spraying stop point of the fourth scheme near the stern area; 8n, the sixth descending trajectory of the spraying robot of the fourth scheme; 8o, the fourth spraying starting point of the fourth scheme near the stern area; 8p, the fourth spraying trajectory of the fourth scheme near the stern area. ; DETAILED DESCRIPTION

[0026] Figure 2 The embodiment of the present invention provides an elevated spraying robot system combination, the robot system includes: an elevated spraying robot body, a feeding and recovery pipeline 1g and a ground auxiliary work vehicle 1h, and the robot body is connected to the ground auxiliary work vehicle through the feeding and recovery pipeline. The spraying robot body includes: an elevated spraying robot body 1d, a robot arm mechanism 1e, and a robot operation execution end 1f; the arm mechanism includes a bottom arm and a front arm; the elevated spraying robot body can achieve left and right lateral movement and self-rotation, and at the same time, it is displaced by the carrying operation execution end as a robot ground mobile platform, and the robot arm mechanism connects the elevated spraying robot body and the robot operation execution end, and the robot operation execution end includes a spray gun, a paint mist recovery cover, a recovery hole, etc. The ground auxiliary work vehicle is equipped with spraying feeding equipment and paint mist recovery equipment. Before the operation, the paint bucket is opened manually and poured into the feeding equipment, and then transmitted to the robot operation execution end through the pipeline. During the operation, the paint mist is recovered by the paint mist recovery equipment through the recovery pipeline.

[0027] Figure 6 The operation process of the overhead spraying robot in the dock provided by the embodiment of the present invention includes: Step 1: According to the number of pre-spraying ships and the area of ​​the operation area, select 3 overhead spraying robots, assign each robot a corresponding main spraying area, and complete the preparation work before the spraying operation.

[0028] The number of hulls on which the spraying robot needs to perform spraying operations and the large surface operation area of ​​the hull steel structure are selected. According to the operation needs in the dock, three corresponding overhead spraying robots are selected, namely the first spraying robot 1a, the second spraying robot 1b, and the third spraying robot 1c; the dock is divided into three main spraying areas, each spraying robot corresponds to a different area, and the three robots are used to complete the large surface spraying tasks between the flat side line of the hull on the left and right sides of the first to-be-sprayed ship 2a and the second to-be-sprayed ship 2b to the top line of the bulwark (such as Figure 1 as shown).

[0029] Step 2: The first, second and third spraying robots are operated by the ground control personnel to enter the first, second and third spraying areas respectively, and the initial spraying position is the bow area of ​​the hull to be sprayed. The travel trajectory of each spraying robot is set to 3m from the required spraying hull surface, and each spraying robot is equipped with a corresponding ground auxiliary operation vehicle system.

[0030] The travel trajectory of the spraying robot is set in different main spraying areas, and each spraying robot is equipped with a corresponding ground auxiliary work vehicle 1h; the spraying robot body is controlled to enter the spraying area, and the distance between the robot body and the outer surface of the hull to be sprayed is maintained at the spraying distance; the initial spraying position is set, and the robot runs along the third spraying robot ground walking trajectory 3c, and the distance from the outer surface of the hull remains unchanged; the first spraying robot 1a operates within the operating range of the first main spraying area 2c according to its preset first spraying robot ground walking trajectory 3a, the second spraying robot 1b operates within the operating range of the second main spraying area 2d according to its preset second spraying robot ground walking trajectory 3b, and the third spraying robot 1c operates within the operating range of the third main spraying area 2e according to its preset third spraying robot ground walking trajectory 3c; each set of ground auxiliary work vehicles 1h is equipped with paint supply and paint mist recovery mechanisms, which are connected to the robot operation execution end 1f through pipelines, and can cooperate with the spraying robot in operations.

[0031] Step 3: Perform spray positioning of the large surface space of the overhead spray robot steel structure (such as Figure 3 and Figure 4 ), the specific control steps are as follows: Step 3.1: Issue the spatial positioning command for the overhead spraying robot to start; Step 3.2: Ground positioning of the elevated spray painting robot body. In order to determine the working position of the bottom of the robot and avoid collisions during work, the ground position of the robot body needs to be confirmed. The laser radar installed on the robot body emits a laser beam and receives reflected light to complete the working environment detection. The front laser radar continuously scans the working surface ZOY facing the robot body, and feeds back the reflection of the laser point on the working surface. The rear laser radar continuously scans the working surface XOY facing the side of the robot body, and feeds back the reflection of the laser point on the XOY surface. Analyze the geometric changes between consecutive laser radar frames, perform real-time mileage and distance calculations, and use the distance from the base of the robot body to the XOY plane. R 1 express, R 1 The value range is between 3 and 3.5 m. The distance from the robot body base to the ZOY plane is expressed as R 2 express, R 2 The value range is [ L min , L max ], the ground coordinates of the overhead spraying robot body are expressed as P 底 ( R 2 ,0, R 1 ); Based on the position coordinates, the overhead spray robot system integrates the above multi-frame radar data to optimize the ground posture of the vehicle body, iterate the posture trajectory, and send real-time positioning information to the robot system.

[0032] Step S3.3: Numerical control of the end extension and retraction of the robot's arm mechanism. The arm mechanism includes a bottom arm and a front arm. In order to keep the nozzle and the wall surface of the robot's execution end within the optimal spraying range and avoid the situation where the spraying distance is too close and the film thickness is too thick, and the distance is too far and the film thickness is too thin, the end change numerical control is achieved by adjusting the rotation and extension amplitude and angle of each joint of the robot's arm mechanism. The bottom arm of the robot is driven to extend and retract. The bottom arm pull rope sensor is installed at the front joint of the robot to detect the extension length from the XOY plane. The sensor has a built-in arm rotary encoder connected to the pull rope reel. As the robot's arm extends and retracts, the reel rotates, and the encoder generates a corresponding pulse signal and transmits it to the robot control system, converting the signal into the extension length of the overhead spray robot's execution end from the XOY plane. or 1 , or 1 The value range is [ d 1min , d 1max]; the front arm pull rope sensor is installed at the front joint of the robot arm to detect the telescopic length from the ZOX plane. The signal conversion is completed through the built-in arm rotary encoder and transmitted to the robot control system. The telescopic length from the execution end of the overhead spray robot to the ZOX plane is measured by or 2 express, or 2 The value range is [ d 2min , d 2max ]; The end pull rope sensor is installed at the connection between the robot execution end and the forearm to detect the telescopic length between the ZOY plane. When the end motor drives the execution end to extend or retract, the moving part drives the pull rope, so that the pull rope is released or retracted from the reel inside the end pull rope sensor, and the pull rope displacement is converted into an electrical signal to complete the transmission. The telescopic length between the execution end of the overhead spray robot and the ZOY plane is measured by or 3 express, or 3 The value range is [ d 3min , d 3max ]between.

[0033] Step 3.4: Control of the angle variation of the robot's arm mechanism joints. The robot's bottom arm is equipped with a bottom swing cylinder, on which a first angle sensor is installed, which is positioned using the mounting boss of the first sensor to control the arm's amplitude variation; the front arm is equipped with a front swing cylinder, on which a second angle sensor is installed, which is positioned using the mounting boss of the second sensor to control the arm's angle variation; when the bottom swing cylinder or the front swing cylinder is controlled to move, it drives the corresponding angle sensor to rotate, and the potentiometer inside the angle sensor generates a robot arm mechanism rotation voltage signal proportional to the rotation angle and transmits the signal. The robot control system converts the original signal into a specific value of the rotation angle of the overhead spray robot's arm mechanism. The arm rotation angle is i 1 , the arm rotation angle is i 2 .

[0034] Step 3.5: Establish the overall spatial positioning relationship of the overhead spraying robot. Complete the initialization setting and set the distance from the overhead spraying robot body base to the XOY plane. R 1 , the distance from the robot body base to the ZOY plane R 2 , import the ground coordinates of the overhead spraying robot body P 底 (R 2 ,0, R 1 ), determine the target position of the robot when performing the hull spraying task in the dock, and establish the spatial positioning coordinates of the overhead spraying robot P G ( x G , y G , z G ),in: x G =R 2 +n 1 +M 1 cosθ 1 +M 2 cosθ 2 y G =h 2 +M 1 sinth 1 +M 2 sinth 2 z G =R 1 +n 3 R 1 It is expressed as the distance from the robot body base to the XOY plane, R 1 Between 3 and 3.5m; R 2 It is expressed as the distance from the robot body base to the ZOY plane, R 2 The value range is [ L min , L max ]between; or 1 Indicates the telescopic length between the execution end of the overhead spraying robot and the XOY plane. or 1 The value range is [ d1min , d 1max ]between; or 2 It indicates the telescopic length between the execution end of the overhead spraying robot and the ZOX plane. or 2 The value range is [ d 2min , d 2max ]between; or 3 It indicates the telescopic length between the execution end of the overhead spraying robot and the ZOY plane. or 3 The value range is [ d 3min , d 3max ]between; i 1 Indicates the arm rotation angle, i 2 Indicates the rotation angle of the forearm. M 1 Indicates the length of the upper arm, M 2 Indicates the length of the forearm.

[0035] Step 4: The spraying robot starts working from the initial point and sets the robot's working path according to the actual working space of the dock and the requirements of the spraying process. The method for setting the robot's working path is as follows: let the occupied area of ​​the robot's working path plan 1 be A1 and the working efficiency be E1, the occupied area of ​​the path plan 2 be A2 and the working efficiency be E2, the occupied area of ​​the path plan 3 be A3 and the working efficiency be E3, the occupied area of ​​the path plan 4 be A4 and the working efficiency be E4, and the actual ground working range of the dock is limited to [n,m]. The optimal working path plan occupies an area of ​​A i The following conditions are met: n≤A i ≤m, for each path plan, its plan benefit coefficient function is: , check whether its occupied area is within the restricted range. If the condition is met, select the path solution with the highest score: .

[0036] The ground operator starts the control key, the robot starts working according to the trajectory, and the feeding pump of the ground auxiliary work vehicle starts within 1 hour to start conveying the evenly stirred paint into the feeding pipeline; the corresponding recovery hole is set at the robot operation execution end 1f, and the toxic volatile gas overflowed by the spraying is recovered to the ground system through the paint mist recovery pipeline.

[0037] Step 5, the arm mechanism of the first spraying robot 1a is driven to rise to the top operation point A1 of the left operation area of ​​the first ship to be sprayed, and the distance between the operation execution end and the hull surface is adjusted to L1, and the size range of L1 is 50~60cm; the arm mechanism of the second spraying robot 1b is driven to rise to the top operation point B1 of the right operation area of ​​the first ship to be sprayed, and the distance between the operation execution end and the hull surface is adjusted to L1, and the size range of L1 is 50~60cm; the arm mechanism of the third spraying robot 1c is driven to rise to the top operation point D1 of the right operation area of ​​the second ship to be sprayed, and the distance between the operation execution end and the hull surface is adjusted to L1, and the size range of L1 is 50~60cm; Step 6: The body part of each spraying robot always moves along the preset third spraying robot ground walking track 3c, and keeps a distance L2 from the hull boundary line, and the size range of L2 is 3m; the robot moves until the current work station is completed, and enters the next work station, and the process is repeated; Step 7, each spraying robot is driven by the big arm mechanism to move the operation execution end vertically downward, and the motor drives to complete the spraying of the last section of the flat side line direction of the hull; the big arm mechanism of the first spraying robot shrinks, closes the paint supply control valve, and the robot drives away from the first and third main spraying areas according to the set trajectory; it is determined whether the left side of the second ship to be sprayed needs to be sprayed, if not, the second spraying robot drives away from the second main spraying area, the operation of the spraying robot in the dock is completed, and the post-spraying processing work is performed manually; if yes, the body of the second spraying robot rotates 180° and performs the spraying operation according to the set travel trajectory, and the big arm mechanism drives to rise to the top operation point C1 of the operation area on the left side of the second ship to be sprayed, and the distance between the operation execution end and the hull surface is adjusted to L1, and the size range of L1 is 50~60cm. The above operation process is repeated until it is completed, and the post-spraying processing work is performed. Example

[0038] Figure 7The scheme 1 is shown in the figure, which is a large area continuous spraying trajectory in the shape of a "horizontal bow". The spraying robot operates in the shape of a "horizontal bow". The execution end sprays horizontally in a large area from the bow to the stern, and descends and reciprocates. During the specific operation, spraying is carried out from the initial spraying point 4a of the large surface scheme one along the first spraying trajectory 4d of scheme one, and the area of ​​the small spraying area is 0.5m×1m; first start the control valve to complete the spraying of the initial spraying small area 4b of scheme one, and the robot body moves 1m to the second spraying small area 4c of scheme one for spraying, and repeats this process; until the robot reaches the first spraying stop point 4e of scheme one, the spraying pipeline control valve is closed, and the spraying of the first horizontal row area stops; the robot arm mechanism 1e is driven vertically downward by 0.5m along the first robot downward movement trajectory 4f of scheme one to the second spraying starting point 4g of scheme one, and the spraying of the second horizontal row area begins; the spraying pipeline control valve is started, and the previous steps are repeated along the second spraying trajectory 4h of scheme one until the spraying operation of the large surface of this side of the hull is completed.

[0039] Figure 8 The second scheme is shown in the figure as a large area continuous spraying trajectory of "vertical bow". The spraying robot sprays from top to bottom in the shape of "vertical bow". After the car body moves horizontally, it sprays from bottom to top, and repeats the process. In the specific operation, spraying is carried out from the initial spraying point 5a of scheme 2 along the first spraying trajectory 5d of scheme 2. The area of ​​the spraying small area is 0.5m×1m. The control valve is first started to complete the spraying of the initial spraying small area 5b of scheme 2. The robot arm mechanism 1e drives the operation execution end to move vertically downward, and moves down 0.5m to complete the spraying of the second spraying small area 5c of scheme 2. The above process is repeated until the first spraying stop point 5e of Scheme 2 is reached, the spraying pipeline control valve is closed, and the spraying of the first vertical column area is completed; the robot body drive moves along the first lateral movement trajectory 5f of the robot in Scheme 2 to the second spraying starting point 5g of Scheme 2 and stops, and the control valve is started to restart spraying; the robot arm mechanism 1e moves upward along the second spraying trajectory 5h of Scheme 2 to the second spraying stop point 5i of Scheme 2 to complete the spraying of the second vertical column area, and the previous steps are repeated until the spraying operation of the entire large surface of this side of the hull is completed.

[0040] Figure 9The figure shows that the third scheme is a "vertical one" multi-area combined spraying trajectory. The spraying robot sprays from top to bottom in the "vertical one" shape. After the body moves horizontally, the arm is raised again, and then sprays from top to bottom, reciprocating. In the specific operation, the spraying robot sprays from the initial spraying point 6a of scheme three along the first vertical column spraying trajectory 6d of scheme three, and the area of ​​the spraying small area is 0.5m×1m; the control valve is first started to complete the spraying of the initial spraying small area 6b of scheme three, and the robot arm mechanism 1e drives the operation execution end to move vertically downward, and moves down 0.5m to complete the spraying of the second spraying small area 6c of scheme three. The above process is repeated until the first spraying stop point 6e of Scheme 3 is reached, the spraying pipeline control valve is closed, and the spraying of the first vertical column area is completed; the robot body moves 0.5m along the ground moving direction 6l of the robot in Scheme 3 to the second vertical column spraying area, and the robot arm mechanism 1e drives the operation execution end to move vertically upward to reach the second spraying starting point 6f of Scheme 3, the control valve is started to start spraying, and the arm moves downward along the second vertical column spraying trajectory 6g of Scheme 3 until it reaches the second spraying stop point 6h of Scheme 3 to end the operation; the above steps are repeated until the spraying operation of the large surface of the hull on this side is completed.

[0041] Figure 10Scheme 4 is shown as a "horizontal bow" multi-area combined spraying trajectory, which divides the working area into more than two areas. In a single area, the machine spray robot operates in a "horizontal bow" shape, and the execution end sprays horizontally from one end of the large area to the other end. After the execution end descends, it returns to spray, and reciprocates until the spraying of a single area is completed. The elevated spray robot body 1d moves horizontally to the next spraying area and re-executes the spraying operation in the single area until all single areas are sprayed. During the specific operation, the robot starts from the initial spraying point 7b of the bow area of ​​Scheme 4, and operates along the first spraying trajectory 7d of the bow area of ​​Scheme 4, and the size of the spraying small area is 0.5m×1m; first start the control valve to complete the spraying of the initial spraying small area 7a of Scheme 4 near the bow area, and the robot body moves 1m to the second spraying small area 7c of Scheme 4 near the bow area for spraying, and repeats this process; until the robot reaches the first spraying stop point 7e of Scheme 4 near the bow area, the spraying pipeline control valve is closed, and the first spraying stop point 7e of Scheme 4 is closed. The spraying of one horizontal row of areas stops; the robot arm mechanism 1e is driven vertically downward by 0.5m along the first descending trajectory 7f of the spraying robot in Plan 4 to the second spraying starting point 7g of Plan 4 near the bow area, and the spraying of the second horizontal row of areas begins; the spraying pipeline control valve is started, and the previous steps are repeated along the second spraying trajectory 7h of Plan 4 near the bow area until the spraying of the first large area is completed; the robot body is driven to move to the initial point of spraying of the next area, and the above spraying process is repeated to complete the spraying of the large bow area, and the robot moves to the stern area.The robot body is positioned to the initial spraying point 8b of the fourth scheme near the stern area through the guide rail, and the robot arm mechanism is aligned with the initial spraying small area 8a of the fourth scheme near the stern area, and the size of the small area is maintained at 0.5m×1m operation unit; the spray pipeline control valve is started, and it moves horizontally along the first spraying trajectory 8d of the fourth scheme near the stern area; after completing 1m of travel, it reaches the second small spraying area 8c of the fourth scheme near the stern area for continuous spraying; repeat the horizontal reciprocating motion until it reaches the first spraying stop point 8e of the fourth scheme near the stern area; the control valve is closed to complete the first row of spraying operation; the arm mechanism vertically descends 0.5m along the fourth descending trajectory 8f of the spray robot in scheme four; the robot arm mechanism shrinks to the second spraying small area 8c of the fourth scheme near the stern area Starting point 8g; open the control valve to perform the second horizontal row spraying along the second spraying trajectory 8h of Scheme 4 near the stern area; repeat the above process until reaching the second spraying stop point 8i of Scheme 4 near the stern area to perform the third vertical displacement: descend 0.5m along the fifth descending trajectory 8j of Scheme 4 spraying robot to the third spraying starting point 8k of Scheme 4 near the stern area; complete the third spraying stop point 8m of Scheme 4 near the stern area along the third spraying trajectory 8l of Scheme 4 near the stern area; perform the fourth vertical displacement: descend 0.5m along the sixth descending trajectory 8n of Scheme 4 spraying robot to the fourth spraying starting point 8o of Scheme 4 near the stern area; complete the horizontal row spraying along the fourth spraying trajectory 8p of Scheme 4 near the stern area, and the spraying operation of all the large surfaces of this side of the hull is completed.

[0042] Finally, it should be noted that the above is merely the technical solution of the present invention and does not limit it; even though the above real-time method is described in detail, it does not limit it; technicians in this field can modify the case described or replace the technology with the same features; but no matter the modification or replacement, it should not deviate from the technical essence of the present invention.

Claims

1. A method for positioning large surface space spraying of an elevated spraying robot steel structure, characterized in that: The method steps include: Step S1: selecting the number of hulls on which the spraying robot needs to perform spraying operations and the large surface area of ​​the hull steel structure; Step S2: setting the travel trajectory of the spraying robot in different main spraying areas, and each spraying robot is equipped with a corresponding ground auxiliary work vehicle (1h); controlling the spraying robot body to enter the spraying area, and keeping the distance between the robot body and the outer surface of the hull to be sprayed at the spraying distance; setting the initial spraying position, and running along the ground walking trajectory (3) of the spraying robot, and keeping the distance from the outer surface of the hull constant; Step S3: Perform spray positioning of the large surface space of the steel structure of the overhead spray robot. The specific control steps are as follows: Step S3.1: issuing a spatial positioning instruction for the overhead spraying robot to start; Step S3.2: The body of the overhead spray painting robot is positioned on the ground; the laser radar installed on the robot body emits a laser beam and receives reflected light to complete the working environment detection. The front laser radar continuously scans the working surface ZOY facing the robot body and feeds back the reflection of the laser point on the working surface. The rear laser radar continuously scans the working surface XOY facing the side of the robot body and feeds back the reflection of the laser point on the XOY surface. Analyze the geometric changes between consecutive LiDAR frames, perform real-time mileage and distance calculations, and calculate the distance from the robot body base to the XOY plane. R 1 express, R 1 The value range is between 3 and 3.5 m. The distance from the robot body base to the ZOY plane is expressed as R 2 express, R 2 The value range is [ L min , L max ], the ground coordinates of the overhead spraying robot body are expressed as P 底 ( R 2 ,0, R 1 ); Step S3.3: Numerical control of the robot's arm mechanism's end extension and retraction: The arm mechanism includes a bottom arm and a front arm, which drives the robot's bottom arm to extend and retract. The bottom arm pull rope sensor is installed at the robot's front joint to detect the extension and retraction length from the XOY plane. η 1 , η 1 The value range is [ d 1min , d 1max ]; The front arm pull rope sensor is installed at the front joint of the robot arm to detect the telescopic length between the ZOX plane η 2 , η 2 The value range is [ d 2min , d 2max ]; The end pull rope sensor is installed at the connection between the robot execution end and the forearm to detect the telescopic length between the ZOY plane η 3 , η 3 The value range is [ d 3min , d 3max ]between; Step S3.4: Control of the angle variation of the robot's upper arm: The lower arm of the robot is equipped with a lower swing cylinder, on which a first angle sensor is installed, which is positioned using the mounting boss of the first sensor to control the arm's amplitude variation; the front arm is equipped with a front swing cylinder, on which a second angle sensor is installed, which is positioned using the mounting boss of the second sensor to control the arm's angle variation; the arm's rotation angle is θ 1 , the arm rotation angle is θ 2 ; Step S3.5: Establish the overall spatial positioning relationship of the overhead spraying robot: Complete the initialization setting and set the distance from the overhead spraying robot body base to the XOY plane R 1 , the distance from the robot body base to the ZOY plane R 2 , import the ground coordinates of the overhead spraying robot body P 底 ( R 2 ,0, R 1 ), determine the target position of the robot when performing the hull spraying task in the dock, and establish the spatial positioning coordinates of the overhead spraying robot P G ( x G , y G , z G ),in: x G =R 2 +η 1 +M 1 cosθ 1 +M 2 cosθ 2 y G =η 2 +M 1 sinθ 1 +M 2 sinθ 2 z G =R 1 +η 3 R 1 It is expressed as the distance from the robot body base to the XOY plane, R 1 Between 3 and 3.5m; R 2 It is expressed as the distance from the robot body base to the ZOY plane, R 2 The value range is [ L min , L max ]between; η 1 Indicates the telescopic length between the execution end of the overhead spraying robot and the XOY plane. η 1 The value range is [ d 1min , d 1max ]between; η 2 It indicates the telescopic length between the execution end of the overhead spraying robot and the ZOX plane. η 2 The value range is [ d 2min , d 2max ]between; η 3 It indicates the telescopic length between the execution end of the overhead spraying robot and the ZOY plane. η 3 The value range is [ d 3min , d 3max ]between; θ 1 Indicates the arm rotation angle, θ 2 Indicates the rotation angle of the forearm. M 1 Indicates the length of the upper arm, M 2 Indicates the length of the forearm; Step S4: The spraying robot starts to operate from the initial point, and sets the robot operation path plan according to the actual operation space of the dock and the spraying process requirements; Step S5: The spraying robot completes the spraying operation on a large surface area of ​​the hull from the stern area to the bow area according to a predetermined trajectory.

2. The method for spraying positioning of a large surface space of a steel structure by an overhead spraying robot according to claim 1 is characterized in that: In the step S1, three corresponding overhead spraying robots are selected according to the operation requirements in the dock, namely a first spraying robot (1a), a second spraying robot (1b), and a third spraying robot (1c); the dock is divided into three main spraying areas, each spraying robot corresponds to a different area, and the three robots are used to complete the large surface spraying task between the flat side line of the hull and the top line of the bulwark on the left and right sides of the first ship to be sprayed (2a) and the second ship to be sprayed (2b).

3. The method for spraying positioning of a large surface space of a steel structure by an overhead spraying robot according to claim 1 is characterized in that: In the step S2, the first spraying robot (1a) operates within the operating range of the first main spraying area (2c) according to its preset first spraying robot ground walking track (3a), the second spraying robot (1b) operates within the operating range of the second main spraying area (2d) according to its preset second spraying robot ground walking track (3b), and the third spraying robot (1c) operates within the operating range of the third main spraying area (2e) according to its preset third spraying robot ground walking track (3c); each ground auxiliary operation vehicle (1h) is equipped with a paint supply and paint mist recovery mechanism, is connected to the robot operation execution end (1f) through a pipeline, and can cooperate with the spraying robot in operation.

4. The method for spraying positioning of a large surface space of a steel structure by an overhead spraying robot according to claim 1 is characterized in that: In step S4, the method for setting the robot operation path plan according to the actual operation space of the dock and the spraying process requirements is: According to the occupied area A and the operating efficiency E of the robot operation path plan, the optimal operation path is selected in combination with the actual ground operation area range limit interval [n,m] of the dock; the optimal operation path plan occupies an area A i The following conditions are met: n≤A i ≤m, for each path plan, its plan benefit coefficient function is: , check whether the area occupied by each solution is within the restricted range. If only one solution meets the conditions, the solution that meets the conditions is the robot operation path; if there are multiple solutions that meet the conditions, the solution with the highest score is selected as the operation path solution; Solution 1 is a large-area continuous spraying trajectory in the shape of a "horizontal bow". The spraying robot operates in the shape of a "horizontal bow". The execution end sprays horizontally on a large surface from the bow to the stern. After the execution end descends, it sprays horizontally on a large surface from the stern to the bow, and repeats this process until the spraying is completed. The second scheme is a large-area continuous spraying trajectory in the shape of a "vertical bow". The spraying robot sprays from top to bottom in the shape of a "vertical bow". The elevated spraying robot body (1d) moves horizontally and then sprays from bottom to top, reciprocating from the bow to the stern until the spraying is completed. Solution three is a "vertical one" multi-area combined spraying trajectory, in which the spraying robot sprays from top to bottom in a "vertical one" shape, and after the elevated spraying robot body (1d) moves horizontally, the robot arm mechanism (1e) is lifted again, and then sprays from top to bottom, and the process is repeated until the spraying is completed; Solution 4 is a "horizontal bow" multi-area combined spraying trajectory, which divides the working area into more than two areas. In a single area, the spray robot operates in a "horizontal bow" shape. The execution end sprays horizontally from one end of the large area to the other end, and then returns to spray after descending. This process is repeated until the spraying of a single area is completed. The elevated spray robot body (1d) moves horizontally to the next spraying area and re-executes the spraying operation in a single area until all single areas are sprayed.

5. The method for spraying positioning of a large surface space of a steel structure by an overhead spraying robot according to claim 1 is characterized in that: In step S4, after setting the robot's operating path, the ground operator activates the control key, the robot starts to operate according to the trajectory, the feed pump in the ground auxiliary operation vehicle (1h) starts, and begins to deliver the evenly stirred paint to the feed pipeline; the robot operation execution end (1f) is provided with a corresponding recovery hole, and the toxic volatile gas overflowed by the spraying is recovered to the ground system through the paint mist recovery pipeline.

6. The method for spraying positioning of a large surface space of a steel structure by an overhead spraying robot according to claim 1 is characterized in that: In step S5, the first spraying robot (1a) and the third spraying robot (1c) leave the spraying area, and the second spraying robot (1b) turns 180 degrees and drives to the left side of the second ship to be sprayed (2b), 50 to 60 cm away from the outer surface of the ship.

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