Method for welding by adopting collaborative welding robot
By adaptively setting welding parameters through a collaborative welding robot, the problem of existing welding robots being unable to adapt to different workpieces is solved, achieving efficient and precise welding results and adapting to various workpiece shapes and welding methods.
Patent Information
- Application Number
- CN202511918361.9
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2025-12-18
- Publication Date
- 2026-03-03
AI Technical Summary
Existing welding robots cannot determine welding parameters based on the actual working conditions of the bevel to be welded, resulting in poor adaptability and limited application.
By employing a collaborative welding robot, welding parameters are adaptively adjusted by setting the number of weld layers, welding parameters, welding torch displacement trajectory, arc initiation and arc termination retraction distance, and welding wire extension length, combined with manual input and automatic confirmation.
Improve welding efficiency and quality, reduce human intervention and failure rate, realize intelligent welding, ensure welding quality and dimensional accuracy, and adapt to various workpiece shapes and welding methods.
Smart Images
Figure CN121589398A_ABST
Abstract
Description
Technical Field
[0001] This invention relates to the field of welding robot technology, specifically to a method for welding using a collaborative welding robot. Background Technology
[0002] With the continuous development of advanced technologies such as machine vision, deep learning, cloud computing, and big data, intelligent welding robots are able to achieve high-precision and high-quality welding operations. These technologies enable remote monitoring and data analysis of welding robots, further improving their intelligence level. Welding robots can replace multiple industrial workers in large-scale production, enabling uninterrupted continuous production and thus reducing labor costs. In addition, with the application of high-speed and high-efficiency welding technology, the cost reduction of using welding robots is even more significant.
[0003] However, existing welding robots have limitations. They are typically only adaptable to one or a few specific welding methods and workpiece shapes; they require programming and debugging based on different workpieces and weld seams to determine appropriate motion trajectories, speeds, currents, voltages, and other parameters, making programming and debugging complex; they require high workpiece positioning accuracy, and improper fixture design or workpiece deformation can lead to welding deviations; and their poor adaptability prevents them from determining welding parameters based on the actual working conditions of the weld bevel, resulting in a narrow range of applications for welding robots.
[0004] Therefore, there is an urgent need to propose a method for welding using collaborative welding robots to solve the problem in existing technologies that cannot determine welding parameters based on the actual working conditions of the bevel to be welded. Summary of the Invention
[0005] In view of the above facts, in order to solve the problem in the prior art that welding parameters cannot be determined according to the actual working conditions of the bevel to be welded, the present invention designs a welding method using a collaborative welding robot.
[0006] To achieve the above objectives, the present invention adopts the following technical solution:
[0007] A welding method using a collaborative welding robot, specifically:
[0008] Step 1: Set the number of weld layers for the collaborative welding robot according to the depth of the bevel to be welded;
[0009] Step 2: Set the welding parameters for each weld layer to the collaborative welding robot according to the number of weld layers;
[0010] Step 3: Set the welding torch displacement trajectory for the collaborative welding robot according to the width of the bevel to be welded;
[0011] Step 4: Set the retraction distance for arc initiation and arc termination for the collaborative welding robot according to the direction of the weld bevel;
[0012] Step 5: Set the wire extension length to the collaborative welding robot according to the size of the bevel to be welded;
[0013] Step 6: Adjust the welding parameters of the collaborative welding robot according to the actual welding parameters of the bevel to be welded.
[0014] Furthermore, in step two, the welding parameters include current, voltage, and welding speed.
[0015] Furthermore: In step three, when the welding wire moves in a straight line to meet the width requirement of the groove to be welded, the displacement trajectory of the welding gun is a straight line;
[0016] When the welding wire cannot meet the width requirement of the groove to be welded by moving in a straight line, the welding torch swings along the width direction of the groove to be welded.
[0017] Furthermore: In step four, when the number of weld layers is one, the arc start position and arc end position are set to the collaborative welding robot according to the coordinates of the bevel to be welded;
[0018] When there are multiple weld layers, the starting and ending positions of the first layer weld are set to the collaborative welding robot according to the coordinates of the groove to be welded. The starting and ending positions of the remaining weld layers are determined based on the starting and ending positions of the first layer weld.
[0019] Furthermore, the arc initiation position of each layer of weld does not coincide with the arc initiation position of other layers of weld, and the arc termination position of each layer of weld does not coincide with the arc termination position of other layers of weld.
[0020] Furthermore: In step one, the number of weld layers or the weld depth is input manually, and the collaborative welding robot automatically confirms the number of weld layers based on the weld depth;
[0021] In step two, welding parameters or the material to be welded are input manually, and the collaborative welding robot automatically confirms the welding parameters based on the material to be welded.
[0022] Furthermore: the welding torch oscillates along an equilateral triangle, an inverted triangle, a Z-shape, or a bow shape, with the oscillation pattern input by the operator.
[0023] Furthermore, the collaborative welding robot achieves welding parameters of 10mm-80mm plate thickness and welding positions of flat welding, horizontal welding, and vertical welding.
[0024] Furthermore, the collaborative welding robot has the function of automatically planning multi-layer and multi-pass welding paths through simple parameter settings after a single teaching demonstration, and has automatic arc initiation and arc termination functions.
[0025] Furthermore, the collaborative welding robot has welding machine data communication function, and can control welding parameters such as welding machine current and voltage through a teach pendant or wireless tablet.
[0026] The beneficial effects of this invention are as follows:
[0027] 1. The collaborative welding robot of the present invention improves welding efficiency and quality, reduces human intervention and failure rate, and realizes intelligent transformation of welding production through functions such as automatic identification, self-adaptation and automatic path planning.
[0028] 2. The welds obtained by the collaborative welding robot of this invention are smooth and beautiful, free from defects such as porosity, cracks, and slag inclusions, and meet welding standards. It can accurately control the welding trajectory and parameters, ensuring that the welding dimensional accuracy meets the design drawings. Under the premise of ensuring welding quality, it achieves efficient welding operations and improves production efficiency.
[0029] 3. In actual welding operations, this invention only requires setting the number of weld layers and welding parameters to achieve automated welding operations, greatly improving welding efficiency. Attached Figure Description
[0030] Figure 1 This is a flowchart of the present invention;
[0031] Figure 2 This is a schematic diagram of the trajectory of the welding torch in trapezoidal motion in this invention;
[0032] Figure 3 This is a schematic diagram of the trajectory of the welding torch when it moves in a Z-shape in this invention;
[0033] Figure 4 This is a schematic diagram of the cross-section of the multi-layer, multi-pass weld groove in this invention;
[0034] Figure 5 This is a schematic diagram of the multi-layer, multi-pass welding path points and welding torch posture in this invention. Detailed Implementation
[0035] To enable those skilled in the art to better understand the present application, the technical solutions in the embodiments of the present application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present application, and not all embodiments. Based on the embodiments in the present application, all other embodiments obtained by those of ordinary skill in the art without creative effort should fall within the scope of protection of the present application.
[0036] The terms "set up," "connect," and "fix" should be interpreted broadly. For example, "connection" can be a fixed connection, a detachable connection, or an integral structure; it can be a mechanical connection, a direct connection, or an indirect connection through an intermediate medium, or an internal connection between two devices, components, or parts. Those skilled in the art can understand the specific meaning of the above terms in this application according to the specific circumstances.
[0037] It should be noted that, unless otherwise specified, the embodiments and features described in this application can be combined with each other. This application will now be described in detail with reference to the accompanying drawings and embodiments.
[0038] Preferred embodiments of the present invention will now be described in detail with reference to the accompanying drawings.
[0039] Example 1: A welding method using a collaborative welding robot in this example is as follows:
[0040] Step 1: Set the number of weld layers for the collaborative welding robot according to the depth of the bevel to be welded;
[0041] Step 2: Set the welding parameters for each weld layer to the collaborative welding robot according to the number of weld layers;
[0042] Step 3: Set the welding torch displacement trajectory for the collaborative welding robot according to the width of the bevel to be welded;
[0043] Step 4: Set the retraction distance for arc initiation and arc termination for the collaborative welding robot according to the direction of the weld bevel;
[0044] Step 5: Set the wire extension length to the collaborative welding robot according to the size of the bevel to be welded;
[0045] Step 6: Adjust the welding parameters of the collaborative welding robot according to the actual welding parameters of the bevel to be welded.
[0046] More specifically: In step two, the welding parameters include current, voltage, and welding speed.
[0047] More specifically: In step three, when the welding wire moves in a straight line to meet the width requirement of the groove to be welded, the displacement trajectory of the welding gun is a straight line;
[0048] When the welding wire cannot meet the width requirement of the groove to be welded by moving in a straight line, the welding torch swings along the width direction of the groove to be welded.
[0049] More specifically: In step four, when the number of weld layers is one, the arc start position and arc end position are set to the collaborative welding robot according to the coordinates of the bevel to be welded;
[0050] When there are multiple weld layers, the starting and ending positions of the first layer weld are set to the collaborative welding robot according to the coordinates of the groove to be welded. The starting and ending positions of the remaining weld layers are determined based on the starting and ending positions of the first layer weld.
[0051] More specifically: the arc initiation position of each layer of weld does not coincide with the arc initiation position of other layers of weld, and the arc termination position of each layer of weld does not coincide with the arc termination position of other layers of weld.
[0052] More specifically: In step one, the number of weld layers or the weld depth is input manually, and the collaborative welding robot automatically determines the number of weld layers based on the weld depth;
[0053] In step two, welding parameters or the material to be welded are input manually, and the collaborative welding robot automatically confirms the welding parameters based on the material to be welded.
[0054] More specifically: the welding torch oscillates along an equilateral triangle, an inverted triangle, a zigzag, or a bow shape, with the oscillation pattern input by the operator.
[0055] More specifically: the collaborative welding robot is equipped with an input panel, which has input keys.
[0056] More specifically: the collaborative welding robot achieves welding parameters of 10mm-80mm plate thickness and welding positions of flat welding, horizontal welding, and vertical welding.
[0057] More specifically: the collaborative welding robot can perform multi-layer, multi-pass welding of right-angle welds and butt welds with plate thickness of 10mm-80mm, as well as bevel fillet welds. It is adaptable to bevels with uneven blunt edge gaps. Welding materials include carbon steel, low-alloy high-strength steel, martensitic stainless steel, etc., ensuring that the weld quality passes UT flaw detection.
[0058] More specifically: the collaborative welding robot has the function of automatically planning multi-layer and multi-pass welding paths through simple parameter settings after a single teaching demonstration, and has the functions of automatic arc initiation and arc termination.
[0059] More specifically: the collaborative welding robot has welding machine data communication function, and can control welding parameters such as welding machine current and voltage through a teach pendant or wireless tablet.
[0060] Example 2: When welding ultra-thick plates and welds with bevels, in order to ensure welding quality and welding strength, a multi-layer, multi-pass welding method is required, which is characterized by high technical difficulty, long welding time, and high stability requirements.
[0061] Traditional welding methods involve programming the welding program by calibrating each layer individually or setting offsets. The disadvantages are that the setup is cumbersome, requires a high level of operator experience, and is difficult to adjust.
[0062] When a multi-layer, multi-pass welding method is required, regardless of the number of layers and passes, the process parameters for the multi-layer, multi-pass welding can be set simply by manually inputting the start and end positions of the welding in the control system of this invention. The control system inside the collaborative welding robot automatically sets the offset between each layer and each pass according to the type of weld, and automatically generates the corresponding welding angle and the welding method required for different welds, which greatly improves programming efficiency and lowers the threshold for use.
[0063] More specifically: Because the product to be welded is relatively thick and the welding quality requirements are high, it is necessary to ensure the welding quality after the welding is completed. Therefore, it is necessary to process the bevel at the welding position in advance.
[0064] Currently, most welding is done using flame cutting, which causes the bevel to deviate from the theoretical value during the cutting process. The welding method and motion control trajectory are automatically generated based on the bevel angle, so the processing error of the bevel will seriously affect the welding quality.
[0065] This invention involves manually dragging a collaborative welding robot before welding, causing it to take a point on each of the bevel's visual feature points. The control system automatically calculates the actual angle of the bevel, automatically readjusts the collaborative welding robot's movement trajectory based on the actual angle, and adjusts the welding process parameters according to the new bevel angle.
[0066] More specifically: Welding oscillation is usually horizontal, and the bevel has a certain angle. If ordinary translational oscillation is used during the welding process, the molten pool will not fit the bevel edge, resulting in incomplete fusion and slag inclusion defects between the weld and the base metal. Therefore, during the welding process, the welding torch needs to be oscillated in a Z-shape around the welding torch according to the bevel angle.
[0067] The present invention sets the normal horizontal swing amplitude and frequency, and the angle of the welding torch pendulum motion on the control system. At this time, the control system can realize the movement of the welding torch in three directions. That is, in the welding process, on the basis of the horizontal swing of the welding torch, a pendulum-like motion is added to fully fuse the weld pool after the welding wire is melted with the bevel edge, thereby reducing the welding defects of incomplete fusion at the bevel edge.
[0068] More specifically: Welding process parameters differ at the moment of arc initiation, during welding, and at the end of welding, which can easily lead to welding defects such as buildup, porosity, and pits, resulting in problems such as stress concentration and lack of fusion;
[0069] This invention incorporates a welding retraction function in the control system. By manually inputting the retraction distance and speed, the welding torch can automatically complete actions such as arc initiation, arc termination, and retraction, effectively avoiding welding defects caused by arc accumulation during arc initiation and termination.
[0070] More specifically: Since most of the plates need to be beveled on both sides, when the bevel on one side is completed, there will be some weld pool that has seeped in on the other side. Therefore, when welding on the other side, the weld pool that has seeped in needs to be cleaned up before normal welding can be performed.
[0071] The current cleaning method is manual carbon arc gouging. The bevel after cleaning is generally narrow, making it difficult for the welding torch to enter. The welding wire needs to be extended for welding. The extension of the welding wire leads to a decrease in the protective effect of the welding shielding gas, which easily produces porosity defects.
[0072] Meanwhile, when the welding torch is welding to the edge of the bevel and the welding wire remains unchanged, the shielding gas does not act directly on the weld pool and may blow to the edge of the bevel. Therefore, the collaborative welding robot needs to shorten the welding wire during welding.
[0073] This invention uses a manual input method to input the welding wire extension distance, which can effectively avoid welding porosity problems.
[0074] More specifically: In step six, due to the influence of objective factors such as cable length, resistance, and equipment performance, the actual process parameters during welding have a certain error compared with the preset parameters, resulting in inconsistent weld leg sizes of the actual weld seam, which in turn affects the final welding effect, quality, and appearance of multi-layer and multi-pass welding.
[0075] When the actual weld leg size is inconsistent with the preset parameters, the present invention adjusts the relative positional relationship between each layer and each weld by adjusting the relevant parameters of the control system, thereby effectively avoiding defects such as incomplete welding fusion.
[0076] More specifically: Due to the limitations of the reach and welding range of collaborative welding robots, longer welds exceed the range of a single welding operation. In such cases, long welds need to be spliced together, which can easily lead to defects such as incomplete fusion.
[0077] In multi-layer, multi-pass welding, this invention allows inputting offset parameters at positions where offset is required. If the offset is sequential or trapezoidal, the required offset distance is set, effectively avoiding defects caused by splicing.
[0078] More specifically: When welding a vertical weld bevel, because there is no platform below to support the molten pool, the molten pool flows downward under the influence of gravity, resulting in voids in the first part of the weld.
[0079] The control system of this invention automatically switches different process parameters at the beginning of welding, welding at a lower speed and current, and then automatically switches to normal welding parameters after a period of time, effectively avoiding the problem of voids when the welding arc is started.
[0080] More specifically: Due to processing errors or plate deformation, gaps may appear in the welded products during the splicing process. In this case, a welding method that swings along an inverted triangle is generally required. This swinging method is difficult to cover the gap error of the bevel and is prone to welding defects.
[0081] This invention employs a trapezoidal oscillation, where the displacement amplitude of the welding torch is determined by the size of the gap. Regardless of whether there is a gap at the bevel, welding can be performed using oscillation welding.
[0082] More specifically: Due to issues such as assembly or processing errors of the plates, the opening of the bevel weld is larger on one side and smaller on the other, forming an "eight" shape. In this case, a welding method of oscillating along a "Z" shape is generally required. However, due to the different openings, using a fixed oscillation frequency and speed can easily lead to welding defects.
[0083] The control system of this invention can adaptively swing according to the algorithm. After manual dragging and teaching is completed, the control system will automatically determine the size of the bevel according to the point. If an inconsistency in size is detected, the system will automatically activate the corresponding algorithm and automatically adjust the swing parameters, such as swing amplitude and frequency.
[0084] More specifically: such as Figures 4-5 As shown, the first layer of multi-layer, multi-pass weld filler The layer consists of a three-sided constrained A-type weld bead and It consists of a double-sided constrained type B weld bead, wherein the constrained source is the bevel or an already welded seam;
[0085] The cross-sectional shape of type A weld bead is trapezoidal. Path points of type weld bead It is the midpoint of the bottom edge of the trapezoidal weld bead section;
[0086] The cross-sectional shape of type B weld bead is a parallelogram. Path points of type weld bead The intersection of the constrained sides of the parallelogram cross section;
[0087] Multi-layer weld bead planning adopts the same cross-sectional area planning method for similar weld beads. The path points and corresponding welding torch postures of all weld beads are generated by the following process:
[0088] S1: Determine the welding posture of the weld bead;
[0089] S2: Confirm Path points of type weld bead ;
[0090] S3: Confirm Path points of type weld bead .
[0091] More specifically: In S1, the feature points of the bevel are obtained through teaching by a collaborative welding robot or identification by a line laser sensor. ( (The set of real numbers), and construct the bevel side direction vector and the cross-sectional layer direction vector:
[0092] ;
[0093] ;
[0094] ;
[0095] in, This is the left feature point at the top of the bevel;
[0096] This is the right feature point at the top of the bevel;
[0097] This is the left feature point at the bottom of the bevel;
[0098] This is the right feature point at the bottom of the bevel;
[0099] The left-side direction vector of the bevel;
[0100] The direction vector is on the right side of the bevel.
[0101] The direction vector of the cross-section layer;
[0102] Its unit vector is:
[0103] ;
[0104] ;
[0105] ;
[0106] in, The unit vector on the left side of the bevel;
[0107] The unit vector on the right side of the bevel;
[0108] The unit vector of the cross-section layer;
[0109] Regulation The welding torch posture for the bevel bead is along the direction of the bevel angle bisector, and the unit vector in this direction is... for:
[0110] ;
[0111] The welding torch posture for type B weld bead is specified as being along the direction of the angle bisector of the constraint side, where the unit vector is... for:
[0112] .
[0113] More specifically: In S2, the total number of filler layers in a multi-layer, multi-pass weld is . , No. Path points of type A weld bead in layer The following is obtained from the feature points at the bottom of the bevel and the lateral direction vector:
[0114] .
[0115] More specifically: In S3, let the first... layer middle The starting point of the weld bead is The starting point is defined as the path point of the weld bead closest to the bevel side, and the ending point is the path point of the weld bead closest to the A-type weld bead side. can be and get:
[0116] ;
[0117] ;
[0118] Because of the uniform cross-sectional area of type B weld beads, the path point of type B weld beads is... and Evenly distributed between them, the first road Path points of type B weld It is obtained from the following formula:
[0119] .
[0120] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention, and not to limit them; although the present invention has been described in detail with reference to the foregoing embodiments, modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some or all of the technical features therein; as long as there is no structural conflict, the various features in the specific embodiments disclosed in this application can be combined with each other in any way, and will not cause the substance of the corresponding technical solutions to deviate from the scope of the technical solutions of the present invention.
[0121] Furthermore, it should be understood that although this specification describes embodiments, not every embodiment contains only one independent technical solution. This narrative style is merely for clarity. Those skilled in the art should consider the specification as a whole, and the technical solutions in each embodiment can also be appropriately combined to form other embodiments that can be understood by those skilled in the art.
Claims
1. A welding method using a collaborative welding robot, characterized in that, Specifically: Step 1: Set the number of weld layers for the collaborative welding robot according to the depth of the bevel to be welded; Step 2: Set the welding parameters for each weld layer to the collaborative welding robot according to the number of weld layers; Step 3: Set the welding torch displacement trajectory for the collaborative welding robot according to the width of the bevel to be welded; Step 4: Set the retraction distance for arc initiation and arc termination for the collaborative welding robot according to the direction of the weld bevel; Step 5: Set the wire extension length to the collaborative welding robot according to the size of the bevel to be welded; Step 6: Adjust the welding parameters of the collaborative welding robot according to the actual welding parameters of the bevel to be welded.
2. The welding method using a collaborative welding robot according to claim 1, characterized in that, In step two, the welding parameters include current, voltage, and welding speed.
3. The welding method using a collaborative welding robot according to claim 1, characterized in that, In step three, when the welding wire moves in a straight line to meet the width requirement of the groove to be welded, the displacement trajectory of the welding gun is a straight line. When the welding wire cannot meet the width requirement of the groove to be welded by moving in a straight line, the welding torch swings along the width direction of the groove to be welded.
4. The welding method using a collaborative welding robot according to claim 1, characterized in that, In step four, when the number of weld layers is one, the arc start position and arc end position are set to the collaborative welding robot according to the coordinates of the bevel to be welded. When there are multiple weld layers, the starting and ending positions of the first layer weld are set to the collaborative welding robot according to the coordinates of the groove to be welded. The starting and ending positions of the remaining weld layers are determined based on the starting and ending positions of the first layer weld.
5. A welding method using a collaborative welding robot according to claim 4, characterized in that, The arc initiation position of each layer of weld does not coincide with the arc initiation position of other layers of weld, and the arc termination position of each layer of weld does not coincide with the arc termination position of other layers of weld.
6. The welding method using a collaborative welding robot according to claim 1, characterized in that, In step one, the number of weld layers or weld depth is input manually, and the collaborative welding robot automatically confirms the number of weld layers based on the weld depth. In step two, welding parameters or the material to be welded are input manually, and the collaborative welding robot automatically confirms the welding parameters based on the material to be welded.
7. A welding method using a collaborative welding robot according to claim 3, characterized in that, The welding torch oscillates along an equilateral triangle, an inverted triangle, a Z-shape, or a bow shape, with the oscillation pattern input by the operator.
8. A welding method using a collaborative welding robot according to claim 1, characterized in that, The collaborative welding robot achieves welding parameters of 10mm-80mm plate thickness and welding positions of flat welding, horizontal welding, and vertical welding.
9. A welding method using a collaborative welding robot according to claim 1, characterized in that, The collaborative welding robot has the function of automatically planning multi-layer and multi-pass welding paths through simple parameter settings after a single teaching demonstration, and has automatic arc initiation and arc termination functions.
10. A welding method using a collaborative welding robot according to claim 1, characterized in that, The collaborative welding robot has welding machine data communication function and can control welding parameters such as welding machine current and voltage through a teach pendant or wireless tablet.