Crawling, welding and cutting integrated robot and working method thereof

Abstract

The invention discloses a crawling, welding and cutting integrated robot and a working method thereof. The integrated robot comprises an X-axis sliding table module, two Y-axis sliding table modules and a Z-axis sliding table module which are perpendicular to one another. The two Y-axis sliding table modules are arranged side by side at intervals, the Y-axis sliding table modules are connected with torque motor modules, and the torque motor modules are connected with magnetic attraction wheels; the X-axis sliding table module is connected with sliding blocks of the two Y-axis sliding table modules. The Z-axis sliding table module is fixedly connected with a sliding block of the X-axis sliding table module; a sliding block of the Z-axis sliding table module is connected with a visual device and a clamping mechanism, and the clamping mechanism is used for clamping and installing a cutting gun or a welding gun. The visual device is used for recognizing and tracking the oval door opening contour line, and the cutting gun and the welding gun are used for cutting and welding the oval door opening contour line. Through the arrangement, the wind power tower can climb on the wind power tower, a reserved position on the wind power tower is cut to form a door opening and welded to form a door frame, manual machining is replaced, and efficiency and quality can be improved easily.

Description

Technical Field

[0001] This invention belongs to the technical field of intelligent welding and cutting robot technology, specifically relating to a crawling welding and cutting integrated robot and its working method. Background Technology

[0002] A wind turbine tower is the support structure for wind power generation. It typically houses power generation or energy storage devices for wind turbines. An elliptical doorway is also provided on the outside of the wind turbine tower to allow staff to enter the tower for regular inspections and maintenance.

[0003] Currently, when processing the door openings of wind turbine towers, factories typically need to lay the entire tower flat and then manually cut and weld the door openings horizontally. Because the elliptical door openings have large spans on both the major and minor axes, and the wind turbine towers also have large diameters, the towers need to be rolled according to the actual workable height during processing to adjust the door openings to a workable height. This method of adjusting and processing simultaneously increases processing difficulty, reduces processing efficiency, increases processing errors, and reduces processing quality. Summary of the Invention

[0004] In order to overcome the shortcomings of the prior art, the purpose of this invention is to provide a crawling welding and cutting integrated robot and its working method, which can crawl on wind turbine towers and cut pre-reserved positions on the wind turbine towers to form door openings, and weld the elliptical rings on the edge of the door openings to form door frames, so as to replace manual processing and help improve processing efficiency and processing quality.

[0005] The objective of this invention is achieved through the following technical solution:

[0006] A crawling welding and cutting integrated robot includes three mutually perpendicular X-axis slide modules, Y-axis slide modules, and Z-axis slide modules. There are two sets of Y-axis slide modules, arranged side-by-side with a gap between them, and a connecting frame is fixedly connected between them. Torque motor modules are fixedly connected to the bottom surfaces of both ends of the main body of each Y-axis slide module, and magnetic wheels are connected to the drive ends of the torque motor modules. The two ends of the main body of the X-axis slide module are fixedly connected to the sliders of the two sets of Y-axis slide modules. The middle part of the main body of the Z-axis slide module is connected to the slider of the X-axis slide module. The block is fixedly connected; the slider of the Z-axis slide module is fixedly connected to a clamping mechanism, the main body of the clamping mechanism is fixedly connected to a vision device, the vision device is a vision camera with a tracker, and the clamping part of the clamping mechanism is detachably connected to a cutting gun or a welding gun; the vision shooting end of the vision device, the cutting end of the cutting gun, and the welding end of the welding gun are all set downwards; the vision device is used to identify and track the outline of the elliptical doorway drawn in advance on the wind turbine tower, and the cutting gun and welding gun perform flame cutting and arc welding on the outline of the elliptical doorway respectively according to the trajectory tracked by the vision device.

[0007] Furthermore, the distance between the two sets of Y-axis sliding table modules is greater than the minor axis of the elliptical doorway outline drawn in advance on the wind turbine tower, and the length of the Y-axis sliding table module is greater than the major axis of the elliptical doorway outline drawn in advance on the wind turbine tower.

[0008] Furthermore, both the cutting torch and the welding torch are equipped with pressure sensors, and the pressure sensing end of the pressure sensor is at the same horizontal position as the cutting end of the cutting torch and the welding end of the welding torch.

[0009] Furthermore, it also includes a robot system, which comprises a switch, an industrial computer, a motion controller, and a power conversion circuit, all electrically connected to the switch. The motion controller can be electrically connected to the torque motor module, the X-axis slide module, the Y-axis slide module, and the Z-axis slide module via network or line connection, respectively. The switch is electrically connected to the tracker and vision camera of the vision device via network. The switch is electrically connected to the cutting gun or welding gun via I / O interface. The power conversion circuit is used to power the switch. The industrial computer is electrically connected to a touch screen.

[0010] A method for operating a crawling welding and cutting integrated robot includes the following steps:

[0011] S10: Draw the outline of an elliptical doorway outside the wind turbine tower. The color of the elliptical doorway outline is different from the color of the wind turbine tower surface.

[0012] S20: The crane places the integrated robot directly below the elliptical doorway outline of the wind turbine tower, so that the wheel surfaces of all the magnetic wheels are in contact with the surface of the wind turbine tower. The robot system controls the torque motor module to drive the magnetic wheels to roll, so that the integrated robot crawls towards the elliptical doorway outline until the integrated robot covers the elliptical doorway outline.

[0013] S30: The linear drive devices of the Y-axis slide module and the X-axis slide module of the robot system synchronously drive the vision device to scan layer by layer from bottom to top. The vision device identifies the position of the elliptical doorway outline based on the color of the outline.

[0014] S40: Install the cutting gun in the clamping part of the clamping mechanism and adjust the position of the cutting gun. The robot system controls the Y-axis slide module and the X-axis slide module to drive the cutting gun to move along the trajectory of the elliptical door opening outline. The Z-axis slide module is used to make the welding head of the cutting gun contact the elliptical door opening outline and perform flame cutting to cut out the elliptical door opening.

[0015] S50: Temporarily fix the door frame to the inner wall of the elliptical doorway;

[0016] S60: After removing the cutting gun from the clamping part of the clamping mechanism, install the welding gun and adjust the position of the welding gun. The robot system drives the welding gun to further contact the outline of the elliptical doorway and perform arc welding through the Y-axis slide module, X-axis slide module and Z-axis slide module to weld and fix the doorway frame.

[0017] S70: The robot system controls the Z-axis slide module to retract the vision device and welding torch to the highest position, and the torque motor module drives the magnetic chuck to roll, so that the integrated robot can crawl to the bottom of the wind turbine tower.

[0018] Furthermore, in S10, the method further includes: extending the straight lines on both sides of the minor axis of the elliptical doorway outline downwards to draw an extension line, the extension line extending to the bottom of the wind turbine tower, the color of the elliptical doorway outline and the extension line being different from the color of the wind turbine tower surface, and the color of the elliptical doorway outline being different from the color of the extension line.

[0019] In step S20, the control torque motor module drives the magnetic chuck to roll, causing the integrated robot to crawl towards the elliptical doorway outline until it covers the outline. This includes: after the crane places the integrated robot directly below the elliptical doorway outline of the wind turbine tower, both sets of Y-axis slide modules are positioned outside the two extended lines, and the length direction of the Y-axis slide modules is parallel to the extended lines. The integrated robot crawls towards the elliptical doorway outline through the drive of the torque motor module until the top of the Y-axis slide module exceeds the top of the elliptical doorway outline, but the bottom of the Y-axis slide module does not exceed the bottom of the elliptical doorway outline.

[0020] Furthermore, in S30, the vision device scans layer by layer from bottom to top, and the vision device obtains the position of the elliptical doorway outline based on the color of the elliptical doorway outline, including:

[0021] S31: The robot system establishes an XY-axis coordinate system on the plane formed by two sets of Y-axis sliding modules, and takes the center of the ellipse of the elliptical doorway contour as the origin, which is defined as (h, k). Given that the length of the major semi-axis of the elliptical doorway contour is a and the length of the minor semi-axis is b, the parametric equations of the elliptical doorway contour are: x(t) = h + a*cos(t); y(t) = k + b*sin(t), where the range of t is [0, 2π].

[0022] S32: During layer-by-layer scanning, the vision device simultaneously discretizes the elliptical trajectory of the elliptical doorway outline. Based on the distance L that the Y-axis slide module moves the vision device each time, the number N of discretized points after layer-by-layer scanning can be obtained. Therefore, the number of discretized points N and the discretization parameter t can be calculated. i N = 4a / L - 2; t i =2πi / N=πi*(L-2) / 2a, where i=0, 1, 2,…, N−1;

[0023] S33: The coordinates (x, y) of each discrete point on the corresponding elliptical doorway outline obtained by the vision device through layer-by-layer scanning can be calculated based on the parameter ti. i y i ):x i =h+a*cos(πi*(L-2) / 2a), y i =k+b*sin(πi*(L-2) / 2a).

[0024] Furthermore, in S40, the robot system controls the Y-axis slide module and the X-axis slide module to move the cutting gun along the trajectory of the elliptical doorway outline, including: obtaining the coordinates of one endpoint of the straight line on the left or right side of the elliptical doorway according to the coordinates of each discrete point of the elliptical doorway outline in S33, and using it as the starting point / end point for the cutting gun or welding gun to perform cutting or welding; the Y-axis slide assembly and the X-axis slide assembly move the cutting gun to the starting point / end point, and then control the cutting gun to move clockwise along the elliptical doorway outline.

[0025] Furthermore, in S40, when the cutting gun performs flame cutting on the outline of the elliptical doorway, the industrial control computer of the robot system receives the pressure value sensed by the pressure sensor of the cutting gun in real time. When the pressure value of the pressure sensor is in the range of 50N-100N, it indicates that the cutting is in normal condition. When the pressure value sensed by the pressure sensor jumps from the range of 50N-100N to 0, it indicates that the corresponding position has been cut. Otherwise, it indicates that the flame cutting is abnormal.

[0026] In S60, when the welding torch is welding the elliptical weld seam, the switch of the robot system receives the pressure value sensed by the pressure sensor of the welding torch in real time. When the pressure value of the pressure sensor is in the range of 5N-10N, it indicates that the welding is in normal condition; otherwise, it indicates that the arc welding process is abnormal.

[0027] Furthermore, in S20, after the crane places the integrated robot directly below the elliptical doorway outline of the wind turbine tower, it also includes: adjusting the mounting bolts of the torque motor module to adjust the angle between the torque motor module and the magnetic chuck so that the wheel surface of the magnetic chuck fits well with the surface of the wind turbine tower, and then tightening the bolts to fix the torque motor module.

[0028] The present invention has the following beneficial effects:

[0029] 1. The crawling welding and cutting integrated robot of the present invention, by setting up magnetic suction wheels controlled by a torque motor module, a vision device capable of capturing, recognizing and tracking the outline of an elliptical doorway on the three-dimensional model of the X-axis slide module, Y-axis slide module and Z-axis slide module, a clamping mechanism for the cutting gun or welding gun that can be replaced or adjusted according to work needs, a cutting gun capable of flame cutting, and a welding gun capable of arc welding, can improve the efficiency of manual labor. The integrated robot is magnetically attached to the wind turbine tower, and by controlling the torque motor module, it can achieve the function of crawling in a straight line on the wind turbine tower. This allows the vision device and the clamping mechanism with the cutting gun or welding gun to be moved to the position of the pre-drawn elliptical doorway outline. Then, the X-axis slide module, Y-axis slide module and Z-axis slide module drive the vision device to capture, recognize and track the elliptical doorway outline, and further drive the cutting gun or welding gun to perform flame cutting or arc welding functions on the elliptical doorway outline.

[0030] 2. The working method of the crawling welding and cutting integrated robot of the present invention is mainly based on the crawling welding and cutting integrated robot. In step S10, an elliptical doorway outline is drawn beforehand using a color matching the color recognized by the vision device, thus facilitating the subsequent capture of the integrated robot's crawling process. In step S20, the integrated robot is placed directly below the elliptical doorway outline and then the crawling operation is performed, allowing the robot to crawl to the position of the elliptical doorway outline in the fastest way. In step S30, the robot system controls the vision device to scan layer by layer from bottom to top through the X-axis slide module and the Y-axis slide module, using color recognition... The method involves obtaining the position of the elliptical doorway outline 10, facilitating subsequent flame cutting and arc welding operations. In S40, a cutting torch is mounted using a clamping mechanism. The robot system, via X-axis slide module 1, Y-axis slide module 2, and Z-axis slide module 3, drives the cutting torch to contact the elliptical doorway outline 10 and perform flame cutting to create the elliptical doorway. In S50 and S60, a welding torch is mounted using the clamping mechanism. The robot system, via X-axis slide module 1, Y-axis slide module 2, and Z-axis slide module 3, drives the welding torch to contact the elliptical doorway outline 10 and perform arc welding to weld and fix the doorway frame. Therefore, the working method of this invention has the function of automatically identifying and obtaining the elliptical doorway outline, and can perform flame cutting followed by arc welding based on the obtained elliptical doorway outline. Compared with the existing manual operation mode, it has the advantages of simple and efficient operation and helps improve processing quality. Attached Figure Description

[0031] Figure 1 This is a schematic diagram of the integrated robot of the present invention.

[0032] Figure 2 This is a schematic diagram of the robot system of the present invention.

[0033] Figure 3 This is a schematic diagram of the elliptical doorway outline and cutting and welding trajectory of the present invention.

[0034] Figure 4 This is a flowchart illustrating the working method of the integrated robot of the present invention.

[0035] In the diagram: 1. X-axis slide module; 2. Y-axis slide module; 21. Connecting frame; 3. Z-axis slide module; 4. Torque motor module; 5. Magnetic chuck; 6. Clamping mechanism; 7. Vision camera; 71. Tracker; 8. Cutting gun; 9. Welding gun; 10. Elliptical doorway outline; 11. Wind turbine tower; 12. Doorway frame. Detailed Implementation

[0036] The present invention will now be described in further detail with reference to the accompanying drawings and specific embodiments. Terms such as “upper,” “inner,” “middle,” “left,” “right,” and “one” used in this specification are merely for clarity of description and are not intended to limit the scope of the invention. Changes or adjustments to their relative relationships, without substantially altering the technical content, should also be considered within the scope of the invention.

[0037] Example 1

[0038] A crawling welding and cutting integrated robot, such as Figures 1 to 3 As shown, an elliptical doorway is cut out by flame after crawling on the wind turbine tower 11, and then the doorway frame 12, which is temporarily fixed on the elliptical doorway, is arc welded to fix the doorway frame 12. It mainly includes three mutually perpendicular components: an X-axis slide module 1, a Y-axis slide module 2, and a Z-axis slide module 3. The X-axis slide module 1, Y-axis slide module 2, and Z-axis slide module 3 all adopt conventional lead screw modules. The control motor of the lead screw module can drive the lead screw to rotate, thereby moving the slider in a linear direction.

[0039] The Y-axis slide module 2 consists of two sets, arranged side by side with intervals, and a connecting frame 21 is fixedly connected between the two sets of Y-axis slide modules 2. The bottom surfaces of both ends of the main body of the Y-axis slide module 2 are fixedly connected to a torque motor module 4 by bolts. The torque motor module 4 adopts a conventional motor base and torque motor structure. The torque motor can be a torque motor with model number eRob90H100I-BS-18EN (V3). The drive end of the torque motor module 4 is connected to a magnetic chuck 5, which is mainly made of magnetic material and has extremely strong magnetic force.

[0040] The two ends of the main body of the X-axis slide module 1 are fixedly connected to the sliders of the two sets of Y-axis slide modules 2, so the X-axis slide module 1 can achieve linear motion in the Y-axis direction by utilizing the synchronous movement of the two sets of Y-axis slide modules 2.

[0041] The main body of the Z-axis slide module 3 is fixedly connected to the slider of the X-axis slide module 1 by bolts. The slider of the Z-axis slide module 3 is fixedly connected to a clamping mechanism 6. The main body of the clamping mechanism 6 is equipped with a vision device. The clamping part of the clamping mechanism 6 can clamp and install the cutting gun 8 or the welding gun 9 according to the working needs. Therefore, under the synchronous action of the X-axis slide module 1, the Y-axis slide module 2 and the Z-axis slide module 3, the vision device, the cutting gun 8 and the welding gun 9 can move arbitrarily in three-dimensional space, and it is convenient to visually recognize and track the elliptical doorway outline 10 drawn in advance on the wind turbine tower 11 and perform flame cutting or arc welding operations.

[0042] The vision device employs an existing vision camera 7 with a tracker 71 for the identification and tracking of specific colors. The vision imaging end of the vision device, the cutting end of the cutting torch 8, and the welding end of the welding torch 9 are all positioned downwards. When the crawling welding and cutting robot crawls on the wind turbine tower 11, the vision camera 7 captures and tracks the pre-drawn elliptical doorway outline 10 of the wind turbine tower 11. The color of the elliptical doorway outline 10 matches the color identified by the vision device, facilitating subsequent tracking of the trajectory of the elliptical doorway outline 10 using the laser of the tracker 71. Therefore, both the cutting torch 8 and the welding torch 9 can perform flame cutting or arc welding on the elliptical doorway outline 10 based on the trajectory tracked by the vision device. Both the cutting torch 8 and the welding torch 9 are equipped with pressure sensors, and the pressure sensing end of the pressure sensor is at the same horizontal position as the cutting end of the cutting torch 8 and the welding end of the welding torch 9. This allows the cutting torch 8 and the welding torch 9 to determine whether they are in a normal cutting or welding state based on the pressure feedback from the pressure sensors during flame cutting or arc welding.

[0043] Meanwhile, it should be noted that the distance between the two sets of Y-axis sliding modules 2 is greater than the minor axis of the elliptical doorway outline 10 pre-drawn on the wind turbine tower 11, and the length of the Y-axis sliding module 2 is greater than the major axis of the elliptical doorway outline 10 pre-drawn on the wind turbine tower 11. Therefore, when the crawling welding and cutting integrated robot crawls, the overall structure can cover the elliptical doorway outline 10 pre-drawn on the wind turbine tower 11, which facilitates subsequent operations such as capturing and tracking the elliptical doorway outline 10, flame cutting, and arc welding.

[0044] The crawling welding and cutting integrated robot of the present invention also includes a robot system, which includes a switch, an industrial control computer, a motion controller, and a power conversion circuit, all of which are electrically connected to the switch.

[0045] The motion controller can be electrically connected to the torque motor module 4, X-axis slide module 1, Y-axis slide module 2, and Z-axis slide module 3 via network or wired connection to control their operating status. The switch is electrically connected to the vision camera 7 and tracker of the vision device via network. It receives images captured by the vision camera 7, captures matching color positions, and then uses the tracker to mark, track, and record the captured positions. The switch is electrically connected to the cutting torch 8 or welding torch 9 via I / O interface to control their operation and monitor pressure feedback during cutting and welding processes in real time to determine the effectiveness of the flame cutting and welding process. The power conversion circuit converts power to supply power to the switch. The industrial control computer is electrically connected to a touchscreen for controlling the switch's startup and shutdown via touch and for displaying images captured by the vision camera 7.

[0046] In summary, the crawling welding and cutting integrated robot of the present invention, by setting up a magnetic suction wheel 5 controlled by a torque motor module 4, a vision device that can capture, identify and track the outline of an elliptical doorway 10, a clamping mechanism 6 that can be replaced or adjusted according to work needs, a cutting gun 8 that can realize flame cutting, and a welding gun 9 that can realize arc welding on the three-dimensional model of the X-axis slide module 1, Y-axis slide module 2 and Z-axis slide module 3, can improve the efficiency of manual labor. The integrated robot is magnetically attached to the wind turbine tower 11, and by controlling the torque motor module 4, it can achieve the function of crawling in a straight line on the wind turbine tower 11. In order to facilitate the movement of the vision device and the clamping mechanism 6 with the cutting gun 8 or welding gun 9 to the position of the pre-drawn elliptical doorway outline 10, the vision device is then driven by the X-axis slide module 1, the Y-axis slide module 2 and the Z-axis slide module 3 to capture, identify and track the elliptical doorway outline 10, and then drive the cutting gun 8 or welding gun 9 to perform flame cutting or arc welding on the elliptical doorway outline 10.

[0047] It should be noted that the crawling welding and cutting integrated robot of the present invention can not only cut and weld ellipses in three-dimensional space, but also cut and weld different structures of three-dimensional multi-curved surfaces, and has the application diversity and versatility of three-dimensional multi-curved or curved surface cutting and welding.

[0048] Example 2

[0049] A working method for a crawling welding and cutting integrated robot, such as Figures 1 to 4 As shown, the crawling welding and cutting integrated robot of Embodiment 1 includes the following steps:

[0050] S10: Draw an elliptical doorway outline 10 outside the wind turbine tower 11, and extend the straight lines on both sides of the minor axis of the elliptical doorway outline 10 downwards to the bottom of the wind turbine tower 11. The color of the elliptical doorway outline 10 and the extension lines are different from the color of the surface of the wind turbine tower 11, and the color of the elliptical doorway outline 10 is also different from the color of the extension lines. The color of the elliptical doorway outline 10 matches the color recognized by the visual camera 7 of the vision device.

[0051] S20: Using a crane, place the integrated robot directly below the elliptical doorway outline 10 of the wind turbine tower 11. Adjust the position of the integrated robot so that both sets of Y-axis slide modules 2 are outside the two extended lines, and the length direction of the Y-axis slide modules 2 is parallel to the extended lines. Then adjust the mounting bolts of the torque motor module 4 to adjust the angle between the torque motor module 4 and the magnetic chuck 5 so that the wheel surface of the magnetic chuck 5 fits well with the surface of the wind turbine tower 11. Then tighten the bolts to fix the torque motor module 4. Next, the switch controls the torque motor module 4 to drive the magnetic chuck 5 to roll, so that the integrated robot crawls towards the elliptical doorway outline 10 until the integrated robot covers the elliptical doorway outline 10. Specifically, when the top of the Y-axis slide module 2 exceeds the top of the elliptical doorway outline 10, and the bottom of the Y-axis slide module 2 does not exceed the bottom of the elliptical doorway outline 10, it means that the integrated robot completely covers the elliptical doorway outline 10.

[0052] S30: The linear drive devices of the Y-axis slide module 2 and the X-axis slide module 1 synchronously drive the vision device to scan layer by layer from bottom to top. The switch uses the vision device to obtain the position of the elliptical doorway outline 10 based on the color of the elliptical doorway outline 10. Specifically:

[0053] S31: The robot system's switch establishes an XY-axis coordinate system on the plane formed by the two sets of Y-axis slide modules 2, and takes the center of the ellipse of the elliptical doorway contour line 10 as the origin, which is defined as (h, k). It is known that the length of the major semi-axis of the elliptical doorway contour line 10 is a, and the length of the minor semi-axis of the elliptical doorway contour line 10 is b. Therefore, the parametric equations of the ellipse of the elliptical doorway contour line 10 are listed as follows: x(t)=h+a*cos(t); y(t)=k+b*sin(t), where the range of t is [0, 2π].

[0054] S32: When the robot system's switch controls the vision device to perform layer-by-layer scanning, it simultaneously discretizes the elliptical trajectory of the elliptical doorway contour 10. Based on the distance L that the Y-axis slide module 2 moves the vision device each time (L ranges from 1cm to 5cm), the number N of discretized points after layer-by-layer scanning can be obtained. Normally, each lateral scan by the vision device will obtain two discretized points corresponding to the elliptical doorway contour 10. However, when scanning the upper and lower endpoints of the elliptical doorway contour 10, only one discretized point will be obtained. Therefore, the number of discretized points N and the discretization parameter t can be calculated. i N = 4a / L - 2; t i =2πi / N=πi*(L-2) / 2a, where i=0, 1, 2,…, N−1.

[0055] S33: The coordinates (x, y) of each discrete point of the corresponding elliptical doorway outline 10 obtained by the vision device through layer-by-layer scanning can be calculated based on the parameter ti. i y i ):x i =h+a*cos(πi*(L-2) / 2a), y i =k+b*sin(πi*(L-2) / 2a), thus the overall coordinate position of all elliptical doorway outlines 10 can be obtained, which facilitates the subsequent use of the robot system's switch to control the X-axis slide module 1, Y-axis slide module 2 and Z-axis slide module 3 according to the coordinate position of the elliptical doorway outlines 10, thereby driving the cutting gun 8 or welding gun 9 to cut or weld the elliptical doorway outlines 10 of the wind turbine tower 11.

[0056] S40: Install the cutting gun 8 on the clamping part of the clamping mechanism 6, and adjust the cutting gun 8 so that it is vertically oriented towards the wind turbine tower 11. The switch of the robot system obtains the coordinates of one endpoint of the straight line on the left or right side of the elliptical doorway according to the coordinates of each discrete point of the elliptical doorway outline 10 in S33, and uses it as the start / end point for the cutting gun 8 or welding gun 9 to perform cutting or welding. The switch of the robot system controls the Y-axis slide assembly and the X-axis slide assembly to move the cutting gun 8 to the start / end point, and then controls the cutting gun 8 to move clockwise on the elliptical doorway outline 10. At the same time, the Z-axis slide module 3 is used to make the cutting gun 8 contact the elliptical doorway outline 10 and perform flame cutting to cut out the elliptical doorway.

[0057] When the cutting gun 8 performs flame cutting on the elliptical doorway outline 10, the industrial control computer of the robot system receives the pressure value sensed by the pressure sensor in real time. When the pressure value sensed by the pressure sensor is within the range of 50N-100N, it indicates that the flame cutting is in a normal state. When the pressure value sensed by the pressure sensor jumps from the range of 50N-100N to 0, it indicates that the corresponding position has been cut. Otherwise, it indicates that the flame cutting is abnormal. This step, combined with the pressure value changes sensed by the pressure sensor, determines whether the flame cutting is in a normal and effective state, and has the function of facilitating real-time detection and control of the flame cutting process.

[0058] S50: The door frame 12 is temporarily fixed to the inner wall of the elliptical doorway with glue so that an elliptical weld is formed between the edge of the doorway and the surface of the wind turbine tower 11 for subsequent welding.

[0059] S60: After removing the cutting gun 8 from the clamping part of the clamping mechanism 6, install the welding gun 9 and adjust the welding head of the welding gun 9 to be vertically oriented towards the wind turbine tower 11. The switch of the robot system controls the Y-axis slide module 2, X-axis slide module 1 and Z-axis slide module 3 to drive the welding gun 9 to further contact the elliptical doorway outline 10. At the same time, the welding gun 9 is used to perform arc welding on the elliptical weld seam to weld and fix the doorway frame 12.

[0060] When welding torch 9 performs arc welding on the elliptical weld seam, the robot system's switch receives the pressure value sensed by the pressure sensor in real time. When the pressure value is within the range of 5N-10N, it indicates that the arc welding is in a normal state; otherwise, it indicates that the arc welding process is abnormal. This step, combined with the pressure sensor's sensing of pressure value changes, determines whether the arc welding is in a normal and effective state, providing a convenient function for real-time detection and control of the arc welding process.

[0061] S70: The robot system's switch controls the Z-axis slide module 3 to retract the vision device and welding torch 9 to their highest positions, meaning both are higher than the doorway frame 12. At this point, the robot system's switch controls the torque motor module 4 to drive the magnetic wheels 5 to roll, allowing the integrated robot to crawl to the bottom of the wind turbine tower 11, reducing the likelihood of collisions or interference between the vision device and welding torch 9 and the doorway frame 12. Finally, the integrated robot is manually transported back to the workshop for inspection and repair, ready for the next cutting and welding operation on the elliptical doorway of the wind turbine tower 11.

[0062] In summary, the working method of the crawling welding and cutting integrated robot of the present invention is mainly based on the crawling welding and cutting integrated robot. Specifically, in step S10, an elliptical doorway outline 10 is drawn beforehand using a color matching the color recognized by the vision device, thus facilitating the subsequent capture of the integrated robot's crawling process; in step S20, the integrated robot is placed directly below the elliptical doorway outline 10 and then the crawling operation is performed, allowing the robot to crawl to the position of the elliptical doorway outline 10 in the fastest way; in step S30, the robot system controls the vision device to scan layer by layer from bottom to top through the X-axis slide module 1 and the Y-axis slide module 2, and the color recognition... The method involves obtaining the position of the elliptical doorway outline 10, thus facilitating subsequent flame cutting and arc welding operations. In S40, the cutting torch 8 is mounted using the clamping mechanism 6. The robot system uses the X-axis slide module 1, Y-axis slide module 2, and Z-axis slide module 3 to drive the cutting torch 8 to contact the elliptical doorway outline 10 and perform a flame cutting operation to cut out the elliptical doorway. In S50 and S60, the welding torch 9 is replaced using the clamping mechanism 6. The robot system uses the X-axis slide module 1, Y-axis slide module 2, and Z-axis slide module 3 to drive the welding torch 9 to contact the elliptical doorway outline 10 and perform an arc welding operation to weld and fix the doorway frame 12. It can be seen that the working method of this invention has the function of automatically identifying and obtaining the elliptical doorway outline 10, and can perform flame cutting followed by arc welding based on the obtained elliptical doorway outline 10. Compared with the existing manual operation mode, it has the advantages of simple and efficient operation and helps to improve processing quality.

[0063] It should be noted that the working method of the crawling welding and cutting integrated robot of the present invention can not only cut and weld ellipses in three-dimensional space, but also cut and weld different structures of three-dimensional multi-curved surfaces, and has the application diversity and versatility of three-dimensional multi-curved or curved surface cutting and welding.

[0064] The embodiments of the present invention are not limited thereto. Based on the above description of the present invention, and using common technical knowledge and conventional means in the field, the present invention can be modified, replaced or combined in various other forms without departing from the basic technical idea of ​​the present invention, and all such modifications, replacements or combinations fall within the scope of protection of the present invention.

Claims

1. A crawling welding and cutting integrated robot, characterized in that, The system includes three mutually perpendicular sliding modules: an X-axis sliding module, a Y-axis sliding module, and a Z-axis sliding module. There are two sets of Y-axis sliding modules, arranged side-by-side with a gap between them, and a connecting frame is fixedly connected between them. Torque motor modules are fixedly connected to the bottom surfaces of both ends of the main body of each Y-axis sliding module, and magnetic wheels are connected to the drive ends of the torque motor modules. The main bodies of the X-axis sliding modules are fixedly connected to the sliders of the two sets of Y-axis sliding modules at both ends. The middle part of the main body of the Z-axis sliding module is fixedly connected to the slider of the X-axis sliding module. The slider of the Z-axis slide module is fixedly connected to a clamping mechanism. The main body of the clamping mechanism is fixedly connected to a vision device. The vision device is a vision camera with a tracker. The clamping part of the clamping mechanism is detachably connected to a cutting gun or a welding gun. The vision shooting end of the vision device, the cutting end of the cutting gun, and the welding end of the welding gun are all set downwards. The vision device is used to identify and track the outline of the elliptical doorway drawn in advance on the wind turbine tower. The cutting gun and the welding gun perform flame cutting and arc welding on the outline of the elliptical doorway respectively according to the trajectory tracked by the vision device.

2. The crawling welding and cutting integrated robot as described in claim 1, characterized in that, The distance between the two sets of Y-axis sliding modules is greater than the minor axis of the elliptical doorway outline drawn in advance on the wind turbine tower, and the length of the Y-axis sliding module is greater than the major axis of the elliptical doorway outline drawn in advance on the wind turbine tower.

3. The crawling welding and cutting integrated robot as described in claim 1, characterized in that, Both the cutting gun and the welding gun are equipped with pressure sensors, and the pressure sensing end of the pressure sensor is at the same horizontal position as the cutting end of the cutting gun and the welding end of the welding gun.

4. The crawling welding and cutting integrated robot as described in any one of claims 1 to 3, characterized in that, It also includes a robot system, which comprises a switch, an industrial computer, a motion controller, and a power conversion circuit, all electrically connected to the switch. The motion controller can be electrically connected to the torque motor module, the X-axis slide module, the Y-axis slide module, and the Z-axis slide module via network or line connection, respectively. The switch is electrically connected to the tracker and vision camera of the vision device via network. The switch is electrically connected to the cutting gun or welding gun via I / O interface. The power conversion circuit is used to power the switch. The industrial computer is electrically connected to a touch screen.

5. A method for operating the crawling welding and cutting integrated robot as described in claim 4, characterized in that, Includes the following steps: S10: Draw the outline of an elliptical doorway outside the wind turbine tower. The color of the elliptical doorway outline is different from the color of the wind turbine tower surface. S20: The crane places the integrated robot directly below the elliptical doorway outline of the wind turbine tower, so that the wheel surfaces of all the magnetic wheels are in contact with the surface of the wind turbine tower. The robot system controls the torque motor module to drive the magnetic wheels to roll, so that the integrated robot crawls towards the elliptical doorway outline until the integrated robot covers the elliptical doorway outline. S30: The linear drive devices of the Y-axis slide module and the X-axis slide module of the robot system synchronously drive the vision device to scan layer by layer from bottom to top. The vision device identifies the position of the elliptical doorway outline based on the color of the outline. S40: Install the cutting gun in the clamping part of the clamping mechanism and adjust the position of the cutting gun. The robot system controls the Y-axis slide module and the X-axis slide module to drive the cutting gun to move along the trajectory of the elliptical door opening outline. The Z-axis slide module is used to make the welding head of the cutting gun contact the elliptical door opening outline and perform flame cutting to cut out the elliptical door opening. S50: Temporarily fix the door frame to the inner wall of the elliptical doorway; S60: After removing the cutting gun from the clamping part of the clamping mechanism, install the welding gun and adjust the position of the welding gun. The robot system drives the welding gun to further contact the outline of the elliptical doorway and perform arc welding through the Y-axis slide module, X-axis slide module and Z-axis slide module to weld and fix the doorway frame. S70: The robot system controls the Z-axis slide module to retract the vision device and welding torch to the highest position, and the torque motor module drives the magnetic chuck to roll, so that the integrated robot can crawl to the bottom of the wind turbine tower.

6. The working method of the crawling welding and cutting integrated robot as described in claim 4, characterized in that: S10 further includes: extending the straight lines on both sides of the minor axis of the elliptical doorway outline downwards to draw an extension line, the extension line extending to the bottom of the wind turbine tower, the color of the elliptical doorway outline and the extension line being different from the color of the wind turbine tower surface, and the color of the elliptical doorway outline being different from the color of the extension line. In step S20, the control torque motor module drives the magnetic chuck to roll, causing the integrated robot to crawl towards the elliptical doorway outline until it covers the outline. This includes: after the crane places the integrated robot directly below the elliptical doorway outline of the wind turbine tower, both sets of Y-axis slide modules are positioned outside the two extended lines, and the length direction of the Y-axis slide modules is parallel to the extended lines. The integrated robot crawls towards the elliptical doorway outline through the drive of the torque motor module until the top of the Y-axis slide module exceeds the top of the elliptical doorway outline, but the bottom of the Y-axis slide module does not exceed the bottom of the elliptical doorway outline.

7. The working method of the crawling welding and cutting integrated robot as described in claim 4, characterized in that, In step S30, the vision device scans layer by layer from bottom to top, and obtains the position of the elliptical doorway outline based on its color, including: S31: The robot system establishes an XY-axis coordinate system on the plane formed by two sets of Y-axis sliding modules, and takes the center of the ellipse of the elliptical doorway contour as the origin, which is defined as (h, k). Given that the length of the major semi-axis of the elliptical doorway contour is a and the length of the minor semi-axis is b, the parametric equations of the elliptical doorway contour are: x(t) = h + a*cos(t); y(t) = k + b*sin(t), where the range of t is [0, 2π]. S32: During layer-by-layer scanning, the vision device simultaneously discretizes the elliptical trajectory of the elliptical doorway outline. Based on the distance L that the Y-axis slide module moves the vision device each time, the number N of discretized points after layer-by-layer scanning can be obtained. Therefore, the number of discretized points N and the discretization parameter t can be calculated. i N = 4a / L - 2; t i =2πi / N=πi*(L-2) / 2a, where i=0, 1, 2,…, N−1; S33: The coordinates (x, y) of each discrete point on the corresponding elliptical doorway outline obtained by the vision device through layer-by-layer scanning can be calculated based on the parameter ti. i y i ):x i =h+a*cos(πi*(L-2) / 2a), y i =k+b*sin(πi*(L-2) / 2a).

8. The working method of the crawling welding and cutting integrated robot as described in claim 7, characterized in that, In step S40, the robot system controls the Y-axis slide module and the X-axis slide module to move the cutting gun along the trajectory of the elliptical doorway outline, including: Based on the coordinates of each discrete point of the elliptical doorway outline in S33, the coordinates of one endpoint of the straight line on the left or right side of the elliptical doorway are obtained and used as the starting / ending point for the cutting or welding gun to perform cutting or welding; the Y-axis slide assembly and the X-axis slide assembly drive the cutting gun to the starting / ending point, thereby controlling the cutting gun to move clockwise along the elliptical doorway outline.

9. The working method of the crawling welding and cutting integrated robot as described in claim 4, characterized in that: In step S40, when the cutting gun performs flame cutting on the outline of the elliptical doorway, the industrial control computer of the robot system receives the pressure value sensed by the pressure sensor of the cutting gun in real time. When the pressure value of the pressure sensor is within the range of 50N-100N, it indicates that the cutting is in normal condition. When the pressure value sensed by the pressure sensor jumps from the range of 50N-100N to 0, it indicates that the corresponding position has been cut. Otherwise, it indicates that the flame cutting is abnormal. In S60, when the welding torch is welding the elliptical weld seam, the switch of the robot system receives the pressure value sensed by the pressure sensor of the welding torch in real time. When the pressure value of the pressure sensor is in the range of 5N-10N, it indicates that the welding is in normal condition; otherwise, it indicates that the arc welding process is abnormal.

10. The working method of the crawling welding and cutting integrated robot as described in claim 4, characterized in that, In S20, after the crane places the integrated robot directly below the elliptical doorway outline of the wind turbine tower, it also includes: adjusting the mounting bolts of the torque motor module to adjust the angle between the torque motor module and the magnetic chuck so that the wheel surface of the magnetic chuck fits well with the surface of the wind turbine tower, and then tightening the bolts to fix the torque motor module.

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