Ship robot double-wire welding process and welding equipment based on model driving and visual matching fusion

Abstract

The invention discloses a ship robot double-wire welding process and welding equipment based on model driving and visual matching fusion. The ship robot double-wire welding process comprises the following steps that an adaptive robot double-wire welding process is selected; visual scanning, model introduction and fusion are completed by the structured light shooting camera; clicking the welding plan to generate a welding operation file; a welding seam information json file is imported, and a robot welding operation list is generated; gun cleaning operation is executed, and welding is conducted after gun cleaning is completed; a welding task is automatically executed according to the welding operation list, gun cleaning is automatically completed according to the length of the welding seam, and welding of the next welding seam is continued; through the model driving and visual matching fusion algorithm, collaborative operation of model importing and visual scanning is achieved, the success rate of one-time workpiece recognition is high, the recognition precision is high, the welding seam positioning time is shortened, the arcing rate of the robot is increased, and the overall welding capacity and the unit area output efficiency are improved.

Description

Technical Field

[0001] This invention relates to the field of ship manufacturing technology, specifically to a ship robot dual-wire welding process and welding equipment based on the fusion of model-driven and vision matching. Background Technology

[0002] The shipbuilding industry is facing increasingly fierce market competition. Shipyards are being driven to promote automated and intelligent production of small assembly lines due to factors such as a surge in orders, difficulty in recruiting workers and high labor costs. This has also driven the technological upgrading of process equipment suppliers.

[0003] Existing robotic welding equipment for ships generally suffers from insufficient welding capacity, output per unit area that cannot match the production needs of shipyards, and low return on investment. Therefore, it is urgent to develop efficient robotic welding equipment and supporting processes through technological innovation to solve these problems. Summary of the Invention

[0004] This invention proposes a dual-wire welding process and welding equipment for marine robots based on model-driven and vision matching fusion. Through the combination of dual-wire welding, structured light camera, and line laser sensor, multiple workpieces and multiple weld seams in the welding area can be identified at once.

[0005] To achieve the above objectives, the technical solution of the present invention is as follows: A dual-wire welding process for marine robots based on model-driven and vision-matching fusion includes the following steps: Step S1) Select the appropriate robotic twin-wire welding process based on the actual ship welding application scenario; Step S2) The structured light camera completes visual scanning, model import and fusion, generates point cloud files, groups and selects the generated point cloud files, and trims off the redundant point clouds that do not need to be welded for recognition. Step S3) Click on the welding plan to generate a welding operation file. Before the robot performs welding, the welding current and voltage can be dynamically adjusted by modifying the plate thickness parameters and retrieving the welding parameter database. Step S4) Import the weld information JSON file and generate a list of robot welding jobs; Step S5) Switch the teach pendant to external automatic mode and complete BCO confirmation. Perform the torch cleaning operation in external operation or automatic mode. After the torch cleaning is completed, perform welding. Step S6) The robot automatically executes the welding task according to the welding job list, automatically cleans the torch according to the weld length and continues welding the next weld. Step S7) If a stop command is triggered during the welding process, the robot will stop its action after the current weld seam is completed; Step S8) Repeat steps S1 to S7 to realize the dual-wire welding operation of the ship robot based on the fusion of model-driven and vision matching.

[0006] Furthermore, before welding in step S6, stiffener identification is performed based on the scanning results of the structured light camera to confirm the position of the small group of stiffeners on the base plate and identify the weld type. The rationality of the weld length and type is verified, and the weld length is checked for any missing parts to avoid the risk of robot collision caused by weld interference.

[0007] Furthermore, in step S6, an additional manual torch cleaning and venting is required before the first welding operation each day.

[0008] Furthermore, in step S6, for the scenario of double-wire vertical welding with lower wrap corner welding, a welding strategy of continuous spot welding with small parameters is adopted, including the following steps: Step S61) Arrange several arc-starting / arresting points on the welding trajectory of the lower corner; Step S62) Set the first arc ignition / extinguishing point at the center of the plate thickness of the material to be welded, and perform arc ignition, delayed pause welding, and arc extinguishing operations at this point; Step S63) Move the welding torch 2-3mm outward from the plate to the next arc ignition / extinguishing point, and repeat the arc ignition, delayed pause welding, and arc extinguishing operation; Step S64) Repeat step S83 until the welding torch moves to the point on the outside of the plate thickness; Step S65) Move the welding torch up to the vertical welding arc initiation point and execute the vertical welding procedure to complete the subsequent welding.

[0009] The welding equipment for a marine robot, applied to the dual-wire welding process of a marine robot based on model-driven and vision-matching fusion, includes a welding gantry and two linear guide rails. The linear guide rails are symmetrically arranged on the left and right sides. The welding gantry includes two columns and a crossbeam. The lower ends of the columns are slidably connected to the linear guide rails via sliders. A welding bracket is provided vertically along the front side of the crossbeam. The rear end of the welding bracket and the front end of the crossbeam are driven by gears and racks. A robot is provided at the bottom of the welding bracket. The robot is equipped with a welding torch. A structured light camera is provided in the middle of the front end of the welding bracket. The structured light camera is communicatively connected to the robot.

[0010] Furthermore, the structured light camera is mounted on the front end of the welding bracket via a camera mounting bracket.

[0011] Compared with the prior art, the present invention has the following advantages: By integrating model-driven and vision-matching algorithms, collaborative operation between model import and visual scanning is achieved. This results in a high success rate and accuracy in workpiece recognition, shortens weld positioning time, increases robot arc ignition rate, and improves overall welding capacity and output efficiency per unit area. Attached Figure Description

[0012] Figure 1 This is a schematic diagram of the welding equipment of the present invention; Figure 2 This is a schematic diagram of continuous spot welding with small parameters according to an embodiment of the present invention; Figure Labels 1. Welded gantry frame, 2. Linear guide rail, 3. Upright column, 4. Crossbeam, 5. Welded support frame. 6. Robots; 7. Structured light cameras. Detailed Implementation

[0013] The technical solution of the present invention will now be clearly and completely described with reference to the accompanying drawings. Obviously, the described embodiments are only some, not all, of the embodiments of the present invention. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0014] This embodiment proposes a dual-wire welding process and welding equipment for marine robots based on model-driven and vision-matching fusion, such as... Figure 1 As shown, The welding equipment includes a movable welding gantry 1, a robot 6, a dual-wire welding system, a structured light camera 7, and a line laser sensor. The welding gantry 1 includes two columns 3 and a crossbeam 4. A welding bracket 5 is installed at the front end of the crossbeam 4. The robot 6 is equipped with a welding torch.

[0015] Robot 6 moves via an X-axis moving mechanism and a Y-axis moving mechanism. The X-axis moving mechanism is driven by a gear and rack between the welding bracket 5 and the crossbeam 4, while the Y-axis moving mechanism achieves displacement via double linear guide rails 2. The structure light camera 7 is fixed to the welding bracket 5 via a camera mounting bracket. The structure light camera 7 and robot 6 are connected for communication, enabling accurate identification of multiple workpieces and welds within the welding area.

[0016] The twin-wire welding process specifically includes the following steps: Process selection: For different weld types of T-joints and corner joints in ship assembly, select the corresponding double-wire welding process and clarify the core parameters of welding materials and basic current and voltage range.

[0017] Visual scanning: The robot 6 starts its automatic scanning program, and the structured light camera 7 performs a full-area scan of the welding area to generate a 3D point cloud file. The operator selects the point cloud data corresponding to the target weld and removes redundant point clouds in irrelevant areas to ensure recognition accuracy.

[0018] Weld inspection: The system automatically identifies the group of vertical stiffening plates on the base plate, matches the corresponding weld type, and manually checks the weld length and position offset. After confirming that there is no risk of weld interference, it proceeds to the next step.

[0019] Parameter adjustment and job generation: Based on the actual thickness of the plate to be welded, the welding parameter database is retrieved and the current and voltage parameters are fine-tuned. The welding planning module is clicked to generate a welding job file, and the weld seam JSON information is imported to form an orderly welding job list.

[0020] Gun cleaning and welding: Switch the teach pendant to external automatic mode and complete BCO confirmation. First, perform automatic gun cleaning. Since the welding gun is prone to residual impurities during the first welding of the day, perform an additional manual gun cleaning and venting. After cleaning, start the welding command. Robot 6 completes the welding of the seams in sequence according to the work list. It can also automatically trigger the gun cleaning action and continue to the next seam according to the length of a single weld.

[0021] Emergency Stop: If a pause is required during the welding process, the robot 6 will not stop immediately after the stop command is triggered. It will complete the welding of the current weld seam before stopping all actions to avoid welding defects.

[0022] To address the issue of interference between the welding torch and the base plate in vertical fillet welds of shipbuilding crews, a forming strategy of continuous spot welding with small parameters is adopted, such as... Figure 2 As shown, the specific steps are as follows: Point layout: Multiple arc starting / extinguishing points are planned in advance on the lower corner welding trajectory. The point spacing is set to 2-3mm, and the first point P1 corresponds to the center position of the plate thickness, and the last point P4 extends to the outside of the plate thickness.

[0023] Layered spot welding: The welding torch is started at the first spot P1. Welding is carried out with the preset current and voltage, and the welding is delayed and paused. After ensuring that the molten pool is stable, the arc is extinguished. Then, it is moved 2-3mm outward to the next spot P2. The arc starting, pausing and extinguishing operation is repeated at spot P3 until the spot welding operation of all spots in the plate thickness direction is completed. Then, it is moved to the spot P4 on the outer side of the plate thickness.

[0024] Vertical welding continuation: Move the welding torch upward to the preset arc starting point P5 for vertical welding, switch to continuous welding mode, and complete the overall weld formation of the vertical welding lower corner, effectively avoiding the interference problem between the welding torch and the base plate, and eliminating the need for subsequent manual welding.

[0025] 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, those skilled in the art should understand that 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; and these modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the scope of the technical solutions of the embodiments of the present invention.

Claims

1. A model-driven and vision-matching fusion-based robotic twin-wire welding process for a ship, characterized by, Comprising the following steps: Step S1) Select the appropriate robot double-wire welding process in combination with the actual ship welding application scenario; Step S2) Complete visual scanning, model import and fusion by the structured light camera, generate point cloud files, group and frame the generated point cloud files, and cut off unnecessary point clouds that do not need to be welded; Step S3) Click to generate a welding job file, and before the robot performs welding, the welding current and voltage can be dynamically adjusted by modifying the plate thickness parameters and calling the welding parameter database content; Step S4) Import the weld information json file to generate a robot welding job list; Step S5) Switch the teach pendant to external automatic mode and complete BCO confirmation, perform a gun cleaning operation in external operation or automatic state, and then perform welding after the gun cleaning is completed; Step S6) The robot automatically performs the welding task according to the welding job list, automatically completes the gun cleaning according to the weld length, and continues the next weld welding; Step S7) If the stop instruction is triggered during welding, the robot will stop after the current weld is welded; 2. The ship robotic twin wire welding process of claim 1, wherein, Step S8) Repeat steps S1~S7 to realize ship robot double-wire welding operation based on model-driven and visual matching fusion.

3. The ship robotic twin wire welding process of claim 1, wherein, Before welding in step S6, the rib plate is identified based on the scanning results of the structured light camera, the position of the small group rib plate on the bottom plate is confirmed, the weld type is identified, the rationality of the weld length and type is verified, and the weld length is checked for missing, and the risk of robot collision caused by weld interference is avoided.

4. The ship robotic twin wire welding process of claim 1, wherein, In step S6, an additional manual gun cleaning and deflation are required before the first welding of the day. In step S6, for the double-wire vertical welding under the wrap angle welding scenario, a small parameter continuous spot welding strategy is adopted, comprising the following steps: Step S61) Arrange several arc starting / extinguishing points on the wrap angle welding motion track; Step S62) Set the first arc starting / extinguishing point at the center of the plate thickness of the to-be-welded plate, and perform arc starting, delay pause welding and arc extinguishing operations at this point; Step S63) Move the welding torch 2~3mm to the next arc starting / extinguishing point outside the plate, and repeat the arc starting, delay pause welding and arc extinguishing operations; Step S64) Repeat step S83 until the welding torch moves to the point outside the plate thickness; 5. The ship robot welding equipment applied to the ship robot double-wire welding process based on the model-driven and visual matching fusion of any one of claims 1-4, characterized in that, Step S65) Move the welding torch upward to the vertical upward welding arc starting point, and perform subsequent welding after completing the vertical upward welding program. It comprises a welding gantry and two straight linear guides, the straight linear guides are symmetrically arranged left and right, the welding gantry comprises two upright columns and a crossbeam, the lower end of the upright column is slidably connected with the linear guide through a sliding block, the front side of the crossbeam is provided with a welding support along the vertical direction, the rear end of the welding support and the front end of the crossbeam are drivingly connected through a gear and a rack, the bottom end of the welding support is provided with a robot, the robot is provided with a welding torch, the middle part of the front end of the welding support is provided with a structured light camera, and the structured light camera and the robot are in communication connection.

6. The ship robot welding equipment according to claim 5, wherein the structured light camera is mounted on the front end of the welding support through a camera mounting support.

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