A method for realizing off-line program zero debugging welding of hydraulic support main reinforcement assembly pre-burying based on welding simulation technology

Abstract

The application provides a method for realizing zero-debugging welding of hydraulic support main rib assembly pre-burying offline program based on welding simulation technology, according to three-dimensional model and finite element analysis, the deformation area of the workpiece after welding and cooling is predicted; according to the prediction result, offline programming is carried out, the workpiece is touched and positioned and stored in different position registers; according to the prediction result and the established position register number, the touch and positioning of the deformation direction are carried out on the area of single direction deformation, and the rest directions are solved through operation; the trajectory point position of the welding offline program is grouped and processed; the offline welding program deviation caused by welding deformation is automatically corrected according to the position register coordinate information obtained by positioning. The method has the advantages that the offline welding program trajectory deviation problem caused by welding deformation is changed from manual on-site debugging to automatic correction by the welding robot using its own system, the welding quality is improved, and the production change time is greatly shortened.

Description

Technical Field

[0001] This invention relates to the field of hydraulic support manufacturing technology, and more specifically, to a method for achieving zero-debugging offline program welding of the main rib assembly of a hydraulic support based on welding simulation technology. Background Technology

[0002] Hydraulic supports, as key support equipment in fully mechanized coal mining, play a vital role in ensuring safe production in coal mines. Their main structural components are primarily large steel structures, such as top beams, shield beams, and bases. Among these, the main reinforcement assembly is the core of the support's main structure, and its welding quality directly affects the support's performance and reliability. During the pre-embedding process of the hydraulic support's main reinforcement assembly, due to the structural characteristics of the assembly, the welding process often suffers from uneven heat input, leading to uneven stress caused by thermal expansion and contraction, resulting in deformation. This affects the welding quality and accuracy of the offline welding process, requiring reliance on manual experience and on-site adjustments to correct welding points. As coal mining moves towards deeper and more complex geological conditions, and with increasing competition in the coal mining machinery market, the requirements for hydraulic support performance and delivery time are becoming increasingly stringent. Therefore, how to weld the main reinforcement assembly of hydraulic supports with high quality and efficiency is one of the urgent problems that major domestic hydraulic support manufacturers need to solve.

[0003] With the continuous development of welding simulation technology and the widespread application of welding robots, the generation, distribution and evolution of stress field during the welding process can be simulated through welding simulation technology, which can help optimize the welding effect.

[0004] Chinese invention patent No. 202211106928.9, published on October 14, 2022, entitled "A Welding Robot Control Method for Positioning-Planning-Correction in a Nuclear-Related Environment," describes a welding robot control method for positioning-planning-correction in a nuclear-related environment. The method includes: the robot entering a nuclear-related environment; acquiring environmental information from the environment using a first sensor component; fusing the acquired environmental information to obtain fused environmental data; acquiring the robot's pose information; inputting the robot's pose information and the fused environmental data into a map reconstruction algorithm to construct a 3D map of the nuclear-related environment; and acquiring feature points of the workpiece to be welded. The data is used to match the workpiece to be welded with a 3D map of the nuclear environment through coordinate transformation, determining the robot's initial welding position. The robot then moves to the initial welding position. A 3D model of the workpiece to be welded is constructed, defining the material parameters and meshing the model. A heat source is set according to the actual welding conditions, and the deformation of the workpiece is obtained by solving the finite element model. The deformation of the workpiece and the robot's machining and assembly errors are used as feedforward inputs to plan the robot's welding path. During the welding process, the robot tracks the weld seam in real time using a second sensor component to obtain the weld seam deviation. Based on the deviation, a correction signal is sent to the robot to correct the welding torch in real time.

[0005] The main drawbacks of this scheme are as follows: 1. When there are multiple weld seam trajectories on the same workpiece, it can only correct the deviation of a single trajectory during the welding process and cannot accurately locate the starting position of the remaining weld seams after the workpiece is deformed by welding; 2. The front-end planning of the welding path is complicated and requires different welding paths to be planned based on the deformation amount and assembly error amount of the simulation results.

[0006] In order to solve the above problems, people have been seeking an ideal technological solution. Summary of the Invention

[0007] The purpose of this invention is to address the shortcomings of existing technologies by providing a method based on welding simulation technology to achieve zero-debugging offline program welding of hydraulic support main rib components. This method addresses the issue of offline welding program trajectory deviation caused by welding deformation by replacing manual on-site debugging with automatic correction by a welding robot using its own system. This improves welding quality and significantly shortens changeover time.

[0008] To achieve the above objectives, the technical solution adopted by this invention is: a method for realizing offline program zero-debugging welding of hydraulic support main rib assembly pre-embedded components based on welding simulation technology, comprising the following steps: Step 1) Obtain the 3D model of the workpiece and perform mesh generation on the 3D model of the workpiece; Step 2) Perform finite element analysis based on welding simulation technology on the meshed workpiece to simulate the generation, distribution and evolution of stress field during welding in advance, and predict the residual stress and deformation area of ​​the workpiece after welding and cooling. Before the previous welding trajectory ends and the next welding trajectory begins, execute steps 3) to 5). Step 3) Number the different position registers based on the position register information of the field welding equipment; Step 3.1) For areas with multi-directional deformation: Perform offline programming based on the prediction results and the established position register numbers, and plan the welding torch to perform touch positioning based on 3D touch sensors on the areas with multi-directional deformation before welding begins, and store different positioning results in different position registers; Step 3.2) For areas deformed in one direction: perform offline programming based on the prediction results and the established position register number, perform touch-and-find positioning in the deformation direction for areas deformed in one direction, and store the positioning results in the position register. For non-deformation directions, use register position operation to obtain the register information of the deformation position in one direction. Step 4) For the trajectory point grouping processing of the welding offline program, based on the prediction results of Step 2) and the position register number established in Step 3), the trajectory point groups within the same deformation range call the same position register number, and the trajectory point groups within different deformation ranges call different position register numbers. Step 5) Send the offline program to the welding robot through the host computer. The robot automatically corrects the deviation of the offline welding program caused by welding deformation based on the position register coordinate information obtained by positioning, so as to realize zero-debugging welding of the main rib component pre-embedded offline program.

[0009] This invention utilizes finite element analysis based on welding simulation technology to predict the deformation area of ​​the workpiece. Based on the prediction results, offline programming is performed in real time. Different strategies are used to determine positioning information based on multi-directional and unidirectional deformation, and this information is stored in corresponding position registers. The trajectory points are then grouped and processed. Finally, this information is corrected and incorporated into the distributed offline program, achieving zero-debugging welding of the main rib assembly's pre-embedded offline program. This solution identifies the deformation caused by the previous welding trajectory through robot touch positioning, achieving multi-trajectory collaborative correction. Furthermore, assembly errors and welding-related deformations do not need to be considered during the planning stage. Secondary positioning is achieved through planning based on a 3D model and robot touch positioning, with real-time correction based on the positioning results, achieving zero-debugging welding and significantly improving welding efficiency.

[0010] Based on the above, the position register is the position register that comes with the welding robot.

[0011] This solution relies on the existing hardware structure for planning and correction, eliminating the need for additional hardware purchases and thus controlling the transformation costs.

[0012] Based on the above, in step 4), the register position operation used in the other directions means that the information in the non-deformed direction is the same as that in the previous position register, and can be updated according to the data of the single-direction deformation.

[0013] Based on the above, in step 6), the welding robot achieves touch positioning by sensing the current generated when the welding wire touches the workpiece during actual operation. The position information obtained by the touch sensing is stored in the position register in the robot system. Each group of points is based on the coordinates of different position registers, and the offline welding program deviation caused by welding deformation is automatically corrected, so as to realize the offline program zero-debugging welding of the main rib component.

[0014] This invention has outstanding substantive features and significant progress compared to the prior art. Specifically, this invention utilizes a three-dimensional model based on finite element analysis of welding simulation technology to predict the deformation area of ​​the workpiece after welding and cooling, obtain the deformation trend, and then use the robot's touch-and-positioning function to locate the multi-directional deformation area and the unidirectional deformation area with different strategies, obtain the specific deformation amount, store it in the position register and assign it a number, and process it in groups according to the different deformation ranges. Finally, based on the position register coordinate information obtained from the positioning, the offline welding program deviation caused by welding deformation is automatically corrected, realizing zero-debugging offline program welding of the hydraulic support main rib assembly.

[0015] Furthermore, this solution requires no additional hardware investment, relying entirely on the welding robot's own system for computation, thus saving costs and facilitating the transformation of existing systems.

[0016] Furthermore, by repeatedly touching and positioning the robot during operation, it can identify the amount of deformation generated during the welding of the previous welding trajectory, thus achieving multi-trajectory collaborative correction. Attached Figure Description

[0017] Figure 1 This is a flowchart of the method for achieving zero-debugging offline program welding of hydraulic support main rib components based on welding simulation technology in this invention. Detailed Implementation

[0018] The technical solution of the present invention will be further described in detail below through specific embodiments.

[0019] like Figure 1 As shown, a method for achieving zero-debugging offline welding of hydraulic support main rib components based on welding simulation technology includes the following steps: Step 1) Obtain the 3D model of the workpiece and perform mesh generation on the 3D model of the workpiece.

[0020] Step 2) Use welding simulation technology to perform finite element analysis on the meshed workpiece, simulate the generation, distribution and evolution of stress field during welding in advance, and predict the residual stress and deformation area of ​​the workpiece after welding and cooling.

[0021] Before the previous welding trajectory ends and the next welding trajectory begins, execute steps 3) to 5). This is because each welding action causes the workpiece to deform in real time. The deformation trend can be obtained based on the prediction in step 2), but the specific amount of deformation cannot be determined during the welding process. Therefore, it is necessary to achieve positioning through real-time positioning.

[0022] Step 3) Number the different position registers based on the position register information of the welding robot; Step 3.1) Perform offline programming based on the prediction results. Plan the welding torch, carrying the welding wire, to perform touch positioning based on 3D touch sensors on the multi-directional deformation area before welding begins. Store different positioning results in different position registers and assign different position register numbers PR[n1], PR[n2], PR[n3], etc. The following is the deformation situation of the multi-directional area: Deformation direction Deformation range X 5mm-8mm Y 2mm-5mm Z 3mm-6mm Input logic for the multi-directional deformation region position register: 1: Search Start [1] PR[n1]; 2:LP[1] 300mm / sec FINE; 3:LP[1] 300mm / sec FINE Search[X]; 4:LP[2] 300mm / sec FINE; 5:LP[2] 300mm / sec FINE Search[Y]; 6:LP[3] 300mm / sec FINE; 7:LP[3] 300mm / sec FINE Search[Z]; 8: Search End.

[0023] Step 3.2) Based on the prediction results and the established position register numbers, perform register position calculations on the unidirectional deformed area. The information in the non-deformed direction is the same as that in the previous position register. The deformed direction re-touches the sensor for positioning and obtains the unidirectional deformed position register information. The following is an example of unidirectional area deformation: Deformation direction Deformation range X 0mm Y 0mm Z 7mm Input logic for the region position register that deforms in one direction: 1: Search Start [1] PR[n2]; 2: PR[n2,1]=PR[n1,1]; 3: PR[n2,2]=PR[n1,2]; 4:LP[1] 300mm / sec FINE; 5:LP[1] 300mm / sec FINE Search[Z]; 6: Search End; The last number in the position registers PR[n2,1], PR[n2,2], and PR[n2,3] represents the X, Y, and Z coordinate information of the position register PR[n2], respectively.

[0024] Step 4) For the trajectory point grouping processing of the welding offline program, based on the prediction results of Step 2) and the position register number established in Step 3), the trajectory point groups within the same deformation range call the same position register number, and the trajectory point groups within different deformation ranges call different position register numbers.

[0025] 1: Touch Offset PR[n1]; 2: LP[1] 50mm / sec FINE Weld Start[3,1]; 3: LP[2] WELD_SPEED FINE; 4: Touch Offset End; ... 10: Touch Offset PR[n2]; 11: LP[8] WELD_SPEED FINE; 12: LP[9] WELD_SPEED FINE; 13: Touch Offset End; ... 16: Touch Offset PR[n3]; 17: LP

[14] WELD_SPEED FINE; 18: LP

[15] WELD_SPEED FINE Weld End[3,1,WID:0]; 19: Touch Offset End.

[0026] Step 5) The offline program is sent to the welding robot through the host computer. When the welding robot is actually running, it generates a current sensor based on the welding wire touching the workpiece. The position information obtained by the touch sensor is stored in the position register in the robot system. Each group of points is based on the coordinates of different position registers, and the offline welding program deviation caused by welding deformation is automatically corrected, so as to realize the zero-debugging welding of the main rib component pre-embedded offline program.

[0027] 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 preferred embodiments, those skilled in the art should understand that modifications can still be made to the specific implementation of the present invention or equivalent substitutions can be made to some technical features without departing from the spirit of the technical solutions of the present invention, and all such modifications and substitutions should be covered within the scope of the technical solutions claimed in the present invention.

Claims

1. A method for achieving zero-debugging offline welding of hydraulic support main rib components based on welding simulation technology, characterized in that: Includes the following steps: Step 1) Obtain the 3D model of the workpiece and perform mesh generation on the 3D model of the workpiece; Step 2) Perform finite element analysis based on welding simulation technology on the meshed workpiece to simulate the generation, distribution and evolution of stress field during welding in advance, and predict the residual stress and deformation area of ​​the workpiece after welding and cooling. Before the previous welding trajectory ends and the next welding trajectory begins, execute steps 3) to 5). Step 3) Number the different position registers based on the position register information of the field welding equipment; Step 3.1) For areas with multi-directional deformation: Perform offline programming based on the prediction results and the established position register numbers, and plan the welding torch to perform touch positioning based on 3D touch sensors on the areas with multi-directional deformation before welding begins, and store different positioning results in different position registers; Step 3.2) For areas deformed in one direction: perform offline programming based on the prediction results and the established position register number, perform touch-and-find positioning in the deformation direction for areas deformed in one direction, and store the positioning results in the position register. For non-deformation directions, use register position operation to obtain the register information of the deformation position in one direction. Step 4) For the trajectory point grouping processing of the welding offline program, based on the prediction results of Step 2) and the position register number established in Step 3), the trajectory point groups within the same deformation range call the same position register number, and the trajectory point groups within different deformation ranges call different position register numbers. Step 5) Send the offline program to the welding robot through the host computer. The robot automatically corrects the deviation of the offline welding program caused by welding deformation based on the position register coordinate information obtained by positioning, so as to realize zero-debugging welding of the main rib component pre-embedded offline program.

2. The method for achieving zero-debugging offline program welding of hydraulic support main rib assembly based on welding simulation technology according to claim 1, characterized in that: The position register is the position register that comes with the welding robot.

3. The method for achieving zero-debugging offline program welding of hydraulic support main rib assembly based on welding simulation technology according to claim 1, characterized in that: In step 4), the register position operation used in the other directions means that the information in the non-deformed direction is the same as that in the previous position register.

4. The method for achieving zero-debugging offline program welding of hydraulic support main rib assembly based on welding simulation technology according to claim 1, characterized in that: In step 6), during actual operation, the welding robot uses the current sensing generated by the welding wire touching the workpiece to achieve touch positioning. The position information obtained by the touch sensing is stored in the position register in the robot system. Each group of points uses the coordinates of different position registers as a reference to automatically correct the offline welding program deviation caused by welding deformation, thereby realizing zero-debugging welding of the main rib component pre-embedded offline program.

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