The All-position Welding Robot’s Institution And Control System Design And Implementation

Currently, the robot technology has already widely used in various industries through decades of booming. Especially the emergence of industrial robots to promote the manufacturing scale production, improve production efficiency and production quality. The subject is from actual needs of a unit for different shapes and sizes of specifications’ automated welding, which include pipelines, tank, tanks, ships, pressure vessels, etc. On the basis, we design and develop all-position welding robot.First, we should analyze technical requirements for all-position welding robot based on the actual welding process. Then, on this basis we designed the all-position welding robot mechanical structure and electrical control as well as detection methods.In terms of the mechanical structure, we designed issue multiple degrees of freedom for all-position welding robot by the Pro/E software. To ensure rigidity and strength of the structure to meet the requirements, carry out nonlinear analysis for the key parts by Pro/Mechanica finite element analysis software. Using matlab robotics toolbox for welding robot kinematics simulation and operational route planning, to provide the basis for the control part of the design.In terms of the detection and guidance, we used the high-precision laser sensor to get the real-time accurate detection and tracking. And used the CCD seam image acquisition and using high-speed DSP to image processing and deviation calculation and seam correction process control.In terms of the control system, lower machine adopts PLC controller, host machine adopts LCD touch screen. According to the welding process, design PLC program control the stepper motor drives to complete the automatic welding. Design man-machine interface to realize real-time monitoring and control of the welding process by configuration software on Lower machine. Between PC and PLC, PLC and stepper motor drivers are connected via RS-485 interface.The subject developed arc welding robot has successfully applied to the actual welding work. The welding effect has reached welding process requirements. And the equipment has gotten pre-acceptance.The topic developed all-position welding robot which has high degree of automation and unique and novel mechanical structure. The robot can meet site automated welding of pipelines, tank, tanks, ships, pressure vessels and other large components.