Research On Integrated Controlling System Of Mechatronics And Welding

With the development of science and technology as well as the increasing demand forwelding products of high quality and quality coherence, welding technology is more andmore mechanized and automatic.A controlling integrated system was proposed, based on the welding technique ofultra-thin plate using micro plasma arc welding.The proposed system integrated thefollowing parts(1)the high-precision work-piece assembly system controlled by PLC,including high precision(10-2mm) pneumatic positioner,fixture, gun lifting mechanism andthe gun-adjustment dimensional mechanism. The integration of this part is to control theassemble parameters such as torch transverse alignment, assembly gap between butt jointand so on to meet the welding process requirement. Clock singnals to control theadjustment step motor was achieved.(2) the seeking start/end point system, including thehardware and software wsa researched. The hardware includes BOA camera, gun speeddetecting circuit and the walking mechanism. Based on the requirement of ultra-thin plateswelding process and the integrated hardware, the software accomplished the followingfunctions: realizing the detection of gun speed using A/D, locating the start-point andend-point according to the established work-piece coordinate system. Thus the respectivemathematical model of start-point and end-point was established.(3) the seam trackingsystem, which is to solve the problem of torch transeverse alignment, includs hardware andsoftware. Based on the integrated hardware above such as BOA camera, dimensionaladjustment mechanism walking mechanism and so on, the software realized automatictorch transverse alignment during welding, which solved the welding misalignmentproblem caused by deformation or assembly-related parameters. Communication throughasynchronous serial port was achieved between BOA and DSP controller. To guarantee thereal time control of transverse adjustment, CPU read the deviation information throughSCI interrupt. Based on the real-time welding speed detected by A/D module, themathematical model of collaboration control of walking mechanism and transverseadjustment step motor was established. The real time requirement of seam tracking system was analyzed and discussed.(4)man-machine interaction system, including input devicesintegration such as keys, switches, coder and variable potentionmeter and output devicesintegration, such as LEDS and digital tubes. Man-machine interaction system realized thedetection and processing of input signals as well as displaying parameters and states of theintegrating system during working process.The integrated system accomplished the hardware and software integration of thefunctional subsystem. It provided the welding progress control and welding quality controlfrom work-piece fixing to welding. It provides a fundamental platform to conduct furtherresearch on automatic welding process with micro plasma arc welding and on theoptimization of control methods such as applying intelligent control methods. Tests showthat the integrated system is with high anti-interrupt ability and reliability. Controlperformance is good.