| Aluminum alloy train body is mainly made by welding technology. After the welding work, the weld seam on aluminum alloy train body need smoothing treatment. Currently the weld seam on aluminum alloy train body is mainly processed by manual polishing, its processing efficiency is very low and the labor intensity is very large. In this paper, a robot for milling long and straight weld seam is designed for the smoothing treatment of the weld seam on aluminum alloy train body, and do some related research on the robot. The robot realizes the smoothing treatment of the weld seam by milling process.Work tasks of the robot is analyzed and the program of robot body is designed. Depending on the design of the program, structure of the mechanical body is designed. The three-dimensional solid model of mechanical body parts is created by CATIA. The virtual assembly and interference checking of mechanical body are completed by CATIA. The static analysis of the key components such as roller bracket and the modal analysis of welded frame are completed by ANSYS.The working principle of the robot is introduced. Motion of the robot is provided by a mobile car used differential steering. The motion and the motion characteristics of the mobile car and the milling robot tool system are analyzed. The working pose of the mobile car in the robot working process is analyzed, and the motion condition of the mobile car is obtained. According to the motion characteristics of milling tool system and the motion condition of the mobile car, the motion control solution and motion control flow of the mobile car are determined. And the motion parameters of the mobile car are determined.The functional requirements of the robot control system are analyzed and the program of the robot control system is designed. The controller of the control system is PLC and the host computer of the control system is HMI. The hardware of the control system is designed. The PLC hardware configuration and allocation of the PLC I/O ports are completed. The wiring scheme among the main hardware is determined. The operator interface of HMI is developed. The automatic control flow and the manual control program of the control system are designed. The implementation of PLC main control functions is introduced. The PLC program is designed by LAD in structured programming mode and the PLC program is simulated. The results of the simulation show that the PLC program designed is right and it can achieve its intended function.The PLC control cabinet is made of existing equipment. The experiment of servo motor speed control is carried out, and the control of servo motor speed by PLC using the analog is achieved. The debugging test of the key program blocks is carried out. The results of the test show that the program blocks designed are right and they can achieve their intended function. The experiment of simulating manual control of the mobile car by controlling two servo motor speed of is carried out. The result of the experiment shows that the hand control program designed is right and it can realize its intended control function.The robot designed in this paper can remove long and straight weld seam on the aluminum alloy train body with reinforcement all quickly and reliably, and complete the smoothing treatment of the weld seam. In addition, it can remove most of the weld seam and provide uniform grinding margin and high-quality surface to be machined for the subsequent grinding process. In this way, it is beneficial to reducing labor intensity and reducing the technical requirements for workers. |
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