| High power laser diode has been widely used in laser cladding industry because of its small size and high luminous efficiency. In this thesis, device units, hardware circuits, control programs and debugging of the 3kW laser diode-based laser cladding robot have been holistically studied. The main contributions are as follows:(1) The entire control scheme of the laser cladding robot is designed. The Siemens S7-1200 PLC is chosen as the CPU for the control system. The control requirements and communication characteristics of device units such as laser diode, power supply, ABB robot, refrigerating machine and powder feeder are analyzed. An integration scheme is proposed.(2) The structures, working mechanisms and interface definitions of main device units are analyzed. Main parameters which need to be measured and their variation ranges in refrigerating system are analyzed. Appropriate sensors are selected and hardware circuits are designed. The electrical and control circuits are designed for the laser system, robot and controller. The PLC system hardware is configured and I/O port is designed according to the control requirements.(3) The PLC control program which consists of subprograms for controlling laser power, communicating with robot and controlling water cooling parameters is designed. Each subprogram's workflow is explained and further details of main parts of the program are provided. The TK8100i-based man-machine operation interface is designed by using the EB8000 software, which includes main Interface, laser control interface, refrigerator control interface, alarm interface, etc.(4) Control system debugging including laser power testing, cooler system testing and system stability testing is conducted after the hardware design and software programming. The movement control of the robot is studied by modeling the robot workstation using Robotstudio. In order to validate the reliability, three kinds of samples are selected for cladding experiments. The results meet our expected requirements, which indicates that the 3kW laser diode-based laser cladding robot designed in this thesis is satisfactory for practical use... |
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