基于开放式体系结构的弧焊机器人控制系统设计和实现

主要是结合具体的课题工作，探讨在开放式体系结构下构建一种机器人控制系统的软、硬件模型，以适应生产实践中对现有控制系统更新、改造或二次开发的要求。     

铝合金双面自动 TIG立焊计算机控制系统

为实现空分设备的焊接自动化，本文研究了铝合金双面自动TIG立焊二级分布计算机控制系统，此系统的硬件包括5个子系统，即：焊接电源，弧长控制器，焊矩行走机构和检测机构，软件包括在线执行程序和离线服务程序。介绍了此系统的操作原理，规范说明和控制功能，解决了对计算机控制系统的高频干扰问题，使系统工作稳定，控制精度高，采用汉语菜单，操作方便。     

Adaptive fuzzy sliding mode control for an automatic arc welding system

This paper describes an automatic welding control system developed for alternating current shielded metal arc welding (SMAW). This method could replace manual operations which require a well-trained technician. We have derived a mathematical model of the welding control system and identified the system’s parameters. The sliding surface is used as the input variable to reduce the number of fuzzy reasoning rules, in comparison with the conventional two-dimensional fuzzy logic control (FLC) algorithm. An adaptive fuzzy sliding mode controller (AFSMC) consists of an equivalent control part and a hitting control part. An adaptive law derived from a Lyapunov function is used to obtain the FLC’s parameters, and is applied to approximate the equivalent control part of the sliding mode control (SMC), so that the system states can be forced to zero. By using three-rules FLC, the control part that satisfies the hitting conditions of the SMC can force the system’s states to reach and remain on the sliding surface. Therefore, the stability of the AFSMC can be guaranteed and can be used to modulate the rate of the electrode feeding mechanism that regulates the arc current of the SMAW. The simulation and the experimental results both show that this automatic welding control system, based on the AFSMC, can perform effectively.     

Adaptive fuzzy sliding mode control for an automatic arc welding system

This paper describes an automatic welding control system developed for alternating current shielded metal arc welding (SMAW). This method could replace manual operations which require a well-trained technician. We have derived a mathematical model of the welding control system and identified the system’s parameters. The sliding surface is used as the input variable to reduce the number of fuzzy reasoning rules, in comparison with the conventional two-dimensional fuzzy logic control (FLC) algorithm. An adaptive fuzzy sliding mode controller (AFSMC) consists of an equivalent control part and a hitting control part. An adaptive law derived from a Lyapunov function is used to obtain the FLC’s parameters, and is applied to approximate the equivalent control part of the sliding mode control (SMC), so that the system states can be forced to zero. By using three-rules FLC, the control part that satisfies the hitting conditions of the SMC can force the system’s states to reach and remain on the sliding surface. Therefore, the stability of the AFSMC can be guaranteed and can be used to modulate the rate of the electrode feeding mechanism that regulates the arc current of the SMAW. The simulation and the experimental results both show that this automatic welding control system, based on the AFSMC, can perform effectively.     

TIG焊机中引弧、稳弧脉冲装置的原理与故障排除

结合工作经验和具体机型,分析了直流TIG焊机中引弧脉冲装置的原理和交流TIG焊机中引弧、稳弧脉冲装置的原理,根据具体案例,介绍了此类故障的分析思路和排除方法.     

Tuning PID control of an automatic arc welding system using a SMAW process

A new method to tune the gains of the proportional integral derivative (PID) controller for alternating current shield metal arc welding (SMAW) of automatic arc welding system using a SMAW process is presented in this paper. This method used the genetic algorithm (GA) approach to optimize the gains of the PID auto-tuner and considerably modulated the rate of an electrode feed mechanism that regulates arc current. The proposed controller was verified by simulation and experiments of the transient response in the automatic arc welding system. Finally, the performance indices of the proposed controller are compared with that based on Ziegler–Nichols tuning rules.     

A visual seam tracking system for robotic arc welding

A novel circular laser three-dimensional (3D) scanner is developed instead of a one-dimensional laser spot scanner (1D) and two-dimensional (2D) striped laser light. Using the proposed circular laser scanner, a seam tracking system is constructed, and architecture based on the Visual C++ and RAPID languages which determines the cooperation among image processing modules is carried out. Finally, real seam tracking experiments are investigated and the error analysis is carried out. The results show that: (1) the proposed system can realize seam tracking; (2) the precision of this system is affected by the light scanning system, calibration results, image processing, and the welding seam 3D algorithm—the tracking accuracy is satisfied for robotic arc welding; (3) this system can be used in a welding robot system as a weld seam finder, flatness detector, and weld seam tracker.     

起重机轨道无缝线路焊接技术

介绍了窄间隙强迫成形电弧焊法在钢轨焊接中的应用 ,重点论述了采用该方法焊接QU80起重轨无缝轨道的焊接材料、焊接工艺及实际应用情况。在实际应用中摸索出了一套可在 - 10℃环境中焊接钢轨的方法。该方法已取得了良好的效果。     

IGBT逆变弧焊电源CO2气体保护焊飞溅的波形控制

随着逆变焊机的发展和数字技术的应用,逆变CO2气体保护焊电源可通过调节焊接电源输出的电流与电压来控制熔滴过渡,改善焊缝成形,降低飞溅.根据熔滴过渡不同阶段的要求产生电流与电压控制信号,进行波形控制可实现调节短路电流上升速度,以减小短路峰值电流,降低短路爆炸能量;减少瞬时短路的次数;通过短路后期液桥颈缩电压上升率切断短路电流,消除电爆炸能量.以此有效减少CO2气体保护焊短路过渡产生的飞溅量,为低飞溅CO2气体保护焊的设计与实现提供有力保证.     

Real-time control of welding penetration during robotic GTAW dynamical process by audio sensing of arc length

This paper presents a new technology of real-time arc length monitoring and sag-depression prediction through arc sound signal, which is essential to realize the welding penetration control during gas tungsten arc welding of arc length. A set of automatic measurement and control system have been proposed to achieve real-time arc length control via audio sensing system. After preprocessing of arc sound signal, the piecewise linear models of arc sound signal were established under two different arc length variation 3–4 and 4–5–6 mm, analyzing the prediction errors of linear model, which were proved to be good enough for online monitoring of arc length in pulse GTAW. Based on the linear relationship between arc sound and arc length, the linear fitting model was implemented on predicting the surface height of weld pool. A segmented self-adaptive PID controller was proposed to achieve the monitoring and controlling of arc length;, the confirmatory experiments have been designed to test the control effect of arc-length monitoring based on arc sound signal.     

空间焊缝弧焊机器人焊接路径自动规划研究

开发了面向空间焊缝的弧焊机器人焊接路径自动规划系统。该系统以VB6．0为编程平台，能够实现由三维实体模型直接生成机器人焊枪的位姿文件，进一步地输出为机器人语言程序，采用UP6弧焊机器人系统和S-350MAG焊接系统实际焊接，实验结果验证了该系统的正确性。     

弧焊电源的智能控制

简要介绍在弧焊电源中成熟应用的智能控制技术及方法。     

双焊枪自动焊接机控制系统设计

针对散热器T型多立管相贯线壁障连续焊接难题,设计了基于工控机(IPC)和多轴运动控制器(6K4)的双焊枪自动焊接机控制系统.该系统采用VB编程控制各个子功能模块,并利用6000运动语言开发底层伺服驱动程序,上位机(IPC)直接通过以太网接口调用.整机控制系统能够完成各轴状态实时显示、电机伺服驱动、焊接路径规划、焊接参数自动调节等任务.实际焊接实验表明,该系统满足散热器焊接精度要求,能很好地完成T型管散热器相贯线处的焊接,提高了生产效率和焊接质量.     

Laser visual sensing for seam tracking in robotic arc welding of titanium alloys

Sensor errors arose from detecting the weld-seam profile of titanium alloys with laser-based vision sensors because the surface of such a material is highly reflective to a laser light. In this study, the correct weld-seam profile was established from the distorted raw data by signal processing. Furthermore, a fully automatic seam-tracking system was developed. This system featured training and saving of the template, autofinding of the starting welding point, auto–calibration, detection of seam position and groove dimensions and tracking control. The system was capable of tracking V-groove, fillet, lap and butt joints of titanium alloys with high accuracy of less than 0.4 mm.     

Development of an automatic arc welding system using SMAW process

In end milling of pockets, variable radial depth of cut is generally encountered as the end mill enters and exits the corner, which has a significant influence on the cutting forces and further affects the contour accuracy of the milled pockets. This paper proposes an approach for predicting the cutting forces in end milling of pockets. A mathematical model is presented to describe the geometric relationship between an end mill and the corner profile. The milling process of corners is discretized into a series of steady-state cutting processes, each with different radial depth of cut determined by the instantaneous position of the end mill relative to the workpiece. For the cutting force prediction, an analytical model of cutting forces for the steady-state machining conditions is introduced for each segmented process with given radial depth of cut. The predicted cutting forces can be calculated in terms of tool/workpiece geometry, cutting parameters and workpiece material properties, as well as the relative position of the tool to workpiece. Experiments of pocket milling are conducted for the verification of the proposed method.     

Electromagnetic arc path control in robot plasma welding

Arc welding has always presented a challenge to robot operation. Variations in joint fit-up, positional welding requirements and the high levels of welder skill demanded by transient changes in operating conditions are just some of the variables with which any arc welding robot must cope. The article examines how an inertia-less high-frequency weaving technique using a novel deflector system can solve many of these problems even for high speed seam tracking.     

汽车纵梁液压机器人自动焊机设计要点

汽车纵梁自动焊机由两台焊接机器人和左右纵梁的两套装卡装置组成,每套装卡装置由11个垂直装卡和11个水平装卡组成。液压系统的特点是采用蓄能器与手动方向控制阀,采用反变形法解决焊接变形问题。     

基于LabVIEW和PLC的TIG堵孔焊机的联合控制系统

针对用于核燃料棒的钨极惰性气体保护焊(TIG)堵孔焊机,设计了一套基于LabVIEW软件和可编程控制器(PLC)的联合控制系统。此联合控制系统集数据采集、视频监视、焊接电源控制,以及机械动作控制于一体。从焊机硬件组成、工控机与其他设备通信、PLC程序及具体的控制方法等方面进行了详细描述。实践表明,此联合控制系统可靠、稳定,采集的数据完整,实现了实时监控的目的。     

双工位弧焊机器人系统控制方法

本文介绍了一种基于焊接机器人组成的不锈钢充气柜的焊接工作站、电气组成特点和各个组成单元的协调控制方式.