一种LED晶片支架送料系统的开发研究

LED晶片支架送料系统是实现LED焊线机全自动化关键技术之一。本项目从自动上料、下料和检测系统等整个晶片自动化生产过程进行开发研究,设计了一种LED晶片支架焊接自动送料系统,介绍了此系统的各模块组成及工作原理,实现了LED支架自动上下料,提高了产品的焊接效率,具有一定的社会价值。     

汽车横梁多机器人自动焊接单元及其控制

通过对工件的工艺分析，设立了由2台机器人组成的焊接单元。详细说明了内外环缝焊接工作台上料机构结构特点，规划了焊接单元中各部分的工作时序，解决了各控制器之间的通讯及动作协调问题，完成了整个系统的电气及控制系统的设计。     

混凝土拌合站储料罐仓位报警装置研究

为了实现在混凝土拌合站储料罐仓位超越上下限时及时报警,以便在高于上限停止上料、低于下限及时提醒上料。分别设计基于上料口自动闭锁的仓位报警装置、排料口自动溢出至送料车的仓位报警装置、排料口自动溢出且通过上料口溢至送料车的仓位报警装置。三种报警装置经现场应用,验证了该装置的有效性。     

基于PLC控制的叉车油箱全自动上料装置设计

随着机器人技术的迅猛发展，叉车车架的组焊也越来越多地采用自动化、智能化的生产方式。油箱作为叉车车架的重要组成部件之一，其传统的生产方式是人工将前道工序焊接好的油箱翻转过来，再将油箱搬运到机器人抓取的位置，等待机器人将其搬运到焊接模具上进行组焊。不同于传统的人工搬运组焊生产模式，综合考虑PLC控制器和搬运机器人控制灵活、可靠性高、体积小、质量轻、维修方便、操作简单的特点，基于三菱Q系列PLC控制器设计了一套叉车油箱全自动上料装置。该装置结构设计可靠，生产布局合理，制作工艺简单，整体质量轻量化，维护成本低，可以自主完成叉车油箱的远程输送、组焊前快速翻转和整体组焊前的精确定位，实现叉车油箱上料的无人化，减轻人工劳动强度，保证后续焊接质量，提高叉车车架焊接生产线的工作效率。     

龙门架式焊接机器人系统设计

针对特种马车底盘、大型地磅框架等大型焊接工件实际焊接需要,通过触摸屏和可编程控制器(PLC)将二维工作台与现有焊接机器人集成一体,设计一种龙门架式焊接机器人系统,并将其应用到地磅框架焊接中;给出机械和控制系统的详细设计方案。实际使用结果显示,该焊接机器人系统在保留现有焊接机器人焊接精度的同时,大大扩大了焊接工艺范围。     

拉动式板材送料装置

拉动式板材送料装置是有别于滚筒式送料装置、夹钳式送料装置等送料典型机构的一款结构紧凑、立意新颖的送料装置。拉动方式是它的显著特点。它可应用于塑料板材平板直缝焊接、自动机辅助送料、也可作为特种焊接送料装置使用。特别适合安装在数控机床工作台上,与之构成可拼合长缝、超宽焊件的用于塑料、铝材等的焊接装置。     

基于机器人技术的自动上下料系统设计

为实现多工序数控加工过程的自动化,设计了工件自动上下料系统。系统以工控机和PMAC为核心控制机器人运动,实现工件的装夹。设计了机器人及末端执行器,并对机器人关键的电机及传动系统进行校核。设计了能够自动上料的上料机构,能自动旋转90°的转向机构。最后,对控制系统进行设计,以实现加工过程的自动化。     

基于工业机器人的自动点焊系统构建

为实现不锈钢餐厨具制造行业的点焊自动化,提高传统点焊工艺的自动化水平及生产效率,保证产品质量,设计一套柔性工业机器人自动点焊系统。介绍了系统的总体方案和控制方案,设计了包底片、铝片自动上料装置和复合底点焊夹具以及机器人末端执行器,采用双6轴工业机器人实现了不锈钢锅具的点焊工艺全自动。     

高速剪切设备剪切装置的结构设计

利用高速剪切理论结合裂纹技术设计了一种高效率，结构简单可靠的剪切装置，并对定时定距送料系统和上料控制结构进行分析。     

PLC在气门杆无心外圆磨床自动化改造中的应用

针对气门杆无心外圆磨床需要人工送料,没有工件计量和测量提示报警,也不能对螺杆和滑板进行自动加油等情况,设计开发了自动上料装置,并重点分析PLC控制系统程序设计的过程和要求。目前上料装置已成功地实现了自动化单机生产,并在实际应用中取得良好的经济效益。     

Arc welding robot system with seam tracking and weld pool control based on passive vision

The automatic control in square-wave alternating current (AC) gas tungsten arc welding (GTAW) is significant for a “teach and playback” robot to overcome the variation of the seam trajectory and the seam gap in the welding process. This paper presents a welding robot system based on the real-time visual measurement in the different levels of the welding current. The primary objective is to measure the offset of the torch to the seam center and the size of seam gap by passive vision, track the seam and control the weld pool in real time. A novel visual image analysis algorithm was developed for seam tracking and seam gap measuring, free from robot calibration. The control algorithm based on the knowledge base was established to control the weld formation by regulating the welding current and wire feed rate. The welding practice for the rocket storage tank demonstrates the efficiency of the proposed system.     

规则自调整模糊控制的弧焊机器人焊缝纠偏研究

采用特征谐波法准确识别焊缝偏差,研究熔池对坡口的影响作用,采用补偿因子加权处理可有效地减小这种影响,因此提高了对偏羔的识别能力。采用规则自调整模糊控制器进行焊缝纠偏控制,以克服常规模糊控制器的不足,使其具有良好性能。     

Autonomous seam acquisition and tracking system for multi-pass welding based on vision sensor

Automatic welding technology is a solution to increase welding productivity and improve welding quality, especially in thick plate welding. In order to obtain high-quality multi-pass welds, it is necessary to maintain a stable welding bead in each pass. In the multi-pass welding, it is difficult to obtain a stable weld bead by using a traditional teaching and playback arc welding robot. To overcome these traditional limitations, an automatic welding tracking system of arc welding robot is proposed for multi-pass welding. The developed system includes an image acquisition module, an image processing module, a tracking control unit, and their software interfaces. The vision sensor, which includes a CCD camera, is mounted on the welding torch. In order to minimize the inevitable misalignment between the center line of welding seam and the welding torch for each welding pass, a robust algorithm of welding image processing is proposed, which was proved to be suitable for the root pass, filling passes, and the cap passes. In order to accurately track the welding seam, a Fuzzy-P controller is designed to control the arc welding robot to adjust the torch. The Microsoft Visual C++6.0 software is used to develop the application programs and user interface. The welding experiments are carried out to verify the validity of the multi-pass welding tracking system.     

Offline motion planning and simulation of two-robot welding coordination

This paper focuses on the two-robot welding coordination of complex curve seam which means one robot grasp the workpiece, the other hold the torch, the two robots work on the same workpiece simultaneously. This paper builds the dual-robot coordinate system at the beginning, and three point calibration method of two robots’ relative base coordinate system is presented. After that, the non master/slave scheme is chosen for the motion planning, the non master/slave scheme sets the poses versus time function of the point u on the workpiece, and calculates the two robot end effecter trajectories through the constrained relationship matrix automatically. Moreover, downhand welding is employed which can guarantee the torch and the seam keep in good contact condition all the time during the welding. Finally, a Solidworks-SimMechanics simulation platform is established, and a simulation of curved steel pipe welding is conducted. The results of the simulation illustrate the welding process can meet the requirements of downhand welding, the joint displacement curves are smooth and continuous and no joint velocities are out of working scope.     

基于旋转电弧的机器人角焊缝跟踪建模及仿真

通过对现有旋转电弧传感器采集的焊缝偏差信息和六自由度焊接机器人运动学模型进行研究,结合曲线角焊缝的特点,推导出纠正焊缝偏差后的焊接机器人工具坐标系相对于原工具坐标系的变换矩阵。在此基础上,结合焊接机器人的运动学反解,建立了曲线角焊缝跟踪及焊枪姿态调整模型。输入给定左右偏差及高低偏差信号,利用MATLAB对模型进行仿真验证,结果证明了该模型的有效性与正确性,从而为旋转电弧传感应用于焊接机器人及设计其焊缝跟踪系统提供了理论参考。     

无轨导全位置爬行式弧焊机器人系统

介绍了一种采用新型轮履复合式爬行机构的全位置爬行式弧焊机器人系统,详细地阐述了系统的组成和工作原理。该系统由爬行机构、焊接系统、视觉跟踪系统以及控制系统组成,是一种既无需轨道也无需导向的自动焊接系统。爬行机构具有负重能力强、运动灵活等特点,满足机器人在大型工件上全位置爬行焊接要求。通过大量试验对爬行机构进行了运动分析,建立了机器人运动模型。针对系统的复杂性设计了开关控制器,实现了爬行机构及十字滑块的协调控制,达到焊缝精确跟踪的目的。进行了焊接条件下的跟踪性能试验、全位置多层多道焊接试验,取得了满意的效果,实现了大型工件焊接过程自动化。     

机器人焊缝跟踪神经网络控制的研究

研究神经网络技术在弧焊机器人焊缝跟踪过程中的应用,通过神经网络在笛卡尔空间轨迹的补偿作用,确定出基于笛卡尔空间参考轨迹控制的机器人焊缝跟踪神经网络控制器。与传统的关节计算力矩法相比,所设计的神经网络控制器具有良好的控制特性及较强的鲁棒性,焊缝跟踪精度得到了显著的提高。     

基于旋转电弧传感的弧焊机器人焊缝跟踪系统

研制了一套基于旋转电弧传感的弧焊机器人空间曲线焊缝智能跟踪控制系统。介绍了系统的硬件构成、软件设计及模糊控制方法。研究了不同焊接位置时，焊接熔池金属对坡口的影响作用，提出采用补偿因子加权处理方法，可有效提高平焊、横焊位置焊缝偏差的识别能力。针对立焊位置的脉冲焊接方法，采用形态滤波技术，通过提取脉冲焊接电流的上包络线，利用一次谐波法准确地对立焊焊缝进行了识别。试验结果表明，该焊缝跟踪控制系统对平焊、横焊及立焊位置的曲线焊缝跟踪效果良好，达到焊接工艺要求。     

Robot welding seam tracking method based on passive vision for thin plate closed-gap butt welding

A passive vision sensor is added to a teaching and playback welding robot for pulsed gas tungsten arc welding, which is normally used in the welding of thin plate closed-gap butts. This paper presents a seam tracking method based on this sensor through period visual measurement of the offset between the torch and the seam center. A robust image processing algorithm is developed to extract the seam center. A kind of ARX(auto-regressive with exogenous input) model is studied to describe the relationship between the rectifying voltage and the offset. The fuzzy PID(proportional-integral-derivative) seam tracking controller is analyzed and designed in consideration of various offsets based on the ARX model. The experimental results on straight line weld display a good seam tracking capability of the proposed method.