旋转电弧传感移动焊接机器人机构设计与仿真
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摘要
船舶焊接技术是现代造船模式中的关键技术之一,虽然我国已成为世界造船大国,但造船效率低下,自动化程度低。论文结合我国船舶焊接现状,将移动机器人技术与焊缝跟踪技术相结合,利用虚拟样机技术,研制一种多功能的平面弯曲焊缝焊接移动焊接机器人,可应用于船舶等大型结构件的平面V型焊焊缝与各种折角的角焊缝焊接生产中,提高船舶等大型结构件焊接自动化水平及焊接质量,改善工人劳动条件。
论文系统地阐述移动焊接机器人及虚拟样机技术发展,采用虚拟样机技术一次性成功研制了用于平面弯曲焊缝自动跟踪焊接的移动焊接机器人系统。针对平面弯曲焊缝自动焊接的特点,对移动焊接机器人的移动本体、二维精确运动平台、高速旋转电弧传感器、焊缝跟踪控制算法与控制器、虚拟样机及旋转电弧传感系统与焊缝跟踪实验等关键技术进行了系统的研究;并对基于虚拟样机的大变形且为刚、柔接触的仿真及优化、动平衡仿真与优化进行了研究。
论文介绍了移动焊接机器人国内外发展现状和应用情况,总结了大型结构件平面弯曲焊缝的形式及焊缝跟踪要求与特点后,提出了以旋转电弧作为焊缝跟踪传感器,以二维精确运动平台为微调机构,两轮差速驱动的移动焊接机器人的结构方案,并采用先进的虚拟样机技术,进行移动焊接机器人的研制。
首先,研究设计了移动焊接机器人移动机构,并对其工作能力、转弯特性进行了分析,对其传动机构、焊炬支撑板结构等进行了设计。
在总结旋转电弧传感器国内外发展现状的基础上,研制了一种新型旋转电弧传感器。设计全新循环冷却水路结构及保护气路结构,首次实现了将冷却水、保护气集成于旋转电弧传感器内部;独特的绝缘结构设计,使旋转电弧传感器外壳不带电,提高其使用的安全性;采用虚拟样机技术对其高速旋转时的动平衡进行了优化,使高速旋转时的振动大为降低,不仅提高了焊接质量,而且减小了干扰,为准确提取焊缝偏差信号从而提高焊缝跟踪控制精度提供了保障。
研制成功全密封二维精确运动平台。采用双圆柱移动导轨,不仅大大降低了滚珠丝杠的受力,而且提高了其强度。设计全密封连接结构,利用虚拟样机技术、多柔性体动力学等,进行优化设计,并获得了最优结构。
研究了移动焊接机器人的虚拟样机技术,实现虚拟样机技术在移动焊接机器人研制中的应用。研究基于移动焊接机器人虚拟样机的焊缝跟踪控制算法、控制器的设计。该技术不仅使得机器人一次性地研制成功,而且可提供实际样机无法获得的所需参数。
最后,对轮式移动焊接机器人系统进行性能标定和焊缝跟踪焊接实验,实验结果表明,其性能指标达到设计要求。
该系统的研制,实现了大型结构件的平面弯曲焊缝特别是狭窄空间焊缝的自动焊接。对于提高我国船舶等大型结构件制造自动化设备使用率,减小制造周期,提高制造质量等有现实意义。
According to the present ship welding situation of our country, this dissertation introduces a type of multi-functional mobile welding robot, which combines mobile robot technology with seam tracking based on using virtual prototyping. It can be applied to the fillet weld seam produce in the domin of plane V-type seam and various fillet welding of the large-sized structural components of the ships, and promote the quality of the automatically welding technology of the large-sized structural components, in order to improve the working condition of this area.
The author systematically overviews the developing situation of mobile welding robot and virtual prototyping technology, and successfully develops the mobile welding robot system by using the automatical plane bending welding. According to the features of automatical plane bending welding, the paper studies the related key technology, including mobile body structure, two-dimensional mobile platform, high speed rotating arc sensor, seam tracking controlled algorithm and controller, virtual prototype and rotating arc sensor system and seam tracking experiment, etc. It also studies the large deformation, rigid and flexible contact simulation and optimization, and the dynamic balancing simulation and optimization.
The dissertation introduces the present developing situation at home and abroad and the implementation of mobile welding robot. It concludes the types of plane bending seam of the large-sized structural component and the requirements and features of seam tracking, puts forward the structural scheme of rotating arc as the seam tracking sensor, the precisely two-dimensional platform as the fine adjustment mechanism, and the two differential driving wheels of the mobile welding robot, and uses advanced virtual prototyping technology to develop the mobile welding robot.
At first, the dissertation studies and designs the mobile mechanism of the mobile welding robot, analyzes its working capability, turning features, and designs its transmission mechanism and welding torch supporting plate.
Through concluding the present development of rotating arc sensor at home and abroad, the paper develops a new rotating arc sensor. It designs a new circulating cooling water structure and protecting gas transmission structure, firstly realizes the rotating arc sensor integrated the cooling water and protecting gas. Its distinguished insulating structure design makes the rotating arc sensor shell with no electric charges, and improves its safety. The paper uses virtual prototyping technology to optimize the dynamic balance when it is in a high speed rotating, in order to lower the vibration of the high speed rotating. This technology promotes the welding quality, while decreases it interference, which guarantees the improving of the seam tracking control precision by accurately extracting the seam error signal.
The paper successfully develops a precisely full-closed two-dimensional mobile platform, which uses double cylinder mobile guide, not only decreases force of the ball screw, but also improve its strength. To design the full-closed connecting structure, use the virtual prototyping technology and Flexible Multi-Body Dynamics, this paper optimizes design, and obtains the optimized structure.
This paper studies the virtual prototyping technology of the mobile welding robot, firstly realizes the implementation of the virtual prototyping technology in the development of the mobile welding robot. This development bases on the seam tracking control algorithm and the controller design of the mobile welding robot's virtual prototype. This technology makes the robot being successfully developed, and provides the parameter which cannot be got from the physical prototype.
Finally, this paper develops the calibration performance and the seam tracking experiment of the wheeled mobile welding robot system. The result shows its calibration index reaching the design requirements.
The development of this system realizes automatically seam of the plane bending seam of the large-sized structural component, especially to those in the confined space. It gives a practical significance in promoting the large-sized structural component's manufacture of automatical equipment, decreasing manufacturing period, and improving its quality.
论文系统地阐述移动焊接机器人及虚拟样机技术发展,采用虚拟样机技术一次性成功研制了用于平面弯曲焊缝自动跟踪焊接的移动焊接机器人系统。针对平面弯曲焊缝自动焊接的特点,对移动焊接机器人的移动本体、二维精确运动平台、高速旋转电弧传感器、焊缝跟踪控制算法与控制器、虚拟样机及旋转电弧传感系统与焊缝跟踪实验等关键技术进行了系统的研究;并对基于虚拟样机的大变形且为刚、柔接触的仿真及优化、动平衡仿真与优化进行了研究。
论文介绍了移动焊接机器人国内外发展现状和应用情况,总结了大型结构件平面弯曲焊缝的形式及焊缝跟踪要求与特点后,提出了以旋转电弧作为焊缝跟踪传感器,以二维精确运动平台为微调机构,两轮差速驱动的移动焊接机器人的结构方案,并采用先进的虚拟样机技术,进行移动焊接机器人的研制。
首先,研究设计了移动焊接机器人移动机构,并对其工作能力、转弯特性进行了分析,对其传动机构、焊炬支撑板结构等进行了设计。
在总结旋转电弧传感器国内外发展现状的基础上,研制了一种新型旋转电弧传感器。设计全新循环冷却水路结构及保护气路结构,首次实现了将冷却水、保护气集成于旋转电弧传感器内部;独特的绝缘结构设计,使旋转电弧传感器外壳不带电,提高其使用的安全性;采用虚拟样机技术对其高速旋转时的动平衡进行了优化,使高速旋转时的振动大为降低,不仅提高了焊接质量,而且减小了干扰,为准确提取焊缝偏差信号从而提高焊缝跟踪控制精度提供了保障。
研制成功全密封二维精确运动平台。采用双圆柱移动导轨,不仅大大降低了滚珠丝杠的受力,而且提高了其强度。设计全密封连接结构,利用虚拟样机技术、多柔性体动力学等,进行优化设计,并获得了最优结构。
研究了移动焊接机器人的虚拟样机技术,实现虚拟样机技术在移动焊接机器人研制中的应用。研究基于移动焊接机器人虚拟样机的焊缝跟踪控制算法、控制器的设计。该技术不仅使得机器人一次性地研制成功,而且可提供实际样机无法获得的所需参数。
最后,对轮式移动焊接机器人系统进行性能标定和焊缝跟踪焊接实验,实验结果表明,其性能指标达到设计要求。
该系统的研制,实现了大型结构件的平面弯曲焊缝特别是狭窄空间焊缝的自动焊接。对于提高我国船舶等大型结构件制造自动化设备使用率,减小制造周期,提高制造质量等有现实意义。
According to the present ship welding situation of our country, this dissertation introduces a type of multi-functional mobile welding robot, which combines mobile robot technology with seam tracking based on using virtual prototyping. It can be applied to the fillet weld seam produce in the domin of plane V-type seam and various fillet welding of the large-sized structural components of the ships, and promote the quality of the automatically welding technology of the large-sized structural components, in order to improve the working condition of this area.
The author systematically overviews the developing situation of mobile welding robot and virtual prototyping technology, and successfully develops the mobile welding robot system by using the automatical plane bending welding. According to the features of automatical plane bending welding, the paper studies the related key technology, including mobile body structure, two-dimensional mobile platform, high speed rotating arc sensor, seam tracking controlled algorithm and controller, virtual prototype and rotating arc sensor system and seam tracking experiment, etc. It also studies the large deformation, rigid and flexible contact simulation and optimization, and the dynamic balancing simulation and optimization.
The dissertation introduces the present developing situation at home and abroad and the implementation of mobile welding robot. It concludes the types of plane bending seam of the large-sized structural component and the requirements and features of seam tracking, puts forward the structural scheme of rotating arc as the seam tracking sensor, the precisely two-dimensional platform as the fine adjustment mechanism, and the two differential driving wheels of the mobile welding robot, and uses advanced virtual prototyping technology to develop the mobile welding robot.
At first, the dissertation studies and designs the mobile mechanism of the mobile welding robot, analyzes its working capability, turning features, and designs its transmission mechanism and welding torch supporting plate.
Through concluding the present development of rotating arc sensor at home and abroad, the paper develops a new rotating arc sensor. It designs a new circulating cooling water structure and protecting gas transmission structure, firstly realizes the rotating arc sensor integrated the cooling water and protecting gas. Its distinguished insulating structure design makes the rotating arc sensor shell with no electric charges, and improves its safety. The paper uses virtual prototyping technology to optimize the dynamic balance when it is in a high speed rotating, in order to lower the vibration of the high speed rotating. This technology promotes the welding quality, while decreases it interference, which guarantees the improving of the seam tracking control precision by accurately extracting the seam error signal.
The paper successfully develops a precisely full-closed two-dimensional mobile platform, which uses double cylinder mobile guide, not only decreases force of the ball screw, but also improve its strength. To design the full-closed connecting structure, use the virtual prototyping technology and Flexible Multi-Body Dynamics, this paper optimizes design, and obtains the optimized structure.
This paper studies the virtual prototyping technology of the mobile welding robot, firstly realizes the implementation of the virtual prototyping technology in the development of the mobile welding robot. This development bases on the seam tracking control algorithm and the controller design of the mobile welding robot's virtual prototype. This technology makes the robot being successfully developed, and provides the parameter which cannot be got from the physical prototype.
Finally, this paper develops the calibration performance and the seam tracking experiment of the wheeled mobile welding robot system. The result shows its calibration index reaching the design requirements.
The development of this system realizes automatically seam of the plane bending seam of the large-sized structural component, especially to those in the confined space. It gives a practical significance in promoting the large-sized structural component's manufacture of automatical equipment, decreasing manufacturing period, and improving its quality.
引文
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