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International Electronic Circuit (Shanghai) Exhibition Liangsheng Invitation Letter
Measures to improve the reliability of arc welding robot control system
Release date:
2019/11/11
Composition and functions of the control system
Tianlong No. 2 arc welding robot is a universal arc welding robot designed for the welding line of Yamaha 5D motorcycle frame according to the requirements of Jianfeng motorcycle parts factory. It by robot, the robot manipulator control cabinet, the welding power supply, wire feeding mechanism and bracket, the welding jig of five parts, mechanical structure of ontology is joint coordinates type, five degrees of freedom, repeated positioning accuracy is not greater than 0.3 mm, maximum rate of synthesis of 1 m/s computer control system adopts STDV20 bus industrial control computer, the drive mode for dc servo drive, position detection beam with pulse encoder. Use the keyboard teaching, inhibits PTP and CP can be control: control system by the anti-jamming ability of the industrial control computer and the corresponding interface circuit and five sets of dc what institutions; They form three closed-loop systems of current, speed and position to control the welding process. According to the nature of the operation, the control system communicates with the welding system and fixture system in the form of command flow. The block diagram of the control system is shown in Figure 1. Control system adopts 16 industrial PC, to accelerate the operation speed, increased the 8087 coprocessor, and equipped with corresponding semiconductor memory and disk: control software includes monitoring operation, communication module, control module with automatic control, screen display, modify, edit, compile, process control, fault diagnosis, etc. Movement module has a robot is operation, the inverse operation, smooth acceleration and real-time interpolation, PID control, and other functions, communication module to complete with information about welding machine, fixture.
FIG. 1 Control system block diagram
Setting of the working environment of the control system
This arc welding machine is installed in the welding workshop of motorcycle frame. There are more than ten Panasonic type 500 automatic welding machines, assembly line driving devices and some auxiliary equipment in the workshop, and the power fluctuation, power peak interference, environmental temperature change and electromagnetic interference are serious. The robot can work normally in this environment only after taking corresponding measures.
The control cabinet shall be located in the shielding control room against electromagnetic interference, and the air conditioning shall be installed in the room to ensure appropriate temperature and humidity. Shielding wires shall be strictly used for all connecting cables. In order to avoid the interference of the workshop power supply into the control cabinet, the dedicated line is used to control the constant power supply. The power supply into the computer system in the control cabinet must also be filtered through noise, high precision voltage regulation and other purification measures, and then through high anti-interference switching power supply, the system needs a variety of control power.
Control cabinet with industrial control computer, PWM and SCR dc servo system, servo transformers, switching power supply and control circuit devices such as operation, internal high frequency interference and electromagnetic interference is serious, therefore, when the control cabinet structure design. It should be the interference source and vulnerable to the interference of industrial computer, operating system, such as printing plate layer separated into many space. To prevent interference between each other. Five sets of rotary encoders, the feedback signal channel of the tachometer generator, the motor drive channel and the power line in the cabinet should also be connected
Mutual isolation: On the basis of selecting standard parts and screening components, the principle of forehead reduction should be considered in the design. Redundant design should be adopted in key parts to prevent single point failure.
3. Fault-tolerant design of data acquisition system
The ipC will compare the output code with the feedback code. The difference value exceeds the code limit value set by the software output, and the computer will stop the whole system as a data error. We adopt the method of continuous repetitive code collection. After filtering out the illegal data, take the average value of several times of data as feedback data and input it into the IPC count board. Thus, the average trouble-free working time is greatly extended. If the rotary encoder is interfered before the counter is counted, the data collected by the continuous code collection of the INDUSTRIAL PC will be wrong data, and will still fail to pass the test of the software's undefined code value, thus causing further downtime. Adaptive control should be adopted for the system with great variation of input parameters. We discard the error feedback data and take the feedback data of the previous period as the input code of this period. In order to ensure the control accuracy of machine input, a set of adaptive control algorithm is used after changing the input parameters to eliminate the error caused by this, so that the robot control system will return to the normal control state after several sampling cycles, without affecting the welding accuracy of the robot. Through the above two kinds of data processing, the data acquisition error of the control system is basically suppressed, and we also set up the protection of stop caused by the error in the counting process.
4. Reliability guarantee of field operation
Under the influence of interference and temperature drift, accumulative error will occur in the control system, which will affect the welding accuracy of the robot and make the robot unable to work normally. In the process of welding the workpiece on one fixture to the workpiece on another fixture, we let the robot go through the relative zero position, use the software to reset the robot to zero, and then go to weld another workpiece. In this way, every time a workpiece is welded, the robot will be set to zero by the software, and the accumulated error will be eliminated fundamentally, thus ensuring the working accuracy of the robot.
In robot field, in order to ensure staff safety and protection of robot ontology, to set up multiple protection, in addition to the commonly used scram protection, the robot is also equipped with overload protection, overheating protection, limit protection, software scram protection, limit switch, the workpiece installation workers safety protection and so on dozens of outage protection function, the robot also has detailed error diagnostic hint, check for the cause of the problem, shorten the debugging time provides a great convenience. The robot's basically all downtime, can resume normal work after immediately to add electric start, improve the effectiveness of the robot work. During the teaching process, the teaching program can be edited and modified offline and the offline empty operation can be checked. In view of the robot in place welding phenomenon that may occur before the workpiece is installed, the workpiece in place starting signal is introduced. We also adopt automatic refueling measures to overcome the phenomenon of "plugging" that often occurs in welding gun in welding system, and these measures ensure the robot to work smoothly.
Only when it is in the preset order, otherwise the operation will be invalid, and the power supply will continue to maintain the stable state before the operation, without generating the operation interference pulse. Select different intermediate relays K and K appropriately according to the size of cut-off capacity; . Can meet any capacity of power control. The common feature of both control circuits is to isolate the load from the DC stabilized power supply before an operating overvoltage occurs. This fundamentally eliminates the operation of over-voltage load - microcomputer chip damage.
International Electronic Circuit (Shanghai) Exhibition Liangsheng Invitation Letter
Measures to improve the reliability of arc welding robot control system
Release date:
2019/11/11
Composition and functions of the control system
Tianlong No. 2 arc welding robot is a universal arc welding robot designed for the welding line of Yamaha 5D motorcycle frame according to the requirements of Jianfeng motorcycle parts factory. It by robot, the robot manipulator control cabinet, the welding power supply, wire feeding mechanism and bracket, the welding jig of five parts, mechanical structure of ontology is joint coordinates type, five degrees of freedom, repeated positioning accuracy is not greater than 0.3 mm, maximum rate of synthesis of 1 m/s computer control system adopts STDV20 bus industrial control computer, the drive mode for dc servo drive, position detection beam with pulse encoder. Use the keyboard teaching, inhibits PTP and CP can be control: control system by the anti-jamming ability of the industrial control computer and the corresponding interface circuit and five sets of dc what institutions; They form three closed-loop systems of current, speed and position to control the welding process. According to the nature of the operation, the control system communicates with the welding system and fixture system in the form of command flow. The block diagram of the control system is shown in Figure 1. Control system adopts 16 industrial PC, to accelerate the operation speed, increased the 8087 coprocessor, and equipped with corresponding semiconductor memory and disk: control software includes monitoring operation, communication module, control module with automatic control, screen display, modify, edit, compile, process control, fault diagnosis, etc. Movement module has a robot is operation, the inverse operation, smooth acceleration and real-time interpolation, PID control, and other functions, communication module to complete with information about welding machine, fixture.
FIG. 1 Control system block diagram
Setting of the working environment of the control system
This arc welding machine is installed in the welding workshop of motorcycle frame. There are more than ten Panasonic type 500 automatic welding machines, assembly line driving devices and some auxiliary equipment in the workshop, and the power fluctuation, power peak interference, environmental temperature change and electromagnetic interference are serious. The robot can work normally in this environment only after taking corresponding measures.
The control cabinet shall be located in the shielding control room against electromagnetic interference, and the air conditioning shall be installed in the room to ensure appropriate temperature and humidity. Shielding wires shall be strictly used for all connecting cables. In order to avoid the interference of the workshop power supply into the control cabinet, the dedicated line is used to control the constant power supply. The power supply into the computer system in the control cabinet must also be filtered through noise, high precision voltage regulation and other purification measures, and then through high anti-interference switching power supply, the system needs a variety of control power.
Control cabinet with industrial control computer, PWM and SCR dc servo system, servo transformers, switching power supply and control circuit devices such as operation, internal high frequency interference and electromagnetic interference is serious, therefore, when the control cabinet structure design. It should be the interference source and vulnerable to the interference of industrial computer, operating system, such as printing plate layer separated into many space. To prevent interference between each other. Five sets of rotary encoders, the feedback signal channel of the tachometer generator, the motor drive channel and the power line in the cabinet should also be connected
Mutual isolation: On the basis of selecting standard parts and screening components, the principle of forehead reduction should be considered in the design. Redundant design should be adopted in key parts to prevent single point failure.
3. Fault-tolerant design of data acquisition system
The ipC will compare the output code with the feedback code. The difference value exceeds the code limit value set by the software output, and the computer will stop the whole system as a data error. We adopt the method of continuous repetitive code collection. After filtering out the illegal data, take the average value of several times of data as feedback data and input it into the IPC count board. Thus, the average trouble-free working time is greatly extended. If the rotary encoder is interfered before the counter is counted, the data collected by the continuous code collection of the INDUSTRIAL PC will be wrong data, and will still fail to pass the test of the software's undefined code value, thus causing further downtime. Adaptive control should be adopted for the system with great variation of input parameters. We discard the error feedback data and take the feedback data of the previous period as the input code of this period. In order to ensure the control accuracy of machine input, a set of adaptive control algorithm is used after changing the input parameters to eliminate the error caused by this, so that the robot control system will return to the normal control state after several sampling cycles, without affecting the welding accuracy of the robot. Through the above two kinds of data processing, the data acquisition error of the control system is basically suppressed, and we also set up the protection of stop caused by the error in the counting process.
4. Reliability guarantee of field operation
Under the influence of interference and temperature drift, accumulative error will occur in the control system, which will affect the welding accuracy of the robot and make the robot unable to work normally. In the process of welding the workpiece on one fixture to the workpiece on another fixture, we let the robot go through the relative zero position, use the software to reset the robot to zero, and then go to weld another workpiece. In this way, every time a workpiece is welded, the robot will be set to zero by the software, and the accumulated error will be eliminated fundamentally, thus ensuring the working accuracy of the robot.
In robot field, in order to ensure staff safety and protection of robot ontology, to set up multiple protection, in addition to the commonly used scram protection, the robot is also equipped with overload protection, overheating protection, limit protection, software scram protection, limit switch, the workpiece installation workers safety protection and so on dozens of outage protection function, the robot also has detailed error diagnostic hint, check for the cause of the problem, shorten the debugging time provides a great convenience. The robot's basically all downtime, can resume normal work after immediately to add electric start, improve the effectiveness of the robot work. During the teaching process, the teaching program can be edited and modified offline and the offline empty operation can be checked. In view of the robot in place welding phenomenon that may occur before the workpiece is installed, the workpiece in place starting signal is introduced. We also adopt automatic refueling measures to overcome the phenomenon of "plugging" that often occurs in welding gun in welding system, and these measures ensure the robot to work smoothly.
Only when it is in the preset order, otherwise the operation will be invalid, and the power supply will continue to maintain the stable state before the operation, without generating the operation interference pulse. Select different intermediate relays K and K appropriately according to the size of cut-off capacity; . Can meet any capacity of power control. The common feature of both control circuits is to isolate the load from the DC stabilized power supply before an operating overvoltage occurs. This fundamentally eliminates the operation of over-voltage load - microcomputer chip damage.
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Factory Address: No. 1533 Fengpu Avenue, Jiaotong University National Science Park, Fengxian District, Shanghai
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