CN-121043121-B - Portal type ship deck multi-robot collaborative welding control system

CN121043121BCN 121043121 BCN121043121 BCN 121043121BCN-121043121-B

Abstract

The invention discloses a portal type ship deck multi-robot collaborative welding control system, which relates to the technical field of ship manufacturing automation welding and comprises a large portal travelling mechanism and a plurality of small portal mechanisms, wherein the large portal travelling mechanism is arranged on a factory building track along the X-axis direction, and each small portal mechanism comprises a Y-axis traversing mechanism, a Z-axis lifting mechanism and a theta-axis rotating mechanism and is provided with a welding robot. According to the portal type ship deck multi-robot collaborative welding control system, the problem of full line shutdown caused by single-point faults in a large-scale welding system is solved through dynamic decoupling control of an interlocking grading response mechanism and a safety domain. When the local equipment is abnormal, the system only limits the high-risk action of the associated area, the non-associated equipment keeps running at a reduced speed, unnecessary production stopping time is effectively reduced, and by combining the cross-domain task migration and the long-weld intelligent segmentation technology, the welding task can be dynamically reassigned under the fault state, and the production continuity is maintained to the maximum extent.

Inventors

ZHOU ZHENGBING
ZHU JINTONG
YOU RUICHAO
XU YUANCAI
HU QING
LIU ZHE

Assignees

招商局金陵船舶(江苏)有限公司
唐山开元自动焊接装备有限公司

Dates

Publication Date: 20260508
Application Date: 20250820

Claims (8)

1. A portal vessel deck multi-robot collaborative welding control system, comprising: The large gantry travelling mechanism is arranged on the factory building track along the X-axis direction; each small gantry mechanism comprises a Y-axis traversing mechanism, a Z-axis lifting mechanism and a theta-axis rotating mechanism, and is provided with a welding robot; the PLC control cabinet group is connected with the large gantry and the small gantry control cabinets through a CC-LinkIE bus; a communication network connecting all the control units; characterized by further comprising: The safety domain dynamic dividing module is configured to define an independent safety working domain for each robot through the laser radar and UWB positioning unit; The interlocking grading response module is configured to divide the interlocking condition into three-level response, wherein the L1-level response triggers local deceleration, the L2-level response triggers path re-planning and the L3-level response triggers global shutdown, and the interlocking grading response module executes: l1 level response, namely, when the robot collides with the early warning, the speed of the travelling mechanism is reduced to a preset safety value; l2 level response, namely suspending the association mechanism and starting a path re-planning algorithm when the gantry distance is smaller than a dynamic safety threshold; the L3 level responds that when the communication is interrupted or the power supply is abnormal, a global scram circuit is activated; The dynamic task allocation engine is configured to analyze the weld data and allocate the robot tasks in real time and comprises: A weld topology analyzer analyzing SMARTWELD the KCONG data generated and dividing the dynamic working area; The reinforcement learning decision unit is used for generating a robot task allocation matrix based on the historical welding efficiency database; the conflict resolution unit is used for distributing welding seam tasks overlapped by the working areas by adopting an auction algorithm; The dynamic task allocation engine dynamically divides the working area according to the limit angle and the lifting travel of the robot joint, and if the welding line is positioned within 90% of the maximum extension radius of the robot, the welding line which exceeds the range but meets the segmentation condition is divided into a core working area, and the welding line is divided into an edge working area and a long welding line segmentation mark is activated; The digital twin pre-inspection module is configured to perform double safety verification through the virtual production line before physical actions.
2. The portal vessel deck multi-robot collaborative welding control system of claim 1, wherein the security domain dynamic partitioning module comprises: An adjustable radius electronic fence surrounding the robot; and an intra-domain motion limiting unit which only freezes the Z-axis lifting and theta-axis rotating motion in the safety domain when collision risk is detected, and keeps the X-axis and Y-axis motion outside the safety domain running.
3. The portal vessel deck multi-robot collaborative welding control system of claim 2, wherein the dynamic task allocation engine further comprises: The cross-domain welding protocol unit is used for transferring unfinished welding seams of the cross-domain welding protocol unit to a nearest reachable robot when the robot fault is detected; and the long weld joint segmentation unit is used for carrying out segmentation treatment on the weld joint exceeding the working range of the single machine.
4. The portal vessel deck multi-robot collaborative welding control system according to claim 3, wherein the cross-domain welding protocol unit performs: Calculating Manhattan distance based on the space coordinates, and screening healthy robots closest to the fault point; And executing task migration after verifying the accessibility of the welding gun of the target robot.
5. The portal vessel deck multi-robot collaborative welding control system of claim 1, wherein the digital twin pre-inspection module comprises: the kinematic simulation unit is used for verifying the joint extreme pose and the singular point avoidance path; The physical collision detection unit simulates the interference condition of the tool center point and the workpiece; and the execution permission unit sends an action instruction to the physical device only after the double verification is passed.
6. The portal vessel deck multi-robot collaborative welding control system of claim 1, wherein the communication network employs: a time-sensitive network slicing architecture, dividing a real-time control channel and a task scheduling channel; The real-time control channel transmits the pose data and limit switch signals of the robot; the ad hoc network backup channel is automatically enabled upon failure of the primary communication link.
7. The portal vessel deck multi-robot collaborative welding control system of claim 1, further comprising: the dynamic speed reduction controller is used for adjusting the rotating speed of the walking motor according to the distance proportion when the distance between the two robots approaches a safety threshold value; and the emergency path generator is used for planning a withdrawal path for the fault robot based on a rapid random expansion tree algorithm.
8. The portal vessel deck multi-robot collaborative welding control system according to claim 1, wherein the PLC control cabinet group performs: the global binding limitation of the X/Y axis action is removed through the interlocking grading response module; And maintaining large gantry walking and small gantry traversing of the non-associated area in the L1 level response state.

Description

Portal type ship deck multi-robot collaborative welding control system Technical Field The invention relates to the technical field of automatic welding in ship manufacturing, in particular to a gantry type ship deck multi-robot collaborative welding control system. Background When the existing portal type multi-robot welding system is used for welding 15000 multiplied by 15000mm large-scale components on a ship deck, the contradiction between insufficient multi-machine cooperation instantaneity and system stiffness exists. The system is characterized by strong coupling interlocking limitation that all robots are required to meet hard conditions such as normal original point positions and limit signals, safe gantry spacing, no communication faults and the like, so that the actions such as walking, rotation and the like of a large gantry and a small gantry can be started, single-point fault global stagnation is that any robot is not in place or is locally abnormal, such as sensor faults and communication delays, the whole assembly line is directly frozen, a high-speed running mechanism of 15m/min cannot operate, the production efficiency is severely limited, dynamic task allocation is lacking, an existing CC-LinkIE bus architecture supports multi-PLC linkage, such as communication of the large gantry and 4 small gantry control cabinets, program scheduling depends on fixed interlocking logic, the working area of the robot cannot be adjusted in real time according to the workpiece weld distribution, and the equipment utilization is unbalanced. In view of the above, the problem to be solved is how to release the rigid binding of the actions of multiple robots on the premise of ensuring the safety, realize the fault isolation and the dynamic coordination and avoid the system-level shutdown caused by single-point abnormality. The prior art is difficult to balance the contradiction between high-reliability interlocking and production flexibility, and becomes a key obstacle for high-efficiency welding of a large ship deck. Disclosure of Invention In order to achieve the purpose, the invention is realized by the following technical scheme that the gantry type ship deck multi-robot collaborative welding control system comprises: The large gantry travelling mechanism is arranged on the factory building track along the X-axis direction; each small gantry mechanism comprises a Y-axis traversing mechanism, a Z-axis lifting mechanism and a theta-axis rotating mechanism, and is provided with a welding robot; the PLC control cabinet group is connected with the large gantry and the small gantry control cabinets through a CC-LinkIE bus; a communication network connecting all the control units; Further comprises: The safety domain dynamic dividing module is configured to define an independent safety working domain for each robot through the laser radar and UWB positioning unit; the interlocking grading response module is configured to divide the interlocking condition into three-level response, namely L1-level triggering local deceleration, L2-level triggering path re-planning and L3-level triggering global shutdown; the dynamic task allocation engine is configured to analyze the weld data and allocate the robot tasks in real time; The digital twin pre-inspection module is configured to perform double safety verification through the virtual production line before physical actions. Preferably, the security domain dynamic partitioning module includes: An adjustable radius electronic fence surrounding the robot; and an intra-domain motion limiting unit which only freezes the Z-axis lifting and theta-axis rotating motion in the safety domain when collision risk is detected, and keeps the X-axis and Y-axis motion outside the safety domain running. Preferably, the interlocking hierarchical response module performs: l1 level response, namely, when the robot collides with the early warning, the speed of the travelling mechanism is reduced to a preset safety value; l2 level response, namely suspending the association mechanism and starting a path re-planning algorithm when the gantry distance is smaller than a dynamic safety threshold; the L3 stage responds to activate the global scram circuit when communication is interrupted or power is abnormal. Preferably, the dynamic task allocation engine includes: A weld topology analyzer analyzing SMARTWELD the KCONG data generated and dividing the dynamic working area; The reinforcement learning decision unit is used for generating a robot task allocation matrix based on the historical welding efficiency database; And the conflict resolution unit is used for distributing the welding seam tasks overlapped by the working fields by adopting an auction algorithm. Preferably, the dynamic task allocation engine further comprises: The cross-domain welding protocol unit is used for transferring unfinished welding seams of the cross-domain welding protocol unit to a nearest reachable robot when the rob