CN-122007736-A - Intelligent welding control system of double-end flange robot

CN122007736ACN 122007736 ACN122007736 ACN 122007736ACN-122007736-A

Abstract

The invention discloses an intelligent welding control system of a double-end flange robot, which relates to the technical field of industrial automation control and robot welding and comprises an industrial personal computer, a PLC (programmable logic controller), a welding robot system, a laser sensing system, a servo driving unit and a man-machine interaction terminal, wherein the industrial personal computer is respectively in communication connection with the PLC and the man-machine interaction terminal, and the PLC is respectively in signal connection with the welding robot system, the laser sensing system and the servo driving unit. The intelligent welding control system of the double-end flange robot reduces manual intervention in the production process, adapts to the large-scale automatic production requirement of welding of the steel pipe flange, realizes automatic calculation of welding processes of workpieces with different specifications and automatic generation and issuing of a robot welding program, does not need manual teaching and manual parameter adjustment, improves the adaptation capability of equipment to workpieces with different pipe diameters, wall thicknesses and flange specifications, and meets the flexible production requirement of workpieces with different specifications.

Inventors

ZONG JUN
ZHOU ZHENGBING
YOU RUICHAO
JIANG AIBING
LI QING

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: 20260512
Application Date: 20260316

Claims (10)

1. The intelligent welding control system of the double-end flange robot comprises an industrial personal computer, a PLC (programmable logic controller), a welding robot system, a laser sensing system, a servo driving unit and a man-machine interaction terminal, wherein the industrial personal computer is respectively in communication connection with the PLC and the man-machine interaction terminal, and the PLC is respectively in signal connection with the welding robot system, the laser sensing system and the servo driving unit; the industrial personal computer is internally provided with a double-end collaborative synchronous error closed-loop control module, a full-procedure time sequence linkage state machine scheduling module, a self-adaptive process calculation and program self-generation module and a grading authority and safety linkage control module; The signal output end of the double-end cooperative synchronous error closed-loop control module is connected with the PLC controller and is used for collecting real-time operation data of the main-end welding robot, the auxiliary-end welding robot and the servo driving unit and outputting a synchronous control instruction to the PLC controller so as to realize cooperative control of double-end welding action and workpiece rotation action; The full-process time sequence linkage state machine scheduling module is respectively connected with the double-end cooperative synchronous error closed-loop control module and the PLC controller and is used for disassembling a plurality of process states of the whole welding process to be interlocked, unlocking the subsequent process after checking the execution result of the previous process, and realizing linkage scheduling of the whole processes of workpiece feeding, transplanting positioning, tool clamping, welding seam locating, welding execution, post-welding detection and blanking buffering; the self-adaptive process calculation and program self-generation module is respectively connected with the laser sensing system, the full-process time sequence linkage state machine scheduling module and the double-welding robot system, and is used for receiving workpiece characteristic data acquired by the laser sensing system, completing welding process parameter calculation and automatic generation of a robot welding program and issuing the workpiece characteristic data to the double-welding robot system; The grading authority and safety interlocking control module is respectively connected with the man-machine interaction terminal, the PLC controller and the full-process time sequence interlocking state machine scheduling module and is used for realizing grading operation authority control, full-link equipment state monitoring and multistage safety interlocking control.
2. The intelligent welding control system of the double-end flange robot, according to claim 1, is characterized in that a six-dimensional synchronous error checking unit and a fuzzy self-adaptive sliding mode PID control unit are built in the double-end cooperative synchronous error closed-loop control module, the input end of the six-dimensional synchronous error checking unit is respectively connected with a main-end welding robot, a secondary-end welding robot, an encoder of a servo driving unit and a laser sensing system, and is used for collecting and constructing a six-dimensional synchronous error matrix comprising rotation angles, axial displacement, radial positioning, welding gun postures, welding speeds and arcing and arc-receiving time sequences; The input end of the fuzzy self-adaptive sliding mode PID control unit is connected with the six-dimensional synchronous error checking unit, the output end of the fuzzy self-adaptive sliding mode PID control unit is connected with the PLC controller, and the fuzzy self-adaptive sliding mode PID control unit is used for adjusting control parameters according to real-time data of the six-dimensional synchronous error matrix, outputting synchronous control instructions to the PLC controller, and locking final execution instructions after at least two synchronous error checking and control parameter optimization are completed.
3. The intelligent welding control system of the double-end flange robot, as set forth in claim 1, wherein the full-process time sequence linkage state machine scheduling module is provided with a process state interlocking unit and a double verification admittance unit, the process state interlocking unit disassembles the welding full process into seven interlocked process states of feeding to be detected, transplanting and positioning, fixture clamping, weld seam locating, welding execution, post-welding detection and blanking buffering, and each process state is provided with independent triggering conditions, execution actions and abnormal treatment branches; The double verification admittance unit is connected with the procedure state interlocking unit and is used for completing the consistency verification of the workpiece parameters and the suitability verification of the mechanism before each procedure state is executed, unlocking the execution authority of the corresponding procedure state after the two verification passes, and triggering the abnormal handling branch when the verification does not pass.
4. The intelligent welding control system of the double-end flange robot, as set forth in claim 1, characterized in that the self-adaptive process calculation and program self-generation module is provided with a built-in workpiece digital twin matching unit and a mixed algorithm process calculation unit, wherein the input end of the workpiece digital twin matching unit is connected with a laser sensing system and is used for receiving workpiece three-dimensional characteristic data collected by the laser sensing system, matching a pre-stored standard workpiece database and generating a digital twin body corresponding to a workpiece; The input end of the mixed algorithm process calculation unit is connected with the workpiece digital twin matching unit and is used for completing multi-objective iterative optimization and compliance verification of welding process parameters based on characteristic parameters of the workpiece digital twin.
5. The intelligent welding control system of the double-end flange robot, as set forth in claim 4, wherein the self-adaptive process calculation and program self-generation module further comprises a track correction unit and a program issuing unit, wherein the input end of the track correction unit is respectively connected with the laser sensing system and the mixed algorithm process calculation unit, and is used for receiving the actual welding seam three-dimensional coordinates acquired by the laser sensing system, comparing the actual welding seam three-dimensional coordinates with the theoretical welding seam coordinates of the workpiece digital twin body, and finishing deviation correction and secondary verification of the welding track; The input end of the program issuing unit is respectively connected with the track correction unit and the mixed algorithm process calculation unit, and the output end of the program issuing unit is connected with the double-welding robot system and is used for generating an optimized robot welding program and synchronously issuing welding process parameters and the welding program to the double-welding robot system.
6. The intelligent welding control system of the double-end flange robot, as set forth in claim 1, wherein the hierarchical rights and safety interlocking control module is internally provided with a three-level rights management unit and a three-level safety interlocking unit, the three-level rights management unit is connected with a man-machine interaction terminal, three levels of operation rights of an operator, a maintainer and an administrator are set, and each level corresponds to an independent operation range and data access rights; The three-level safety interlocking unit is respectively connected with the PLC controller and the full-process time sequence linkage state machine scheduling module, and is provided with three levels of safety interlocking rules of an emergency stop level, a safety protection level and an early warning prompt level, and different levels correspond to independent triggering conditions and executing actions.
7. The intelligent welding control system of the double-end flange robot, as set forth in claim 6, wherein the hierarchical authority and safety interlocking control module further comprises a fault self-diagnosis and early warning unit, wherein the input end of the fault self-diagnosis and early warning unit is respectively connected with the PLC, the double-welding robot system, the servo driving unit and the laser sensing system, and is used for collecting the operating data of the full-link equipment in real time, matching with a pre-stored equipment fault tree database, completing the accurate positioning of faults and the early warning of potential faults, and outputting a standardized fault treatment scheme to the man-machine interaction terminal.
8. The intelligent welding control system of the double-end flange robot of claim 1, further comprising an industrial Ethernet switch and a CC-Link IE field bus, wherein communication connection is established among the industrial personal computer, the PLC and the man-machine interaction terminal through the industrial Ethernet switch, and signal connection is established among the PLC, the double-welding robot system, the laser sensing system and the servo driving unit through the CC-Link IE field bus.
9. The intelligent welding control system of the double-end flange robot of claim 1, wherein the man-machine interaction terminal comprises a touch screen, a main operation box and a plurality of groups of emergency stop button boxes, wherein a device state monitoring interface, a parameter configuration interface, an alarm inquiry interface and a permission management interface are arranged in the touch screen, and the main operation box and the emergency stop button boxes are connected with a PLC controller through signals and are used for manual operation of device start-stop, mode switching and emergency stop control.
10. The intelligent welding control system of the double-end flange robot, as set forth in claim 4, wherein the self-adaptive process calculation and program self-generation module further comprises a built-in welding database self-learning unit, wherein the input end of the welding database self-learning unit is respectively connected with the double-welding robot system and the laser sensing system, and is used for collecting welding seam forming data and welding process operation data after welding is completed, and performing iterative optimization on a standard workpiece database and a process calculation algorithm.

Description

Intelligent welding control system of double-end flange robot Technical Field The invention relates to the technical field of industrial automation control and robot welding, in particular to an intelligent welding control system of a double-end flange robot. Background In the fields of ship manufacturing, oil-gas pipeline engineering and the like, the girth welding of the steel pipe, the flange and the sleeve is a core process of pipe system processing, double-end synchronous welding is a key path for improving the production efficiency of the process and ensuring the consistency of weld joint forming, and the intelligent control system of the welding robot is widely applied in the scene and is core equipment for realizing automatic and large-scale production of pipe system welding. The authorization bulletin number CN119620597B records a control method, a system, equipment and a storage medium of a pipe flange welding robot, and the scheme is characterized in that whether the curvature of a welding line meets the preset condition or not is judged to match a corresponding control model, the welding line characteristics are input into a target control model to obtain a welding control strategy, the pipe flange welding robot is controlled to finish welding operation, the welding control mode can be adaptively adjusted according to different welding line characteristics, and the method has the advantages of high welding control precision and high operation reliability. However, the scheme is designed only for a single-channel welding seam welding scene between the pipe-jacking flange and the rib plate, is not adapted to the synchronous welding working conditions of the inner and outer circular seams of the steel pipe double-end flange and the sleeve, and cannot meet the double-robot cooperative control requirement of synchronous welding of multiple welding seams at two ends of the steel pipe; Meanwhile, the control logic focuses on the algorithm optimization and the single robot welding action control of the welding process, the automatic feeding and discharging circulation of workpieces is not covered, the full-flow linkage scheduling of the double-end welding robot and the workpiece rotary driving mechanism, the laser tracking sensing system and the multi-axis servo mechanism is realized, and the automatic closed-loop control of the full process of the steel pipe flange welding cannot be realized. In addition, the existing control system for welding the steel pipe flange has the defect of poor workpiece adaptation universality, and aims at workpieces with different pipe diameters, wall thicknesses and flange specifications, a large number of manual teaching and manual motion and control parameters adjustment are needed by operators, automatic calculation of a welding process, automatic generation and issuing of a robot program cannot be realized, flexible production requirements of workpieces with multiple specifications are difficult to adapt, meanwhile, the whole flow state monitoring, grading authority management and safety linkage system of the existing system are imperfect, equipment fault early warning and emergency handling capability is insufficient, and convenience and safety of operation and operation are required to be improved. The invention aims to solve the practical problems of narrow application scene adaptability, insufficient double-end multi-mechanism cooperative control capability, poor suitability for full-flow automatic and flexible production and imperfect safety control system of the existing pipe flange welding robot control system, and provides an intelligent double-end flange robot welding control system which is suitable for synchronous welding of a double-end flange of a steel pipe and inner and outer welding seams of a sleeve and has full-procedure closed-loop linkage control capability. Disclosure of Invention The invention aims to provide an intelligent welding control system of a double-end flange robot, which aims to solve the problems in the background technology. The intelligent welding control system of the double-end flange robot comprises an industrial personal computer, a PLC (programmable logic controller), a welding robot system, a laser sensing system, a servo driving unit and a man-machine interaction terminal, wherein the industrial personal computer is respectively in communication connection with the PLC and the man-machine interaction terminal, the PLC is respectively in signal connection with the welding robot system, the laser sensing system and the servo driving unit, the welding robot system is a double-welding robot system and comprises a main-end welding robot and an auxiliary-end welding robot, and the main-end welding robot and the auxiliary-end welding robot respectively correspond to flange and sleeve welding seam welding stations at two ends of a steel pipe; the industrial personal computer is internally provided with a double-end collaborative sync