CN103706924B - A kind of intelligent arc welding robot diving wire-feed motor - Google Patents
A kind of intelligent arc welding robot diving wire-feed motor Download PDFInfo
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- 238000003466 welding Methods 0.000 title claims abstract description 119
- 230000009189 diving Effects 0.000 title claims description 11
- 238000001514 detection method Methods 0.000 claims abstract description 52
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- 238000007789 sealing Methods 0.000 claims abstract description 20
- 230000009347 mechanical transmission Effects 0.000 claims abstract description 9
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K9/00—Arc welding or cutting
- B23K9/12—Automatic feeding or moving of electrodes or work for spot or seam welding or cutting
- B23K9/133—Means for feeding electrodes, e.g. drums, rolls, motors
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K9/00—Arc welding or cutting
- B23K9/12—Automatic feeding or moving of electrodes or work for spot or seam welding or cutting
- B23K9/124—Circuits or methods for feeding welding wire
- B23K9/125—Feeding of electrodes
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K9/00—Arc welding or cutting
- B23K9/12—Automatic feeding or moving of electrodes or work for spot or seam welding or cutting
- B23K9/133—Means for feeding electrodes, e.g. drums, rolls, motors
- B23K9/1336—Driving means
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K9/00—Arc welding or cutting
- B23K9/32—Accessories
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K9/00—Arc welding or cutting
- B23K9/32—Accessories
- B23K9/321—Protecting means
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Abstract
本发明提供一种智能型弧焊机器人潜水送丝机,包括密封罩,还包括均设置在密封罩内的DSC控制器、送丝驱动电路、送丝电机、送丝速度检测电路、通信电路、有无焊丝检测电路、漏水检测电路、送丝机械传动部件和设置有焊丝的焊丝盘;DSC控制器、送丝驱动电路、送丝电机和送丝机械传动部件依次连接;DSC控制器还分别与漏水检测电路、通信电路和有无焊丝检测电路连接;送丝速度检测电路一端与DSC控制器连接,另一端与送丝电机连接;焊丝盘的焊丝与送丝机械传动部件连接。本发明可实现全数字控制、故障诊断和数据传输的功能,能够实现水下匀速、变速和脉动送丝等三种模式,并且焊丝送给稳定精确,使得机器人焊接过程的电源-水下电弧系统更为稳定可控。
The invention provides an intelligent arc welding robot submersible wire feeder, which includes a sealing cover, and also includes a DSC controller, a wire feeding drive circuit, a wire feeding motor, a wire feeding speed detection circuit, a communication circuit, Whether there is welding wire detection circuit, water leakage detection circuit, wire feeding mechanical transmission parts and welding wire reel with welding wire; DSC controller, wire feeding drive circuit, wire feeding motor and wire feeding mechanical transmission parts are connected in sequence; DSC controller is also connected with The water leakage detection circuit, the communication circuit and the presence or absence detection circuit are connected; one end of the wire feeding speed detection circuit is connected with the DSC controller, and the other end is connected with the wire feeding motor; the welding wire of the wire reel is connected with the transmission part of the wire feeding mechanism. The invention can realize the functions of full digital control, fault diagnosis and data transmission, and can realize three modes of underwater constant speed, variable speed and pulsating wire feeding, and the welding wire feeding is stable and accurate, so that the power supply of the robot welding process-underwater arc system More stable and controllable.
Description
技术领域technical field
本发明涉及焊接工艺及设备技术,更具体地说,涉及一种智能型弧焊机器人潜水送丝机。The invention relates to welding technology and equipment technology, more specifically, to an intelligent arc welding robot submersible wire feeder.
背景技术Background technique
随着海洋能源、远洋运输、大型船舶等一系列大型工程的开发,我国对水下焊接技术的需求也日益迫切。实现水下焊接自动化的主要方式有三种:水下轨道式焊接系统、远程遥控式焊接系统和机器人焊接系统。水下轨道式焊接需要在水下安装轨道,受到潜水员潜水深度限制;远程遥控焊接精度误差较大,有时难以满足工程焊接精度要求;基于当今社会特殊应用机器人的迅速发展,水下焊接机器人是今后水下焊接自动化的研究方向。其中,水下焊接机器人技术的概况已在“水下焊接机器人技术发展现状及趋势”(张华,李志刚.《机器人技术与应用》2008,(6))文献中公开。由于水下环境的复杂性和不确定性,目前还没有焊接机器人从事完全的水下焊接活动。With the development of a series of large-scale projects such as marine energy, ocean transportation, and large ships, my country's demand for underwater welding technology is becoming increasingly urgent. There are three main ways to realize underwater welding automation: underwater orbital welding system, remote control welding system and robot welding system. Underwater orbital welding needs to install the track underwater, which is limited by the diving depth of divers; the remote control welding accuracy error is large, and sometimes it is difficult to meet the engineering welding accuracy requirements; based on the rapid development of special application robots in today's society, underwater welding robots are the future The research direction of underwater welding automation. Among them, the overview of underwater welding robot technology has been published in the document "Development Status and Trends of Underwater Welding Robot Technology" (Zhang Hua, Li Zhigang. "Robot Technology and Application" 2008, (6)). Due to the complexity and uncertainty of the underwater environment, no welding robot is currently engaged in complete underwater welding activities.
影响水下焊缝质量的因素很多,但焊接时电弧是否稳定燃烧是基本要求。与通常的焊接电弧相比,水环境下的电弧由于水压力及其他因素的影响,其燃烧的稳定性很差。从机理上分析,要使水下电弧燃烧稳定,就必须要有性能稳定可靠的潜水送丝机,确保焊丝稳定精确的送给,能够建立稳定的电源-电弧系统。水下送丝系统的性能至关重要,能根据焊接工艺需求,实现匀速、变速以及脉动等多种送丝模式,之外,还需要实时诊断焊丝余量,确保焊丝从送丝软管送出时比较干燥,不对焊接电弧的稳定性产生不利影响。There are many factors that affect the quality of underwater welds, but whether the arc burns stably during welding is the basic requirement. Compared with the usual welding arc, the arc in the water environment has poor combustion stability due to the influence of water pressure and other factors. From the analysis of mechanism, in order to make the underwater arc burn stably, it is necessary to have a submersible wire feeder with stable and reliable performance to ensure stable and accurate feeding of welding wire and to establish a stable power supply-arc system. The performance of the underwater wire feeding system is very important. It can realize various wire feeding modes such as constant speed, variable speed and pulsation according to the welding process requirements. In addition, it is also necessary to diagnose the welding wire allowance in real time to ensure that the welding wire is delivered from the wire feeding hose. Relatively dry, does not adversely affect the stability of the welding arc.
发明内容Contents of the invention
本发明的目的在于克服现有技术中的缺点与不足,提供一种智能型弧焊机器人潜水送丝机,保证在焊接过程能够确保送丝盘干燥和焊丝送给稳定精确,从而实现匀速、变速以及脉动等多种送丝模式,有助于焊接电源-水下电弧系统自动适应水下焊接电弧的特性,实现高质量的水下机器人焊接。The purpose of the present invention is to overcome the shortcomings and deficiencies in the prior art, and provide an intelligent arc welding robot submersible wire feeder, which can ensure that the wire feeder is dry and the welding wire is fed stably and accurately during the welding process, so as to achieve uniform and variable speed And multiple wire feeding modes such as pulsation help the welding power supply - underwater arc system to automatically adapt to the characteristics of the underwater welding arc to achieve high-quality underwater robot welding.
为了达到上述目的,本发明通过下述技术方案予以实现:一种智能型弧焊机器人潜水送丝机,其特征在于:包括密封罩,还包括均设置在密封罩内的DSC控制器、送丝驱动电路、送丝电机、送丝速度检测电路、通信电路、有无焊丝检测电路、漏水检测电路、送丝机械传动部件和设置有焊丝的焊丝盘;所述DSC控制器、送丝驱动电路、送丝电机和送丝机械传动部件依次连接;所述DSC控制器还分别与漏水检测电路、通信电路和有无焊丝检测电路连接;所述送丝速度检测电路一端与DSC控制器连接,另一端与送丝电机连接;所述焊丝盘的焊丝与送丝机械传动部件连接。In order to achieve the above object, the present invention is achieved through the following technical solutions: an intelligent arc welding robot submersible wire feeder, characterized in that it includes a sealing cover, and also includes a DSC controller, a wire feeding Drive circuit, wire feeding motor, wire feeding speed detection circuit, communication circuit, presence or absence of welding wire detection circuit, water leakage detection circuit, wire feeding mechanical transmission parts and welding wire reel with welding wire; the DSC controller, wire feeding driving circuit, The wire-feeding motor and the transmission parts of the wire-feeding mechanism are connected sequentially; the DSC controller is also connected to the water leakage detection circuit, the communication circuit and the presence or absence of welding wire detection circuit respectively; one end of the wire-feeding speed detection circuit is connected to the DSC controller, and the other end It is connected with the wire feeding motor; the welding wire of the wire reel is connected with the transmission part of the wire feeding mechanism.
在上述方案中,焊丝盘采用通用的焊丝盘,送丝机械传动部件由通用的压紧轮、压紧手柄等构成,而送丝电机为通用的直流电机。In the above scheme, the welding wire reel adopts a general welding wire reel, the transmission parts of the wire feeding mechanism are composed of a general pressing wheel, a pressing handle, etc., and the wire feeding motor is a general DC motor.
所述DSC控制器由最小系统、可视化人机交互系统、按键、旋转编码器、LED状态指示灯、显存和闪存连接组成。具体地说,DSC控制器主要包括型号为STM32F405ZGT6的最小系统,由型号为AT070TN92的触摸屏、型号为RA8875的驱动芯片以及型号为CAT4139的背光芯片为主构成的可视化人机交互系统,按键,旋转编码器,LED状态指示灯,扩展的16MSRAM显存以及扩展的64Mbit的闪存连接构成。The DSC controller is composed of a minimum system, a visual human-computer interaction system, buttons, a rotary encoder, LED status indicators, video memory and flash memory connections. Specifically, the DSC controller mainly includes the smallest system modeled as STM32F405ZGT6, a visual human-computer interaction system mainly composed of a touch screen modeled AT070TN92, a driver chip modeled RA8875, and a backlight chip modeled CAT4139. device, LED status indicators, extended 16MSRAM video memory and extended 64Mbit flash connection.
所述最小系统由微处理器、电源电路、复位电路、晶振电路和JTAG接口通过外围电路连接构成。具体地说,DSC控制器的最小系统主要采用内部固化有运行于FreeRTOS内核的潜水送丝机控制软件的STM32F405RGT6微处理器为主要部件。The minimum system is composed of a microprocessor, a power supply circuit, a reset circuit, a crystal oscillator circuit and a JTAG interface connected through peripheral circuits. Specifically, the minimum system of the DSC controller mainly uses the STM32F405RGT6 microprocessor internally solidified with the submersible wire feeder control software running on the FreeRTOS kernel as the main component.
所述送丝驱动电路由两个N沟道型场效应管构成的半桥电路、驱动芯片、光耦一、继电器一和稳压芯片通过外围电路连接组成;所述驱动芯片通过最小系统的PWM端口与DSC控制器连接。该送丝驱动电路是能够实现匀速送丝、变速送丝以及脉动送丝三种送丝模式的电路。The wire feeding driving circuit is composed of a half bridge circuit composed of two N-channel field effect transistors, a driving chip, an optocoupler 1, a relay 1 and a voltage stabilizing chip connected through a peripheral circuit; the driving chip is connected through a minimum system PWM The port is connected with the DSC controller. The wire feeding driving circuit is a circuit capable of realizing three wire feeding modes of constant speed wire feeding, variable speed wire feeding and pulsating wire feeding.
所述有无焊丝检测电路通过最小系统的GPIO端口与DSC控制器连接,并由电涡流式接近开关、继电器二、光耦二、线性光耦、高速运算放大器通过外围电路连接构成。该有无焊丝检测电路不仅能够检测焊丝的有无,而且能够对焊丝盘焊丝的余量进行预测和判断。The presence or absence detection circuit of welding wire is connected to the DSC controller through the GPIO port of the minimum system, and is composed of an eddy current proximity switch, a relay 2, an optocoupler 2, a linear optocoupler, and a high-speed operational amplifier connected through peripheral circuits. The presence or absence detection circuit of the welding wire can not only detect the presence or absence of the welding wire, but also predict and judge the remaining amount of the welding wire in the welding wire spool.
所述漏水检测电路通过最小系统的GPIO端口与DSC控制器连接,并由漏水电极、光耦三、电阻一和电容一通过外围电路连接构成。The water leakage detection circuit is connected to the DSC controller through the GPIO port of the minimum system, and is composed of a water leakage electrode, an optocoupler 3, a resistor 1 and a capacitor 1 connected through a peripheral circuit.
所述送丝速度检测电路通过最小系统的ADC端口与DSC控制器连接;所述送丝速度检测电路对送丝速度的检测方式为编码器检测方式,或者为检测电机电枢电压的方式。The wire-feeding speed detection circuit is connected to the DSC controller through the ADC port of the minimum system; the detection method of the wire-feeding speed detection circuit for the wire-feeding speed is an encoder detection method, or a motor armature voltage detection method.
所述通信电路一端与焊接机器人连接,另一端通过最小系统的CAN端口与DSC控制器连接,并由型号为SN65HVD230的CAN收发器、电阻二和电容二通过外围电路连接构成。One end of the communication circuit is connected to the welding robot, and the other end is connected to the DSC controller through the CAN port of the minimum system, and is composed of a CAN transceiver model SN65HVD230, a resistor 2 and a capacitor 2 connected through peripheral circuits.
所述密封罩为由不锈钢材料制成的壳体,其与外部的接口采用静密封和动密封相结合的密封方式,从而提高该送丝机在水下工作的密封效果。The sealing cover is a shell made of stainless steel, and its interface with the outside adopts a sealing method combining static sealing and dynamic sealing, thereby improving the sealing effect of the wire feeder working underwater.
与现有技术相比,本发明具有如下优点与有益效果:Compared with the prior art, the present invention has the following advantages and beneficial effects:
1、本发明一种智能型弧焊机器人潜水送丝机采用了DSC控制器,以具备DSP模块的Cortex-M4ARM微处理器为数字控制核心,数据运算处理速度快,控制分辨率非常高,使得潜水送丝机对送丝过程的实时控制更为精细和准确。1. An intelligent arc welding robot submersible wire feeder of the present invention adopts a DSC controller, takes a Cortex-M4ARM microprocessor with a DSP module as the digital control core, has fast data calculation and processing speed, and has a very high control resolution, so that The real-time control of the wire feeding process by the submersible wire feeder is more precise and accurate.
2、本发明一种智能型弧焊机器人潜水送丝机采用了数字化PWM调制的送丝驱动电路,能够实现匀速、变速和脉动送丝等三种模式,对焊接机器人水下焊接过程的电源-电弧系统有更好的适应能力,提高焊接过程的稳定性。2. An intelligent arc welding robot submersible wire feeder of the present invention adopts a digital PWM modulated wire feeding drive circuit, which can realize three modes of uniform speed, variable speed and pulse wire feeding, and the power supply for the welding robot underwater welding process- The arc system has better adaptability and improves the stability of the welding process.
3、本发明一种智能型弧焊机器人潜水送丝机采用了基于电涡流式的检测方法,不仅能够实现有无焊丝的检测,还能够实时检测焊丝的余量,更有利于水下机器人自动化焊接。3. An intelligent arc welding robot submersible wire feeder of the present invention adopts an eddy current-based detection method, which can not only detect the presence or absence of welding wire, but also detect the remaining amount of welding wire in real time, which is more conducive to the automation of underwater robots welding.
本发明的智能型弧焊机器人潜水送丝机的工作原理是这样的:潜水送丝机由DSC控制器、送丝驱动电路、送丝电机、送丝速度检测电路、有无焊丝检测电路、漏水检测电路、通信电路、送丝机械传动部件(包括压紧轮、压紧手柄等)和焊丝盘连接组成;其中,DSC控制器、送丝驱动电路、送丝电机、送丝速度检测电路、有无焊丝检测电路、漏水检测电路、通信电路、送丝机械部件和焊丝盘等均安装在密封罩内。DSC控制器的ARM微处理器STM32F405RG可以接收来自焊接机器人发送的工作状态指令和参数信息,也可以根据触摸屏、按键和数字编码器设定的工作状态指令和参数信息,向送丝驱动电路输出两路互补的带死区PWM信号,经过IR2110驱动芯片的隔离和放大,控制送丝驱动电路的场效应管的开关导通和关闭时间,对电机电压进行实时调节,改变送丝电机的转速,从而改变送丝速度。与此同时,ARM微处理器STM32F405RG按照一定的采样频率,通过送丝速度检测电路实时采样送丝电机两端的电枢电压,采样数据经过软件的算术滤波后,与ARM微处理器STM32F405RG预定的送丝速度给定值进行比较,并按照数字PID调节规律调整输出的PWM脉冲占空比,从而调节送丝电机的送丝速度。通过采样电涡流式接近开关的输出端电压,监测焊丝的消耗情况,当输出电压值低于某一设定值时,说明焊丝余量不足;而当电涡流式接近开关闭合时,说明已经没有焊丝。当漏水电极检测端被下拉至低电平时,触发ARM微处理器STM32F405RG的GPIO口中断,进入相应的中断处理函数进行处理。焊接机器人将设定的控制参数通过CAN总线与送丝机DSC控制器进行通信和信息交互,而潜水送丝机的故障诊断信息也通过DSC的CAN端口,经由通信电路和CAN总线传输至焊接机器人。The working principle of the intelligent arc welding robot submersible wire feeder of the present invention is as follows: the submersible wire feeder consists of a DSC controller, a wire feed drive circuit, a wire feed motor, a wire feed speed detection circuit, a welding wire detection circuit, a water leakage Detection circuit, communication circuit, wire feeding mechanical transmission parts (including pressing wheel, pressing handle, etc.) No welding wire detection circuit, water leakage detection circuit, communication circuit, wire feeding mechanical parts and welding wire reel etc. are installed in the sealing cover. The ARM microprocessor STM32F405RG of the DSC controller can receive the working status instructions and parameter information sent from the welding robot, and can also output two parameters to the wire feeding drive circuit according to the working status instructions and parameter information set by the touch screen, keys and digital encoder. The complementary PWM signal with dead zone, through the isolation and amplification of the IR2110 driver chip, controls the switch on and off time of the field effect tube of the wire feeding drive circuit, adjusts the motor voltage in real time, and changes the speed of the wire feeding motor, thereby Change wire feed speed. At the same time, the ARM microprocessor STM32F405RG samples the armature voltage at both ends of the wire-feeding motor in real time through the wire-feeding speed detection circuit according to a certain sampling frequency. Compare with the given value of wire speed, and adjust the output PWM pulse duty cycle according to the digital PID regulation rule, so as to adjust the wire feeding speed of the wire feeding motor. By sampling the output terminal voltage of the eddy current proximity switch, the consumption of welding wire is monitored. When the output voltage value is lower than a certain set value, it means that the welding wire allowance is insufficient; when the eddy current proximity switch is closed, it means that there is no wire left. welding wire. When the water leakage electrode detection terminal is pulled down to low level, the GPIO port interrupt of the ARM microprocessor STM32F405RG is triggered, and the corresponding interrupt processing function is entered for processing. The welding robot communicates and exchanges information with the DSC controller of the wire feeder through the set control parameters through the CAN bus, and the fault diagnosis information of the submersible wire feeder is also transmitted to the welding robot through the CAN port of the DSC via the communication circuit and the CAN bus .
附图说明Description of drawings
图1是本发明智能型弧焊机器人潜水送丝机的结构示意图;Fig. 1 is the structural representation of intelligent arc welding robot submersible wire feeder of the present invention;
图2是本发明智能型弧焊机器人潜水送丝机的DSC控制器内部结构示意图;Fig. 2 is a schematic diagram of the internal structure of the DSC controller of the intelligent arc welding robot submersible wire feeder of the present invention;
图3是本发明智能型弧焊机器人潜水送丝机的最小系统原理图;Fig. 3 is the minimum system schematic diagram of the intelligent arc welding robot submersible wire feeder of the present invention;
图4是本发明智能型弧焊机器人潜水送丝机的送丝驱动电路原理图;Fig. 4 is a schematic diagram of the wire feeding drive circuit of the intelligent arc welding robot submersible wire feeder of the present invention;
图5是本发明智能型弧焊机器人潜水送丝机的送丝速度检测电路原理图;Fig. 5 is a schematic diagram of the wire feeding speed detection circuit of the intelligent arc welding robot submersible wire feeder of the present invention;
图6(a)和图6(b)是本发明智能型弧焊机器人潜水送丝机的有无焊丝检测电路原理图;Fig. 6 (a) and Fig. 6 (b) are the schematic diagrams of the presence or absence of welding wire detection circuit of the intelligent arc welding robot submersible wire feeder of the present invention;
图7是本发明智能型弧焊机器人潜水送丝机的漏水检测电路原理图;Fig. 7 is a schematic diagram of the water leakage detection circuit of the intelligent arc welding robot submersible wire feeder of the present invention;
图8是本发明智能型弧焊机器人潜水送丝机的通信电路原理图。Fig. 8 is a schematic diagram of the communication circuit of the intelligent arc welding robot submersible wire feeder of the present invention.
具体实施方式detailed description
下面结合附图与具体实施方式对本发明作进一步详细的描述。The present invention will be further described in detail below in conjunction with the accompanying drawings and specific embodiments.
实施例Example
本发明的智能型弧焊机器人潜水送丝机具备匀速送丝、变速送丝以及脉动送丝等三种送丝模式,其包括密封罩,如图1所示,还包括均设置在密封罩内的DSC控制器100、送丝驱动电路200、送丝电机300、送丝速度检测电路500、通信电路700、有无焊丝检测电路800、漏水检测电路600、送丝机械传动部件400和设置有焊丝的焊丝盘;其中,DSC控制器100、送丝驱动电路200、送丝电机300和送丝机械传动部件400依次连接,DSC控制器100还分别与漏水检测电路600、通信电路700和有无焊丝检测电路800连接,送丝速度检测电路500一端与DSC控制器100连接,另一端与送丝电机300连接,焊丝盘的焊丝与送丝机械传动部件400连接。为了提高该送丝机在水下工作的密封效果,本发明的密封罩为由不锈钢材料制成的壳体,其与外部的接口采用静密封和动密封相结合的密封方式。The intelligent arc welding robot submersible wire feeder of the present invention has three wire feeding modes such as uniform speed wire feeding, variable speed wire feeding and pulsating wire feeding. DSC controller 100, wire feeding drive circuit 200, wire feeding motor 300, wire feeding speed detection circuit 500, communication circuit 700, presence or absence of welding wire detection circuit 800, water leakage detection circuit 600, wire feeding mechanical transmission part 400 and welding wire Among them, the DSC controller 100, the wire feeding drive circuit 200, the wire feeding motor 300 and the wire feeding mechanical transmission part 400 are sequentially connected, and the DSC controller 100 is also connected with the water leakage detection circuit 600, the communication circuit 700 and the presence or absence of welding wire respectively. The detection circuit 800 is connected, one end of the wire-feeding speed detection circuit 500 is connected to the DSC controller 100 , the other end is connected to the wire-feeding motor 300 , and the welding wire of the wire reel is connected to the transmission part 400 of the wire-feeding mechanism. In order to improve the sealing effect of the wire feeder working underwater, the sealing cover of the present invention is a shell made of stainless steel, and its interface with the outside adopts a sealing method combining static sealing and dynamic sealing.
如图2所示,DSC控制器由型号为STM32F405ZGT6的最小系统,由型号为AT070TN92的触摸屏、型号为RA8875的驱动芯片以及型号为CAT4139的背光芯片相互连接构成的可视化人机交互系统,按键,旋转编码器,LED状态指示灯,扩展的16MSRAM显存和扩展的64Mbit的闪存通过外围电路连接构成。STM32F405ZGT6为融合了ARM+DSP双芯功能的CortexM4内核ARM微处理器,其通过FSMC端口扩展配置了16M显存,通过SPI端口扩展了64Mbit的闪存。旋转编码器直接与TIMER端口相连,按键直接与GPIO端口相连,LED状态指示灯直接与GPIO端口相连,其中,按键和旋转编码器用于设置参数。最小系统通过CAN接口和通信电路直接与焊接机器人连接,其参数显示采用四线电阻式7寸TFT-LCD-AT070TN92,LCD驱动芯片RA8875直接与最小系统的GPIO端口相连。送丝驱动电路直接通过PWM端口与最小系统连接,送丝速度检测电路直接通过ADC端口与最小系统连接,有无焊丝检测电路和漏水检测电路直接通过GPIO端口与最小系统连接,通信电路一端与焊接机器人连接,另一端通过CAN端口与最小系统连接。该最小系统以FreeRTOS为实时内核,具有数据处理速度快、调节精确灵活和系统扩展便利等优势。As shown in Figure 2, the DSC controller consists of the smallest system model STM32F405ZGT6, a visual human-computer interaction system composed of a touch screen model AT070TN92, a driver chip model RA8875, and a backlight chip model CAT4139. Encoder, LED status indicator light, extended 16MSRAM video memory and extended 64Mbit flash memory are connected through peripheral circuits. STM32F405ZGT6 is a CortexM4 core ARM microprocessor that integrates ARM+DSP dual-core functions. It expands and configures 16M video memory through FSMC port, and expands 64Mbit flash memory through SPI port. The rotary encoder is directly connected to the TIMER port, the button is directly connected to the GPIO port, and the LED status indicator is directly connected to the GPIO port. Among them, the button and the rotary encoder are used to set parameters. The minimum system is directly connected to the welding robot through CAN interface and communication circuit. Its parameter display adopts four-wire resistive 7-inch TFT-LCD-AT070TN92, and the LCD driver chip RA8875 is directly connected to the GPIO port of the minimum system. The wire feeding driving circuit is directly connected to the minimum system through the PWM port, the wire feeding speed detection circuit is directly connected to the minimum system through the ADC port, the welding wire detection circuit and the water leakage detection circuit are directly connected to the minimum system through the GPIO port, and one end of the communication circuit is connected to the welding The robot is connected, and the other end is connected with the minimal system through the CAN port. The minimum system uses FreeRTOS as the real-time kernel, which has the advantages of fast data processing speed, precise and flexible adjustment, and convenient system expansion.
如图3所示,型号为STM32F405RGT6的最小系统由ST公司主频高达168MHz的Cortex-M4内核STM32F405RGT6微处理器,由芯片AMS1117、电容C14-17、电阻R6和二极管D1通过外围电路构成的电源电路,由开关S1、电容C1和电阻R7通过外围电路构成的复位电路,由晶振Y1、电容C2-3和电阻R1通过外围电路构成的晶振电路,以及由电阻R5-8和JTAG芯片构成的JTAG接口通过辅助电路连接构成。STM32F405RGT6最小系统内置DSP功能模块,为基于Cortex-M4内核的SOC级芯片,有多达1MB片上FLASH,192KbSRAM,12位转换速率达2.4MSPS的ADC,具有两路12位DAC,可以产生0-3.3v的模拟电压,预留了UART、RS485和CAN接口。STM32F405RGT6是潜水送丝机的数字化核心,其内部固化有基于FreeRTOS实时内核的潜水送丝机控制软件。As shown in Figure 3, the smallest system modeled as STM32F405RGT6 is composed of the Cortex-M4 core STM32F405RGT6 microprocessor of ST Company with a main frequency of up to 168MHz, and the power supply circuit composed of the chip AMS1117, capacitor C14-17, resistor R6 and diode D1 through the peripheral circuit , a reset circuit composed of a switch S1, a capacitor C1 and a resistor R7 through a peripheral circuit, a crystal oscillator circuit composed of a crystal oscillator Y1, a capacitor C2-3 and a resistor R1 through a peripheral circuit, and a JTAG interface composed of a resistor R5-8 and a JTAG chip Constructed by auxiliary circuit connections. The smallest system of STM32F405RGT6 has a built-in DSP function module. It is a SOC-level chip based on the Cortex-M4 core. It has up to 1MB on-chip FLASH, 192KbSRAM, and a 12-bit ADC with a conversion rate of 2.4MSPS. It has two 12-bit DACs and can generate 0-3.3 The analog voltage of v has reserved UART, RS485 and CAN interfaces. STM32F405RGT6 is the digital core of the submersible wire feeder, and its interior is solidified with the submersible wire feeder control software based on the FreeRTOS real-time kernel.
如图4所示,所述送丝驱动电路主要由2个N沟道型场效应管Q1和场效应管Q2构成的半桥电路、驱动芯片IR2110、光耦PC817、继电器K1、稳压芯片L7815以及其他外围电路连接构成。驱动芯片采用的型号为IR2110,并通过继电器K1与光耦PC817构成的换向电路实现电机的正转、反转的转换。其中,电机两端与连接器P1相连,两路互补的带死区PWM信号分别输入至驱动芯片IR2110。Inversion换向端保持为高电平,继电器保持在正转端,当PWMH为高电平,PWML为低电平时,由于电容C2和C3、二极管D1组成的自举电路的作用,此时场效应管Q1可靠导通,场效应管Q2关断,电机正负两端短接于24V,处于急停状态;当PWMH为低电平,PWL为高电平时,场效应管Q2导通,场效应管Q1关断,此时电机两端电压为+24V,电机处于正转状态。当Inversion换向端保持为低电平时,光耦PC817的三极管导通,继电器保持在反转端,当PWMH为高电平,PWML为低电平时,场效应管Q1导通,场效应管Q2关断,此时电机两端电压为+24V,电机处于反转状态;当PWML为高电平,PWMH为低电平时,电机正负两端短接于24V,处于急停状态。因此,通过控制Inversion换向端的高低电平,可以实现脉动送丝,而通过控制PWMH和PWML的占空比,就可以控制送丝的速度,这两者相结合,就可以方便的实现匀速送丝、变速送丝以及脉动送丝等三种送丝模式。As shown in Figure 4, the wire feeding drive circuit is mainly composed of a half-bridge circuit composed of two N-channel FETs Q1 and FETs Q2, a driver chip IR2110, an optocoupler PC817, a relay K1, and a voltage regulator chip L7815 And other peripheral circuit connections. The model of the driver chip is IR2110, and the forward and reverse conversion of the motor is realized through the commutation circuit composed of the relay K1 and the optocoupler PC817. Wherein, both ends of the motor are connected to the connector P1, and two complementary PWM signals with dead zones are respectively input to the driver chip IR2110. The Inversion commutation end is kept at high level, and the relay is kept at the forward end. When PWMH is at high level and PWML is at low level, due to the role of the bootstrap circuit composed of capacitors C2 and C3 and diode D1, the field effect at this time The tube Q1 is reliably turned on, the field effect tube Q2 is turned off, the positive and negative ends of the motor are shorted to 24V, and it is in an emergency stop state; when PWMH is low and PWL is high, the field effect tube Q2 is turned on, and the field effect The tube Q1 is turned off, and the voltage at both ends of the motor is +24V at this time, and the motor is in the forward rotation state. When the Inversion commutation end is kept at low level, the triode of the optocoupler PC817 is turned on, and the relay is kept at the inversion end. When PWMH is at high level and PWML is at low level, FET Q1 is turned on, and FET Q2 is turned on. Turn off, the voltage at both ends of the motor is +24V, and the motor is in reverse state; when PWML is high and PWMH is low, the positive and negative ends of the motor are shorted to 24V, and it is in an emergency stop state. Therefore, by controlling the high and low levels of the Inversion reversing end, pulsating wire feeding can be realized, and by controlling the duty cycle of PWMH and PWML, the speed of wire feeding can be controlled. The combination of the two can easily realize uniform speed feeding. Three wire feeding modes: wire feeding, variable speed wire feeding and pulsating wire feeding.
电阻R1、二极管D2及电阻R3、二极管D3分别组成场效应管Q1和场效应管Q2的泄流回路,使场效应管能快速关断,防止上下两个场效应管同时导通。电阻R2、电阻R4分别为场效应管Q1、场效应管Q2的输入端保护电阻,防止场效应管因静电等原因意外导通。因为所用直流电机属于感性元件,所以电机在换向时会产生很大的感应电动势,故在输入端加入由二极管D4、二极管D5组成反向电动势吸收电路。为防止模拟电路的高频噪声信号耦合至数字电路一侧,模拟电路的地端与数字电路的地端通过磁珠L1单点连接。Resistor R1, diode D2, resistor R3, and diode D3 form the leakage circuits of FET Q1 and FET Q2 respectively, so that the FET can be turned off quickly and prevent the upper and lower FETs from being turned on at the same time. Resistor R2 and resistor R4 are the input end protection resistors of FET Q1 and FET Q2 respectively, preventing the FET from being turned on accidentally due to static electricity or the like. Because the DC motor used is an inductive element, the motor will generate a large induced electromotive force when commutating, so a reverse electromotive force absorption circuit composed of diode D4 and diode D5 is added at the input end. In order to prevent the high-frequency noise signal of the analog circuit from being coupled to the digital circuit side, the ground terminal of the analog circuit and the ground terminal of the digital circuit are single-point connected through the magnetic bead L1.
本发明的送丝速度检测电路对送丝速度检测,既可以采用编码器检测方式,也可以采用检测电机电枢电压的方式。本实施例以检测电枢电压的方式进行介绍,如图5所示,电机正负两端与连接器P3相连接,电机两端电压经过电阻分压,差分放大,线性光耦隔离,进一步分压后输入到控制芯片STM32F405RG,进过A/D转换后与电压给定值进行比较,从而调整PWM信号的占空比,达到调节电机运行速度的目的。其中,电阻R6、电阻R7与电阻R8、电阻R9分别组成两个输入电压的分压电路,将电压等比例降低至适合运算放大器LF353的输入电压。电感L5、电感L6、电容C10组成输入端的LC滤波电路。运算放大器U4构成差分放大电路,将经过降压后的电机两端的电压先放大至两倍,然后求两者差值后输出,从而将输入的差动信号转变为单边电压信号输出。二极管D6、二极管D7与二极管D8、二极管D9分别为运算放大器U4两输入端的保护二极管,当输入端电压绝对值高于15V时,其中一个二极管导通,有效保护了运算放大器。由于线性光耦U6为电流驱动型光耦元件,所隔离的为电流量,所以运算放大器U5与电阻R17组成电压-电流转换电路,将运算放大器输入端的电压转换成线性光耦HCNR201的LED驱动电流,而运算放大器U5与电阻R16、电容C11、二极管D10组成线性光耦U6的闭环反馈电路,以补偿U6的LED的非线性以及温度漂移,而电容C11也能起到滤除高频噪声信号的作用。运算放大器U7与电阻R22、电阻R18组成电流-电压转换电路,将线性光耦U6的输出电流转换成电压,调整电阻R22的阻值至合适值,即可得到与运算放大器U4单边输出电压相等的电压值,经过电阻R18的进一步降压,将运算放大器U7的输出电压降至控制芯片STM32F405RG合适的输入电压,其中二极管D11、二极管D12组成输入端保护电路,防止Feedback端的电压高于3.3V。The wire-feeding speed detection circuit of the present invention can detect the wire-feeding speed by either an encoder detection method or a motor armature voltage detection method. This embodiment is introduced by detecting the armature voltage. As shown in Figure 5, the positive and negative ends of the motor are connected to the connector P3. After the voltage is input to the control chip STM32F405RG, after A/D conversion, it is compared with the given voltage value, so as to adjust the duty cycle of the PWM signal and achieve the purpose of adjusting the motor running speed. Among them, the resistor R6, the resistor R7, the resistor R8, and the resistor R9 respectively form two voltage divider circuits of the input voltage, which reduce the voltage proportionally to the input voltage suitable for the operational amplifier LF353. Inductor L5, inductor L6, and capacitor C10 form an LC filter circuit at the input end. The operational amplifier U4 constitutes a differential amplifier circuit, amplifies the voltage across the reduced motor to twice, and then calculates the difference between the two before outputting, thereby converting the input differential signal into a unilateral voltage signal for output. Diode D6, diode D7, diode D8, and diode D9 are protection diodes for the two input terminals of the operational amplifier U4 respectively. When the absolute value of the input terminal voltage is higher than 15V, one of the diodes conducts, effectively protecting the operational amplifier. Since the linear optocoupler U6 is a current-driven optocoupler element, what is isolated is the current, so the operational amplifier U5 and the resistor R17 form a voltage-current conversion circuit, which converts the voltage at the input terminal of the operational amplifier into the LED drive current of the linear optocoupler HCNR201 , and the operational amplifier U5, resistor R16, capacitor C11, and diode D10 form a closed-loop feedback circuit of the linear optocoupler U6 to compensate for the nonlinearity and temperature drift of the LED of U6, and the capacitor C11 can also filter out high-frequency noise signals effect. The operational amplifier U7, resistor R22, and resistor R18 form a current-voltage conversion circuit, which converts the output current of the linear optocoupler U6 into a voltage, and adjusts the resistance value of the resistor R22 to an appropriate value to obtain a unilateral output voltage equal to that of the operational amplifier U4. The voltage value is further lowered by the resistor R18 to reduce the output voltage of the operational amplifier U7 to the appropriate input voltage of the control chip STM32F405RG, where the diode D11 and diode D12 form the input terminal protection circuit to prevent the voltage at the Feedback terminal from being higher than 3.3V.
如图6(a)和6(b)所示,本发明的有无焊丝检测电路采用了电涡流式检测方法,主要由电涡流式接近开关、继电器K2、光耦PC817、线性光耦HCNR201、高速运算放大器LF353以及外围辅助电路构成,不仅能够检测焊丝的有无,而且能够对焊丝盘焊丝的余量进行预测和判断。如图6(a)所示,电涡流式接近开关为两线制常闭型接近开关,输出端与连接器P6相连接。当检测到有焊丝时,连接器P6两端断开,继电器K2没有被吸合,工作指示灯LED1点亮,表明此时有焊丝;当检测到焊丝耗尽时,电涡流式接近开关输出端闭合,连接器P6两端连接,回路导通,继电器K2被吸合,指示灯LED1熄灭,而光耦PC817的LED有驱动电流流过,输出端的三极管导通,信号端WIRE被下拉至低电平状态,WIRE端与控制芯片STM32F45RG的GPIO口相连接,当检测到WIRE端口为低电平时,进入GPIO中断处理函数,进行相应的处理。如图6(b)所示,为保证无焊丝故障检测结果的可靠性,对电涡流式接近开关的输出端电压进行检测,当采样端FBWIRE的电压高于一定值时,则认为焊丝已经耗尽。As shown in Figures 6 (a) and 6 (b), the presence or absence of welding wire detection circuit of the present invention adopts an eddy current detection method, mainly consisting of an eddy current proximity switch, a relay K2, an optocoupler PC817, a linear optocoupler HCNR201, Composed of high-speed operational amplifier LF353 and peripheral auxiliary circuits, it can not only detect the presence or absence of welding wire, but also predict and judge the remaining amount of welding wire in the welding wire reel. As shown in Figure 6(a), the eddy current proximity switch is a two-wire normally closed proximity switch, and the output end is connected to the connector P6. When the welding wire is detected, both ends of the connector P6 are disconnected, the relay K2 is not pulled in, and the working indicator LED1 lights up, indicating that there is welding wire at this time; Closed, the two ends of the connector P6 are connected, the loop is turned on, the relay K2 is pulled in, the indicator LED1 is off, and the LED of the optocoupler PC817 has a driving current flowing, the triode at the output end is turned on, and the signal end WIRE is pulled down to low power. In the flat state, the WIRE port is connected to the GPIO port of the control chip STM32F45RG. When it is detected that the WIRE port is at a low level, it enters the GPIO interrupt processing function and performs corresponding processing. As shown in Figure 6(b), in order to ensure the reliability of the detection results of no welding wire fault, the output terminal voltage of the eddy current proximity switch is detected. When the voltage of the sampling terminal FBWIRE is higher than a certain value, it is considered that the welding wire has been consumed. do.
如图7所示,漏水检测电路主要由漏水电极、光耦PC817、电阻R21-22和电容C14通过外围电路连接构成。漏水电极两端与连接器P5相连接。当密封箱体内部没有积水时,漏水电极两端断开,光耦PC817的LED没有电流流过,输出端的三极管截止,检测信号输出端WATER被上拉电阻上拉至3.3V;当检测到密封箱体内部有积水时,漏水电极两端相连接,光耦PC817的LED驱动电流流过而发光,输出端的三极管导通,检测信号输出端WATER被下拉至地。检测信号输出端WATER与控制芯片STM32F405RG的GPIO相连接,当检测到其为低电平时,进入相应的中断处理函数进行处理。As shown in Figure 7, the water leakage detection circuit is mainly composed of water leakage electrodes, optocoupler PC817, resistors R21-22 and capacitor C14 connected through peripheral circuits. Both ends of the leakage electrode are connected with connector P5. When there is no water in the sealed box, both ends of the leakage electrode are disconnected, no current flows through the LED of the optocoupler PC817, the transistor at the output end is cut off, and the detection signal output end WATER is pulled up to 3.3V by the pull-up resistor; When there is water in the sealed box, the two ends of the leaking electrode are connected, the LED drive current of the optocoupler PC817 flows and emits light, the triode at the output end is turned on, and the detection signal output end WATER is pulled down to the ground. The detection signal output terminal WATER is connected to the GPIO of the control chip STM32F405RG, and when it is detected to be low level, it enters the corresponding interrupt processing function for processing.
如图8所示,通信电路由CAN收发器SN65HVD230、电阻R20和电容C13通过外围电路连接构成。送丝机的送丝速度设定值、送气延时设定值、故障诊断信号等参数通过通信电路与焊接机器人进行数据交互。SN65HVD230是TI公司生产的3.3VCAN收发器,该器件适用于较高通讯速率、良好抗干扰能力和高可靠性CAN总线的串行通信。As shown in Figure 8, the communication circuit is composed of CAN transceiver SN65HVD230, resistor R20 and capacitor C13 connected through peripheral circuits. Parameters such as the wire feeding speed setting value, gas feeding delay setting value, and fault diagnosis signal of the wire feeder perform data interaction with the welding robot through the communication circuit. SN65HVD230 is a 3.3VCAN transceiver produced by TI Company. This device is suitable for serial communication of CAN bus with higher communication rate, good anti-interference ability and high reliability.
上述实施例具有以下特点:The foregoing embodiments have the following characteristics:
1、全数字化:本实施例的一种智能型弧焊机器人潜水送丝机首次构建了基于DSC控制器的全数字潜水送丝机,不仅实现了控制过程的数字化,而且实现了送丝机与机器人之间的全数字数据通信和信息交互,数据处理能力强,响应速度快,过程控制更为精确。1. Full digitalization: An intelligent arc welding robot submersible wire feeder in this embodiment constructs a fully digital submersible wire feeder based on DSC controller for the first time, which not only realizes the digitization of the control process, but also realizes the integration of wire feeder and All-digital data communication and information interaction between robots, strong data processing ability, fast response speed, and more precise process control.
2、宽适应性:本实施例的一种智能型弧焊机器人潜水送丝机采用数字PWM调制方式,实现了送丝驱动电路的正反转和调速控制,能够实现匀速、变速和脉动送丝等三种模式,对水下机器人焊接的电源-电弧系统有更好的适应性,更能够得到稳定的焊接过程,获得优质焊缝。2. Wide adaptability: An intelligent arc welding robot submersible wire feeder in this embodiment adopts a digital PWM modulation method to realize the forward and reverse and speed control of the wire feeding drive circuit, and can realize uniform speed, variable speed and pulse feeding. Wire and other three modes have better adaptability to the power-arc system of underwater robot welding, and can obtain a stable welding process and high-quality welds.
3、专业化:本实施例的一种智能型弧焊机器人潜水送丝机不仅能够对有无焊丝以及焊丝余量进行检测,还能实时动态监测潜水送丝机密封罩是否有渗漏,此外,密封罩还采用了静密封和动密封相结合的方式,密封性能更好,能够满足水下焊接的专业需求。3. Specialization: An intelligent arc welding robot submersible wire feeder in this embodiment can not only detect the presence or absence of welding wire and the amount of welding wire, but also dynamically monitor whether there is leakage in the sealing cover of the submersible wire feeder in real time. , The sealing cover also adopts a combination of static sealing and dynamic sealing, which has better sealing performance and can meet the professional needs of underwater welding.
上述实施例为本发明较佳的实施方式,但本发明的实施方式并不受上述实施例的限制,其他的任何未背离本发明的精神实质与原理下所作的改变、修饰、替代、组合、简化,均应为等效的置换方式,都包含在本发明的保护范围之内。The above-mentioned embodiment is a preferred embodiment of the present invention, but the embodiment of the present invention is not limited by the above-mentioned embodiment, and any other changes, modifications, substitutions, combinations, Simplifications should be equivalent replacement methods, and all are included in the protection scope of the present invention.
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