Study On PC+DSP Base Special-Purpose Welding Robot System Of Pipe Inserting

Automation of welding process is a trend in the welding development, more and more welding robots are used in the manufacture. In the modern welding prcess, pipe inserting is applied in the chemical and boiler industry. The exsiting welding robot can not satisfy the using demand(suiting for whole-position welding and real time programme), So handwork welding is used. The working intensity is large, the working condition is very formidable, and welding quality is bad. In this thesis, the problem in the pipe inserting automation is researched, the PC+DSP open style controlling pattern is applied, and the opening architechture special-purpose welding robot system of pipe inserting and the controlling method are developed.The working condition of pipe inserting welding and the characteristic of the welding robot system are analyed. The control device integration hardware flatform controlled by the robot locomotion and welding power parameter is studied. The flatform is based on PC+DSP controlling pattern. For the characteristic of the pipeline pipe inserting, the neotype and protable five freedrom robot is researched. This welding robot implements pointing using inwall additional pipe. The robot gyrating center and additional pipe axial line are in the same line.The new style welding robot hand of two fredom and automatic centring is researched. This new hand is composed by the ratation angle revolving table and a mechanical linkage. The independent control of blowtorch moving angle and working angle attitude is implemented. The demand of pipe inserting welding prcocess is satisfied. The blowtorch position and attitude of the whole welding robot is controlled indenpendly in the welding process.Based on the PMAC, the interface element makes up with welding power, welding robot, wire feeding system and air supplying system is built. The PMAC is used as the parameters and motion controlling centre. The PC is used as the data management centre and open sytle control system hard ware flatform.Pipe inserting intersecting line is typical, complex weld. By analying the intersecting line weld, the characteristic matrix of the pipeline inserting weld position and posture that fit for the robot welding is built, then the controlling math pattern of the blowtorch position and posture is built. The blowtorch position and posture can be decribed quanlitativly. The pipeline intubation intersecting line is the welding puerpose, the real-time controlling welding speed pattern for the different weld position is built.The controlling pattern and weld position pattern of the new welding robot are the theoretical basis of the automatic controlling welding process. The motion pattern based on the D-H for the welding robot is recearched. The motion motion normal solution and inverse solution are proposed.For the open style controlling system, the controlling system nased on the PMAC is built. The layered step-up controlling system flatform is inplemented. Based on the control demand of the welding position,speed and stabilization, the three rings servo system that using the position as the external ring , the current as the internal ring and the speed as the centre ring. Using the Borland C++ builder 6.0, the PComm32PRO from Delta Tau and the SQL Server as the data bank engine. The open style welding robot is built. It makes up with system designing modular, condition monitor modular,motion controlling modular, expert system modular, condition display modular, on-line command modular and the communicating modular.The demand of the pipeline intubation intersecting line welding process is analyed. The system logic structure of the blowborch position, posture, power. The control programm of start control and inherit control. Based on the pipeline butt-joint all-position welding, the weld interval division method that based on the weld posture is suppiled. The welding robot task programm system makes up with condition model building organ, task programmer, parameter arithmetic organ, task planning organ and sensor information processor. The task programm function is implemented.To prove the practicablity and feasibility of the welding robot, the welding experiments are done. The results show that, the welding robot can make the pipeline intubation intersecting line weld very well, can implement independent control of the weld borch position and posture, can finish the integrate control of the robot motion line,weld borch posture and welding process. The stable,applicable working platform for the all-position mutil-layers and tracks welding is built.