Mechanism Design And Simulation Of Mobile Welding Robot With Rotating Arc Sensor

According to the present ship welding situation of our country, this dissertation introduces a type of multi-functional mobile welding robot, which combines mobile robot technology with seam tracking based on using virtual prototyping. It can be applied to the fillet weld seam produce in the domin of plane V-type seam and various fillet welding of the large-sized structural components of the ships, and promote the quality of the automatically welding technology of the large-sized structural components, in order to improve the working condition of this area.The author systematically overviews the developing situation of mobile welding robot and virtual prototyping technology, and successfully develops the mobile welding robot system by using the automatical plane bending welding. According to the features of automatical plane bending welding, the paper studies the related key technology, including mobile body structure, two-dimensional mobile platform, high speed rotating arc sensor, seam tracking controlled algorithm and controller, virtual prototype and rotating arc sensor system and seam tracking experiment, etc. It also studies the large deformation, rigid and flexible contact simulation and optimization, and the dynamic balancing simulation and optimization.The dissertation introduces the present developing situation at home and abroad and the implementation of mobile welding robot. It concludes the types of plane bending seam of the large-sized structural component and the requirements and features of seam tracking, puts forward the structural scheme of rotating arc as the seam tracking sensor, the precisely two-dimensional platform as the fine adjustment mechanism, and the two differential driving wheels of the mobile welding robot, and uses advanced virtual prototyping technology to develop the mobile welding robot.At first, the dissertation studies and designs the mobile mechanism of the mobile welding robot, analyzes its working capability, turning features, and designs its transmission mechanism and welding torch supporting plate.Through concluding the present development of rotating arc sensor at home and abroad, the paper develops a new rotating arc sensor. It designs a new circulating cooling water structure and protecting gas transmission structure, firstly realizes the rotating arc sensor integrated the cooling water and protecting gas. Its distinguished insulating structure design makes the rotating arc sensor shell with no electric charges, and improves its safety. The paper uses virtual prototyping technology to optimize the dynamic balance when it is in a high speed rotating, in order to lower the vibration of the high speed rotating. This technology promotes the welding quality, while decreases it interference, which guarantees the improving of the seam tracking control precision by accurately extracting the seam error signal.The paper successfully develops a precisely full-closed two-dimensional mobile platform, which uses double cylinder mobile guide, not only decreases force of the ball screw, but also improve its strength. To design the full-closed connecting structure, use the virtual prototyping technology and Flexible Multi-Body Dynamics, this paper optimizes design, and obtains the optimized structure.This paper studies the virtual prototyping technology of the mobile welding robot, firstly realizes the implementation of the virtual prototyping technology in the development of the mobile welding robot. This development bases on the seam tracking control algorithm and the controller design of the mobile welding robot’s virtual prototype. This technology makes the robot being successfully developed, and provides the parameter which cannot be got from the physical prototype.Finally, this paper develops the calibration performance and the seam tracking experiment of the wheeled mobile welding robot system. The result shows its calibration index reaching the design requirements.The development of this system realizes automatically seam of the plane bending seam of the large-sized structural component, especially to those in the confined space. It gives a practical significance in promoting the large-sized structural component’s manufacture of automatical equipment, decreasing manufacturing period, and improving its quality.