Design And Development Of Industrial Robot Control System For Arc Welding Application

Industrial robotic technology is considered as an indispensable part of the intelligent transformation of Chinese traditional manufacturing industry.With the continuous development and mature of industrial robot technology,industrial robots are increasingly widely used in various industries.And arc welding is one of the most important applications of industrial robots,achieving the independent development and industrialization of arc welding robot will greatly improve domestic technical level of industrial robots,at the same time will conducive to completing the application of industrial robots and promoting the development of related industries.As the core components of the arc welding robot system,the robot controller plays a key role in the motion control of the arc welding robot.The request of the arc welding operation to the robot control system is not harsh,adding arc welding function in the general-purpose industrial robot control system can also be competent.At present,part of domestic industrial robot controller products are still based on "PC + motion control card" control architecture program.The domestic independent research and development bus controller has many issues such as not open,secondary development interface is limited,can’t increase or decrease the controller function(such as force control function),can’t control multiple robots through a single controller.To deal with these problems,based on the "IPC + real-time operating system + real-time industrial Ethernet bus" bus control architecture,designing a set of open and highly scalable and versatile robotic controller by using open system architecture framework design,component model integration and other methods.The design of the controller is based on the existing trajectory results of the laboratory,the main study is not for trajectory algorithm,but for the openness,security,real-time and operability of the robot control system.Firstly,the industrial robot controller and its motion control system based on EtherCAT bus are designed and built,which provides the hardware basis for realizing the industrial robot movement function.And then follow the PLCopen specification and software design principles,in view of the industrial robot control system required functionality,developing parallel multi-task controller software system in consideration of the robot control system real-time situation.Finally,the arc welding function module is added on the robot controller to construct the arc welding robot control system.The subject eventually took the Estun ER16 universal six-joint robot as the motion control object,The experiments of the basic motion trajectory,JOG motion command,pause function,servo zero,error handling and other motion control functions and experiments of Multi-robot collaboration aiming at bilateral symmetrical welding function were carried out.The experimental results verified the system efficiency,high real-time,reliability and effectiveness of the algorithm and strategy,indicated that the design and related theory of the system control can achieve the industrial robot’s motor function,provided the possibility for the realization of high-speed high-precision control.Welding experiments was conducted in Shenzhen Huayi Long company.