管板自动焊接机器人设计

摘要

在化工、轻工、核能等设备中，管与管板的焊接接头不仅数量多，操作难度大，而且焊接质量要求高。目前上海某工厂管板焊接是手工操作的，生产效率低、工人劳动强度大、焊接质量不稳定。所以本文针对上述情况，设计出管板自动焊接机器人系统。本文所设计的管板自动焊接机器人，包括机械系统、视觉自动定位系统、PLC控制系统和基于触摸屏的人机交互界面。根据工件及焊接工艺要求，焊接基本参数通过触摸屏设定，采用触摸屏实现初始定位精度调试,确定视觉传感识别管孔中心并将位置信息传递给以PLC为控制核心的控制系统，引导焊接初始位置自动识别、焊接。实现了对管板焊接机器进行自动化改造，使原来人工定位，人工控制焊接进程的机械手变为由步进电机驱动，视觉定位和焊接过程自动化控制的一整套焊接设备。

关键词：管板焊接，视觉定位，触摸屏，PLC

Abstract

In chemical,light industry,nuclear industry and other equipment,as for the tube-plate welding,despite the large number of welding joints and the complicated operation process, high welding quality are required.There exsits tube-plate welding based on mannual work at a factory in Shanghai,of which the production efficiency is low,the worker labor intensity is heavy,the welding quality is unstable.This paper about design of tube-plate automatic robots, includes mechanical system,visual automatic positioning system,PLC,man-machine interface system based on the touch screen.According to Requirements of the workpiece and the welding technology,welding basic parametersare is set by the touch screen,which was adopted to realize the initial positioning adjustment,determine center of the visual sensing identify pipe hole and transfer the location information to control system of PLC as the control core;guiding automatic identifications of the initial position and welding.By the implement of automation renovation for the tube-plate welding,transform the original artificial positioning,artificial control of welding process into automatic drive by step motor, visual positioning and welding equipments on the basis of a complete automatic control pocesss.

Keyword:tube-plate welding,visual positioning,touch screen,PLC

目录

1绪论 (1)

1.1课题来源 (1)

1.2课题目的与意义 (1)

1.3管-板焊接应用现状与发展 (2)

1.4主要研究内容 (6)

2机械系统设计 (7)

2.1引言 (7)

2.2技术要求 (8)

2.3X方向传动系统的设计 (8)

2.4Y方向传动系统的设计 (16)

2.5旋转传动系统的设计 (23)

2.6焊机机头机械系统的设计 (32)

3视觉传感系统设计 (36)

3.1视觉传感系统的设计目标及功能特点 (36)

3.2系统工作原理 (36)

3.3视觉系统硬件组成 (37)

3.4视觉系统软件部分 (41)

4运动控制系统设计 (44)

4.1运动控制系统控制要求 (44)

4.2运动控制系统硬件设计 (44)

4.3运动控制系统软件设计 (53)

5人机交互界面设计 (68)

5.1引言 (68)

5.2控制面板设计 (68)

5.3基于触摸屏的人机界面设计 (69)

6管板焊接试验 (76)

6.1样机研制及其操作流程 (76)

6.2焊接试验过程 (78)

6.3模拟工件焊接试验效果 (79)

6.4焊接试验结论 (79)

7结论 (80)

7.1课题结论 (80)

7.2课题展望 (80)

参考文献 (81)

致谢 (83)