弧焊机器人工作站系统设计

弧焊机器人工作站系统设计摘要随着工业技术的提高，机器人被广泛应用于生产实践中，机器人与手工操作相比，有着明显的优势，广泛采用工业机器人不仅可提高产品的质量和产量，而且对保障人身安全，改善劳动环境，减轻劳动强度，提高劳动生产率，节约原材料消耗以及降低生产成本，有着十分重要的意义。

和计算机、网络技术一样，工业机器人的广泛应用日益改变人类的生产生活。

其中，焊接机器人是应用最为广泛的机器人，全球将近一半的工业机器人用于各种形式的焊接加工领域。

本论文以六自由度弧焊机器人为背景，详细介绍了机器人工作站的配置，硬件选型，PLC控制系统的设计、机器人配套设施的建设、仿真软件的应用及在实际环境中的调试。

论文首先总结了前人的工作，对焊接机器人工作站的发展现状和前景进行了展望。

总结了中外弧焊机器人的生产发展情况，对国内的弧焊机器人工作站的优缺点进行了分析。

然后结合工厂实际情况和生产要求，结合目前先进的机器人技术和解决方案，规划了本次机器人工作站的设计模块，对机器人工作站的配置和组成提出了合理创新的设计，采用简单高效的方法完成了工厂的应用要求。

工作站包括两台日本安川机器人公司的MOTOMAN NX100机器人，该机器人采用了6轴运动，能够在空间上做大自由度的运动，一台机器人安装了弧焊焊枪，进行弧焊作业，另一台机器人安装了夹持设备，进行辅助作业，两台机器人协调工作，共同完成作业任务。

本文对工作站的各个组成部分给出合适的规划，保证了机器人工作站的实用高效性，使用双机器人的协调工作及外部轴的控制实现高复杂度的焊接，能够适应不同的工作环境，使工作站拥有良好的柔性化拓展空间。

对工作站系统进行设计时采用了先进的3D模拟仿真技术，能够直观模拟机器人在实际工作环境下的运动状态，观察机器人I/O信号在运行中的应用情况，对现场环境下工作站的系统运行作出充分的模拟演示，保障了机器人工作站的稳定和高效，为机器人工作站的现场搭置提供了精确的数据支持。

通过仿真软件的应用，设计人员脱离了完全靠示教编程的模式，能够更加安全地对机器人的运动进行部署。

通过仿真，大量的隐藏问题得以发现，并在机器人工作站实际部署前得到解决。

仿真是工作站建设的一个重要环节，也是以后工作站技术发展的一个方向。

由于仿真中使用的机器人程序也可以植入实际的机器人中，可以用仿真软件来编制机器人的运行程序，通过仿真软件编写双机器人及外部轴的协调程序，结合机器人I/O 通讯，检验实际运行的可靠性和稳定性。

系统编程包括机器人控制柜内部PLC和专业的外部PLC编程。

工业PLC由于采用光电耦合的方式传递信号，具有很强的信号防干扰能力，非常适合复杂的工厂环境应用。

本文通过对机器人内部的PLC程序进行设计优化，使其更符合实际需求，增加了三色灯的信号反馈、外部操作盒的控制、报警处理等多项功能，通过机器人的PLC管理，已经基本能够实现工作站的正常运行。

为了便于管理和维护，系统还包括外部工业PLC，通过设计PLC程序，使工作站更加人性化。

外部PLC结合液晶触摸屏，可以设计出专用的人机交互界面，通过丰富的界面功能设计，可以满足不同使用人员的需求。

比如，管理人员可以通过其管理界面了解机器人的产量、效率等生产信息，而维修人员能通过故障显示界面快速定位故障信息，大大简化和方便了系统维护。

系统采用欧姆龙公司的CJ1MCPU13小型工业PLC，利用该PLC与机器人内部PLC保持通讯，获取机器人的实时状态信息并显示在触摸屏上。

机器人内部PLC作为主控制器，控制工作站实际运行。

总之，本文对弧焊机器人工作站系统设计，通过采用双机器人协调工作方式，结合仿真编程技术，合理配置工作站及编写系统控制程序，设计出的工作站系统具有兼容性好，柔性程度高，功能丰富可扩展等的优点。

关键词：弧焊机器人，仿真模拟，协调控制Design for Welding Robot Workstation SystemABSTRACTWith the improvement of industrial technology, robots are widely used in production practice, compare with the robot and hand operation, the robot has obvious advantages, the widespread use of industrial robots can not only improve product quality and yield, but also to protect the personal safety, improve the working environment, reduce labor intensity and improve labor productivity, savings in raw materials consumption and lower production costs, It is of great significance. As computer network technologies, the extensive use of industrial robots, is changing the life of mankind. Among the kinds of robot, the most widely used robot is welding robot, nearly half the world's industrial robots used in various forms of welding process in the field.This paper use the welding robot with six degrees of freedom as the background, detailing the configuration of the robot workstation, hardware selection, PLC control system design, the construction of supporting facilities robot, simulation software applications and debugging the program in a real environment.This paper firstly summarized previous works on the development of welding robot workstation status and predicted the prospect. Summarized the production of arc welding robot in foreign and analyzed the development of the domestic arc welding robot workstation in China. Then combined with practical situations and production requirements, combined with the current advanced robotics technology and solutions, planned the modules of this arc welding robot workstation, make a innovative design of the configuration and composition of the robot workstation, and get a simple and efficient method to complete the plant's application requirements.The robot uses two Yaskawa's MOTOMAN NX100 robot, the robot uses six axis motion, so it can get a large freedom of movement space, one robot has installed a arc robotic welding torch, when its operating time it works through the welding power source, another robot installed a clamping device, the clamping device can clamp the work piece to move the space, then the two robots start works together.The project of various devices on the robot using appropriate planning, to ensure the practical efficiency of the robot workstation, using the two robots and a external axes of control to achieve high complexity of the welding, it able to adapt to a wide range of working environment so that the workstation has a good use of flexible. The welding robot has an external axis, the external axis can assist the work of arc welding robot, which welding some of the more complex structure of the work piece.The paper using advanced 3D simulation technology to simulate robot motion state equivalent under the running track, we can also using this technology to watch over the robot's various ports whether it is connected, adequate simulation test of the workstation and on-site environment had ensured the stability and efficient of the robot workstation, it also had provided accurate data support to the construction of the robot workstation. After the simulations of the software, the operator not only test the workstation by teaching programming, it proves great safety to develop the workstation. Through simulation, a large number of hidden problems can be found, and have be resolved before the deployment of the robot workstation, if the problem only be found after the completing of the workstation, it is very hard to rebuilt the workstation and the control program. Therefore, the simulation is a integrant step of the construction of the workstation, but also the direction of future technological development workstation.As the program used in the simulation can also be implanted into a robot, and therefore we can use the simulation software to combine the running program of a robot without warring of the compatibility of the program. Using the running program, we can verify whether the workstation works well using the two robots and the external-axis. If there is anything wrong, we can get the point by monitoring the robot I/O communication in the simulation software. Then we can test the feasibility of the actual workstation.We have used the internal PLC of the robot control box and a outside professional Siemens PLC. The PLC using an Optocoupler way to transmit signals, so the PLC has a strong immunity of signal interference. The environment of the factory is too complex, there are plenty of dust and electromagnetic interference. We cannot use a normal computer device to monitor and manage the robot workstation in a factory, the appearance of PLC has solved the problem of dust and electromagnetic interference and therefore widely used in industry of various factories.We have updated the internal PLC program in the robot control panel, make it able to meet the need of practical conditions required, we have also added the support of the three-color light and support of external control, also provide the alarm system support, the workstation can work basically through the management of the robot's internal PLC management. In order to facilitate the management and maintenance of the arc welding robot workstations, we also get a professional industrial PLC of Siemens. After designed of the control program of this PLC we get the workstation more humanization, and can more easily to manage and maintain the robot workstation. The professional PLC has a LCD touch screen, then we can design the user interface exclusively by using the relevant software to design, then we may change the machine interface rich by an excellent design. Combine with the user interface and the management interface can make the PLC be greatly used. So that regardless of the operator or manager can operate through a single interface in the PLC. In the work time, the operator perform the start or stop command through the user interface, when it is time to manage the work, administrator can get the output data and the efficiency by using the management interface, when the robot have something wrong ,the operator can quickly locate faults through the PLC display panel. If the failure is relatively large, the administrator can also get the detail port information, so that the maintenance personnel can quickly get the point from the various information about failures. Greatly simplified and facilitated the management. PLC programmable controller can be used to increase the adaptability of the robot workstation. itprogram and the PLC control program, and then the workstation can start a new job.The PLC we used is a small dedicated PLC of the Siemens, it have 8 input and 8 output, using the PLC's input and output to communicate with the internal PLC in the control panel, the PLC obtain the robot’s state by the communication, also use this to control the robot by the button on the PLC panel like start and stop. Because the robot's internal PLC has a rich port, in which control most of the workstation peripherals. As there are two robots, one robot can get four inputs and four outputs.In short, the project of this arc welding robot workstation system is using a two-robot coordination in operations, combined with a variety of simulation programming software, get a well arrangement of the workstation peripherals, the workstation system has good compatibility, flexibility , feature-rich, scalable, and other advantages.Key words:robot workstation, emulation, coordinated control目录摘要 ------------------------------------------------------------------------ 1 ABSTRACT--------------------------------------------------------------------- 3 目录 ---------------------------------------------------------------------- 6 第一章绪论------------------------------------------------------------------ 11.1 焊接工业机器人的发展和应用------------------------------------------- 11.1.1 焊接工业机器人在国外的发展和应用------------------------------- 11.1.2 焊接工业机器人在国内的发展和应用------------------------------- 21.2 焊接机器人开发的意义及发展方向--------------------------------------- 31.3 论文组织结构--------------------------------------------------------- 4 第二章弧焊机器人工作站系统总体方案设计-------------------------------------- 52.1 工作站任务与配置----------------------------------------------------- 52.3 机器人基本结构与控制原理--------------------------------------------- 62.4 外围设备介绍-------------------------------------------------------- 102.5 通讯与I/O ---------------------------------------------------------- 11 第三章工作站系统的仿真与离线编程------------------------------------------- 133.1 仿真技术的发展综述-------------------------------------------------- 133.2 仿真模型及空间关系的建立-------------------------------------------- 143.3 工作站仿真程序的建立------------------------------------------------ 15 第四章 PLC控制系统及编程--------------------------------------------------- 194.1 PLC的发展及应用---------------------------------------------------- 194.1.1 PLC的产生及发展---------------------------------------------- 194.1.2 PLC的基本结构和工作原理-------------------------------------- 194.1.3 PLC的编程语言------------------------------------------------ 204.2 机器人内部I/O ------------------------------------------------------ 214.3 控制软件编程实现---------------------------------------------------- 214.3.1 控制内容------------------------------------------------------ 214.3.2 人机界面设计-------------------------------------------------- 214.3.3 基本控制功能实现---------------------------------------------- 23 第五章结论----------------------------------------------------------------- 24 参考文献-------------------------------------------------------------------- 25 谢辞 ----------------------------------------------------------------------- 26第一章绪论据不完全统计，全世界在役的工业机器人中大约有将近一半的工业机器人用于各种形式的焊接加工领域，焊接机器人应用中最普遍的主要有两种方式，即电阻点焊和电弧焊。