Design and modeling analysis of saddle seam welding robot
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摘要: 针对目前马鞍形焊缝焊接装备灵活性差，自动化程度低，接头质量稳定性不足等问题，开发了一种新型的管外锚固式四轴焊接机器人. 通过对机器人机构合理简化建立了D-H连杆坐标系，推导了机器人的正逆运动学表达式，并结合机器人关节变量的限位值确定了逆运动学解的唯一性. 通过MATLAB软件对机器人运动学进行了仿真，仿真结果表明，推导的正逆运动学方程模型完全正确. 通过制作样机进行焊接试验，结果表明，焊缝成形致密美观，机器人焊枪末端在x，y，z方向的误差均在±0.35 mm以内，完全满足工程上自动化焊接的需要，为马鞍形焊缝焊接机器人的连续轨迹控制和离线规划提供了依据和算法支持.Abstract: In view of the problems of poor flexibility, low degree of automation, and insufficient stability of joint quality of the current saddle-shaped weld welding equipment, a new type of external anchored four-axis welding robot was developed. The D-H link coordinate system is established by rationally simplifying the robot mechanism, the forward and inverse kinematics expressions of the robot are deduced, and the uniqueness of the inverse kinematics solution is determined by combining the limit values of the robot joint variables. The kinematics of the robot is simulated by MATLAB software, and the simulation results show that the derived forward and inverse kinematic equations are completely correct. Welding experiment by making a prototype, the experimental results show that the welding seam is compact and beautiful, and the deviation of the robot welding torch trajectory in the x, y and z directions is within ±0.35 mm, which fully meets the needs of automatic welding in engineering. It provides the theoretical basis and algorithm support for the continuous trajectory control and offline programming of the saddle-shaped seam welding robot.
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表 1 机器人各连杆D-H参数
Table 1 D-H parameters of robot links
连杆转角 ${\alpha _{i - 1} }/(^{\circ})$ 连杆长度 ${a_{i - 1}}/\rm mm$ 连杆偏距 ${d_i}/\rm mm$ 关节变量
θi /(°)0 0 0 ${\theta _1}$ 180 $r$ $ - {d_2}$ −90 90 $p$ $ - {d_3}$ −90 90 0 $q$ ${\theta _4}$ 
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表 2 TIG焊接工艺参数
Table 2 TIG welding parameters
焊接电流
I/A电弧电压
U/V送丝速度
vs/(mm·min−1)焊接速度
v/(mm/min−1)气体流量
Q/(L·min−1)220 38 800 130 15
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