Thiết kế chế tạo robot hàn tự động nhận diện mối hàn

m^ mM ^ Thiet he ehe tao Robot han i\X dong nhan dien moi han DEVELOPMENT AND DESIGN OF AUTOMATED TRACKING WELDING ROBOT TS Le Chi Cildng, TS Dang Thi^n Ngdn TrUdng Dai hoc SU pham Ky thuat Tp Ho Chi Minh T6M TAT Bdi bao nghien ciiu thiet ke che tao thii nghiem va van hanh robot han cd khd nang tudong nhan dien moi han cong bat ky mat phang sii dung vi dieu khien vd phan tU dieu khien FID Ket qua qua trinh han thii nghiem cho thay: chuyen dong ciia robot xac dinh dung quy dao han vd cho moi hdn dong deu, khdng c6 khuyet tat De tdi da md mot hUdng di mdi cho viec dp dung robot han tU dong san xuat Tii khoa: robot hdn, hdn tU dong, nhan dien moi hdn ABSTACTS This paper presents a newly developed welding machine that can automatically detect the weld in a plane using micro processor and PID controller The experimental welding result shows that the robot has accrately detected the welding curve and the welding process gave good weld with minor defects, that can be improved by optimizing the welding parameters This result gives a wide range of automated welding robot application into the industry Keywords: welding robot, automated welding, weld tracking GlCfl THIEU cong doan dUoc tap trung nghien ciiu manh me thdi gian gan day Trong nghien Han la mot cong nghe quan trong, dUOc cijfu d giai doan trUdc [1], phuong an nhan dien Ung dung rong rai cac nganh cong nghiep moi han sCl dung cam bien laser hoac cam bien chu liic nhu ca khi, d to, dau khi, hang hai, quang cung vdi ket cau cO da dUOc de xuat Tuy nhien, day la mot cong doan nang nhoc, doc Trong bai nghien ciiu da tien hanh phat trien hai, dac biet la d nhUng nOi khd thao tac thi chat va hoan thien cac nguyen ly, co cau cd khi, he luong moi han phu thuoc rat Idn vao tay nghe thong dieu khien cho robot han; dong thdi van cua ngUdi han Do dd viec phat trien robot han hanh thil nghiem robot va danh gia ket qua han tu dong, thong minh cd the thay the ngUdi thii nghiem TAP CHI CO KHI VIET NAM • S6 12 (Thang 12 nam 2011) NGHIEN CUfU-TRA0D6l robot thiic hien hai chuyen dong: chuyen dong doc theo dudng ban va chuyen dong quet toe Hinh la thiet ke cO va md hinh thiic cao ciia chum tia laser theo phUOng ngang Dau te ciia robot han dUOc che tao thU nghiem, bao dd gan cam bien laser quet ngang qua dUdng ban gom cd cac phan sau: module ray dan de xac dinh vi tri mep ciia dUdng ban (diem va hudng, than robot, module cam bien quet dudng 4) theo nhu hinh 2a, 2b Vi robot vUa quet vUa han va module trUOt gan dau han, man hinh hien di chuyen thiic hien qua trinh ban nen doan 2-4 thi quy dao han, tu dieu khien va bang dieu khien thiic te cd phUOng cheo mat phang, nen tam bang tay De bao dam chinh xac va kha nang cua dudng ban dUOc xac dinh la trung diem ciia tu khda khdng cho phep truyen dong ngUOc (kha doan 2-4 (hinh 2c) PhUOng an quet cho phep nang tii khda), cac chuyen dong tinh tien, chuyen tien hanh qua trinh ban theo hai che do: che dong quet va ban sii dung bo truyen vit me - dai lay mau (sampling) qua trinh quet xac dinh quy 6c bi Do chinh xac toi da cua hai chuyen dong dao ban rdi tien hanh ban, dUOc ap dung cho san doc theo moi ban va phUOng ngang cua dau ban xuat loat Idn cac san pham giong nhau); va che quet-han triic tiep (online scanning): la qua lan lUOt la 0,2mm va 0,1mm [2] trinh quet va ban dUOc tien hanh dong thdi, dUOc ap dung cho san xuat dOn chiec, nhd le, quy dao ban thay doi lien tuc, hoac d nhUng nOi khuat, tay ngUdi khdng thao tac dUOc Che lay mau cdn cho phep chinh sita quy dao trUdng hop quy dao da xac dinh cd nhiing sai so bat thUdng trUdc qua trinh ban bat dau [1] CAU TRUC CUA ROBOT Huong quet ciia chum tia laser Huong quet ctia chum tia laser " ^ b) \r Hinh 1: Thiet ke cd ciia robot han (tren) vd mo hinh thUc te (dUdi) c) N H A N D I E N M O I HAN 3.1 Phifofng phap nhan biet diicfng han De xac dinh quy dao toan bo dUdng han, Hinh 2: Di chuyen ciia chum tia laser denhqn dien mep hdn 2vd4 cg= TAP CHI CO KHI VIET NAM • So 12 (Thang 12 nam 2011) NGHIEN ClifU - TRAO 061 3.2 Dao chieu chuyen dong doi vdi chuyen dqng cong nghe Trong qua tinh ban, dau hi\n cd chuyen dong lac dc tao mdi hi\n, diic biet la doi vdi moi ban cd be rong h'tn Chuyen ddng cd iho theo hinh sin, zig /ai;, rang cUa, bac thang, trdn, De tai chon chuyen ddng trdn bang each ket hop chu)on dong ciia hai dong cO bUdc vdi sU bii trU theo hai phuong loa (hinh 3), dd O la dudng kinh ciia day ban hoac que ban c i i n i i i 11101 ban, nghia k\ cam bien se di chuyen trUdc dau han mot khoang A TrUdc tien hanh ban, dau va dau hi\n dUOc dUa ve vi tri Home (vi tri ban dau) (x,,y,) li tpa cac trung diem thii i cua quy dao ban da nhan biet dUg^c Khi dau ban di tii vi tri (x^.y^) den vi tri (x,^|,y,^|), ta cd: V^j = V COS Qj va V,., = Vsinaj vai Oi = arctan / )u\ Jai) i ,'uii! nylic ^': + i - J Y (l> /^sina Rcosa -0 (.V(), ya): diem bat dau han Hinh 3: Chuyen dong trdn cua dau hdn tao quy dao cong nghe X Doi vdi chuyen ddng theo phUong Y Hinh 4: Toa van toe tai mdi diem (theo phUOng han), dong cO bUdc Y se bii trU ciia quy dao hdn vao chuyen ddng tien cua robot mot luong dich chuyen Rsina Doi vdi chuyen ddng theo phUOng X, ddng CO bUdc X se phai dao chieu chuyen ddng 4.2 So" khoi ciia he thong dieu khien mot luong Rcosa PhUOng an dao chieu dUOc thiic hien bang vitme bi hai chieu (hinh 1) Trong So dd khdi ciia he thdng diau khiln dong dd ddng CO quay theo mot chieu xac dinh CO diroc chi d hinh sudt qua trinh van hanh va viec dao chieu dUOc Power supply 5V thiic hien bang vit me bi cd chieu trai - phai He Magnetic ^ ^ sensors \ thong cho chuyen ddng em, chinh xac, it bi anh Optical VidlJukhiln i_ i LCD Display hudng cua quan tinh, tuoi tho cao sensors ATmegal28 ! Input ^ I Controller '' 4.1 Xac dinh van toe theo hai phiiong: PID Controller Xet he toa hinh 4, dd X la phuong quet cua chum anh sang, Y la phUOng chuyen dong cua robot (phUOng han), A la khoang each theo phUOng Y giUa cam bien va dau m TAP CHI CO KHI VIET NAM • +• -~"-o*Mgch cdng suat H- Bridge < DC Motor X,Y ^ Encoder HE THONG DIEU KHIEN t Power supply 24V Hinh 5: Sa khoi he thong dieu khien robot So 12 (Thang 12 nam 2011) NGHIEN CUfU - TRAO D0\ Mach chinh cd chUa vi dieu khien se nhan tin hieu tU cac cam bien va bang dieu khien bang tay de phat tin hieu dieu khien tdi PID controller [3] Cam bien quang la loai E3X-DA-S phan giai cao [4] Vi dieu khien dUOc sU dung la vi dieu khien ATMEL ATmegal28 [5] Ngdn ngU lap trinh dUOc sii dung la C++ tren he dieu hanh Window XP trd ve sau Dong cO DC Tanagawa Seiki TS-198-2N106E6 cd kem theo encoder cho hieu suat cao, kich thudc nhd gon nen quan tinh nhd va dap Ung van tdc tUc thdi Mach cdng suat H-Bridge MC3388 [6] cd chUc nang cung cap nguon ddng lUc cho ddng co Encoder se hoi tiep thdng tin vi tri va van tdc ve bo PID de dieu chinh Bo dieu khien PID, cung vdi mach cdng suat H Bridge (hinh 6) va DC motor tao module PID dieu khien tdc va vi tri cho ddng ca Ddng vai trd nhan thdng tin dieu khien, xU ly tinh toan, xuat tin hieu cho mach cdng suat dieu khien theo toe dat hoac den dung vi tri can thiet, ddng thdi cung nhan tin hieu hoi tiep, tinh toan sai lech va tU dd tao tin hieu hieu chinh LUu dieu khien dUOc trinh bay hinh H A N THtf NGHIEM VA DANH GIA KET QUA 5.1 Dieu kien thii nghiem: Dieu kien han thU nghiem dUOc liet ke Bang dUdi day VBAT VBOOST Bang 1: Dieu kien hdn thii nghiem MGMRA250 mm 27 V 500 A 0.8 mm m phut ni phut May han Chieu day thep tam Dien the han Dien ap Dirong kinli day han Van toe cap day Van toe han BATDAU t'Au M \ Homo Bdu hdn vi Homa Robot vS HOTTW i=1 Sai ^ ^ - t a v d6 tfni~ cn^m cSm t>i4n hSnh Irtnli I LuutoaagXi, Yi I Ngung hoed a$ng B6o\Si Bki d6 vd Hom« D i u hSn v6 Home Rabat v4 Hoitifl t Xi=>3*AX Yi = Y i * A Y Robot vd oSu hdn di chiiyin VU (XI; Yi) i = i» r' 1=N ^ sal eung NgCing robot KSTTHCIC Hinh 6: Mach cong sudt H-Bridge [6] TAP CHI CO KHI VIET NAM Hinh 7; LUu gidi thuat dieu khien • Sd 12 (Thang 12 nam 2011) c^ NGHIEN CUfU-TRAOOOl Bang 2: l^dnh gia khuyet tat moi hdn bang mat 5.2 Ket qua han thii nghiem Hinh la ket qua ciia qiui trinh ban thii nghiem Ket qua thuc nghiem dUo'c danii gia nhU sau; Tieu chuan Mo ta khuyet tat Co 16 be mat R6 kill be mat nhodtromg kinh 0.5mm Khong phat hien Chay chaii Ngau klioang Do ngau chieu day tam Khong phat hien Nirt nong Nut dong dac Khong phat hien Lech mep Khong phat hien Co 16 be mat nho daiyng kinh L6 ong 0.2mm Chieu day loi khoang O.Smm Qua loi chieu dai 5-lOmm \'c qui' dao ciui duotig hdn: robot di chuyen deu, on dinh, \'an tdc trung binh theo dudng ban dUOc la Im/phiit, cd the tang len don 3m/phut Dau ban thuc hien ban theo diing qui' dao cua dudng han da quet dupe Vc ciuU hwng nidi luin: qua kiem tra bang mat (\ isual testing), mdi han tuOng doi deu ('ac khuyet tat dupe liet ke Bang Mot sd tieu chi tren chUa dat muc tot nhat chUa dUpc tdi Uu bang each dieu chinh cac thdng sd qua trinh han nhu dien ap, dien the han, tdc dd cap day (;'/)/ chii: O: Tot, A: Chap nhan dUdc Danh gia A A 0 A A KET LUAN De tai da hoan dUgfc cac noi dung sau: Thiet ke ca va he thong dieu khien bao gom mach dieu khien va chUOng trinh dieu khien - Xay diing giai thuat nhan dang dUdng ban va dieu khien chuyen ddng cua dong cO sii dung cac phan tii PID « j Ket qua ban thii nghiem cho thay robot hoan toan cd kha nang nhan dien va han chinh xac theo quy dao ban xac dinh dUdc Chat luong moi ban dong deu va cd the dUOc toi Uu hoa mot each tii dong ^ Mot so hudng phat trien tiep theo cua de tai bao gom: Hinh 8: Quy dao moi hdn dUdc xac dinh tren mdn hinh & mdi hdn thUc te TAP CHI CO KHI VIET NAM • Nghien ciiu nhu cau thiic te cua moi ban cd quy dao khdng gian ba chieu de robot c6 the ban theo mot dUdng cong bat ky khong gian Sd 12 (Thang 12 nam 2011) NGHIEN CUfU-TRAO 061 Hoan thien he thdng dieu khien va giao dUpc tien hanh bang mat Can ban thii nghiem d dien cho phu hop nhat vdi ngUdi cdng nhan nhieu dieu kien Idiac va mau ban nen dUpc van hanh va nang cao hon dp chinh xac va dp danh gia theo nhieu tieu chuan khac nhU tin cay phu hop vdi dieu kien san xuat thiic te khuyet tat bang sieu am, dp ben va dp dai va Qua trinh danh gia bai nghien cUu chi dap, • Tai lieu tham khao: [1] Le Chi CUOng, Dang Thien Ngdn, Nghien cUu phat trien robot ban tU ddng nhan dien mdi ban Tap chi Khoa hpc Giao due Ky thuat, sd 22, 2011, DHSPKT TPHCM [2] NSK, Precision Machine Components: NSK Linear Guides, Ball Screw, Monocarriers, NSK Japan, 2003 [3] Farid Golnaraghi, Benjamin C Kuo, Automatic Control Systems, 9th edition, John Wiley & Sons, Inc., 2009 [4] Jon S Wilson, Sensor Technology Handbook, Newnes, 2005 [5] Le Trung Thang, Vi dieu khien AVR ATmegal28, DH Khoa Hpc Tii Nhien TP Ho Chi Minh, 2009 [6] CLB Khoa hpc tre Board mach cdng suat KHT - H Bridge DC Motor MC33883, DHSPKT Tp HCM,2011 TAP CHI CO KHI VIET NAM ••• Sd 12 (Thang 12 nam 2011) ... CUfU-TRA0D6l robot thiic hien hai chuyen dong: chuyen dong doc theo dudng ban va chuyen dong quet toe Hinh la thiet ke cO va md hinh thiic cao ciia chum tia laser theo phUOng ngang Dau te ciia robot. .. ray dan de xac dinh vi tri mep ciia dUdng ban (diem va hudng, than robot, module cam bien quet dudng 4) theo nhu hinh 2a, 2b Vi robot vUa quet vUa han va module trUOt gan dau han, man hinh hien... trUdc qua trinh ban bat dau [1] CAU TRUC CUA ROBOT Huong quet ciia chum tia laser Huong quet ctia chum tia laser " ^ b) \r Hinh 1: Thiet ke cd ciia robot han (tren) vd mo hinh thUc te (dUdi) c)