复杂相贯线接缝自动焊接运动轨迹动态补偿方法

Dynamic compensation method for automatic welding of complex intersecting linear joints

  • 摘要: 复杂相贯线接缝因其自身的不规则性,在自动焊接过程中,焊枪需要频繁地进行加速、减速和变向运动,导致焊接控制系统在接收指令、处理数据和执行动作之间存在一定的滞后时间,焊枪无法立即达到期望的位置和速度,从而产生超调现象,影响最终的焊接效果。为此,提出复杂相贯线接缝自动焊接运动轨迹动态补偿方法。初步采集焊接枪视觉信息,利用Otus算法提取视频帧内的焊接枪末端的主体信息,并引入Mean-Shift算法将其二维位置信息投影至矢量空间,结合卡尔曼滤波算法,对焊接枪末端的运动状态信息展开估计,从而实现焊接运动轨迹的动态跟踪。基于轨迹跟踪结果与既定焊接轨迹之间的偏移量,构建主动扰动抑制控制器,以卡尔曼滤波器输出运动轨迹跟踪结果与实际复杂相贯线接缝之间的误差为输入,通过非线性因子的调整,对误差进行非线性补偿,减少焊接过程中的超调问题,实现焊接运动轨迹动态补偿。实验表明,所提方法轨迹跟踪效果精确,同时具备较高抗干扰能力,对保障焊接作业质量的保障具有重大意义。

     

    Abstract: Due to the irregularity of complex intersecting line seams, the welding gun needs to frequently accelerate, decelerate, and change direction during automatic welding, resulting in a certain lag time between receiving instructions, processing data, and executing actions in the welding control system. The welding gun cannot immediately reach the desired position and speed, leading to overshoot and affecting the final welding effect. Therefore, a dynamic compensation method for the motion trajectory of automatic welding of complex intersecting line seams is proposed. Preliminary collection of visual information of the welding gun, using Otus algorithm to extract the main body information of the welding gun end within the video frame, and introducing Mean Shift algorithm to project its two-dimensional position information into vector space. Combined with Kalman filtering algorithm, the motion state information of the welding gun end is estimated to achieve dynamic tracking of the welding motion trajectory. Based on the deviation between the trajectory tracking results and the established welding trajectory, an active disturbance suppression controller is constructed. The Kalman filter outputs the error between the motion trajectory tracking results and the actual complex intersection seam as input. By adjusting the nonlinear factor, the error is nonlinearly compensated to reduce overshoot during the welding process and achieve dynamic compensation of the welding motion trajectory. The experiment shows that the proposed method has accurate trajectory tracking effect and high anti-interference ability, which is of great significance for ensuring the quality of welding operations.

     

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