焊接机器人在自动化生产线中的优势及应用

　　焊接机器人是机器人应用领域中使用范围最广的，焊接机器人作为一种先进的焊接设备大大的推动了自动化生产的发展。尤其是在焊接恶劣的工作环境中，焊接机器人能够代替人工，满足自动化生产的要求，提高产品品质，降低生产成本，提高生产效率等等，其在自动化生产线中的优势可以总结为以下几点：
　　Welding robots are the most widely used in the field of robot applications. As an advanced welding equipment, welding robots have greatly promoted the development of automated production. Especially in harsh welding environments, welding robots can replace manual labor, meet the requirements of automated production, improve product quality, reduce production costs, improve production efficiency, and so on. Their advantages in automated production lines can be summarized as follows:

　　1.稳定和提高焊接质量，保证其均一性。焊接参数如焊接电流、电压、焊接速度和干伸长量等对焊接结果有着决定作用。采用机器人焊接时，每条焊缝的焊接参数都是恒定的，焊缝质量受人为因素影响较小，降低了对工人操作技术的要求，因此焊接质量稳定。而人工焊接时，焊接速度、干伸长量等都是变化的，很难做到质量的均一性。
　　Stabilize and improve welding quality to ensure its uniformity. Welding parameters such as welding current, voltage, welding speed, and dry elongation have a decisive effect on the welding results. When using robot welding, the welding parameters of each weld are constant, and the weld quality is less affected by human factors, reducing the requirements for worker operation technology, so the welding quality is stable. During manual welding, the welding speed and dry elongation are variable, making it difficult to achieve quality uniformity.
　　2.改善了劳动条件。采用机器人焊接，工人只需要装卸工件，远离了焊接弧光、炯雾和飞溅等。对于点焊来说，工人无需搬运笨重的手工焊钳，使工人从高强度的体力劳动中解脱出来。
　　Improved working conditions. Using robot welding, workers only need to load and unload the workpiece, away from welding arc light, intense fog, and spatter. For spot welding, workers do not need to carry heavy manual welding tongs, freeing them from high intensity manual labor.
　　3.提高劳动生产率。机器人可24h连续生产。随着高速高效焊接技术的应用，采用机器人焊接，效率提高得更为明显。
　　Improve labor productivity. Robots can be continuously produced for 24 hours. With the application of high-speed and efficient welding technology, the efficiency of robot welding has been significantly improved.
　　4.产品周期明确，容易控制产品产量。机器人的生产节拍是同定的，因此安排生产计划非常明确。
　　Clear product cycle, easy to control product output. The production rhythm of the robot is fixed, so the production plan is very clear.
　　5.缩短产品改型换代的周期，减小相应的设备投资。可实现小批量产品的焊接自动化。机器人与专机的最大区别就是可以通过修改程序以适应不同工件的生产。
　　Shorten the cycle of product upgrading and reduce the corresponding equipment investment. It can realize welding automation of small batch products. The biggest difference between robots and specialized machines is that they can adapt their programs to different workpiece production.
　　在实际焊接过程中的环境和条件的变化是不可避免的，如焊接工件加工和装配误差造成接头位置、焊缝间隙和尺寸的分散性，示教轨迹与实际焊缝的差异、焊接过程中热变形、熔透及焊缝成形不稳定等因素都会引起焊接质量的波动，并导致焊接缺陷的产生。
　　Changes in the environment and conditions during the actual welding process are inevitable, such as the dispersion of joint positions, weld gaps, and dimensions caused by welding workpiece processing and assembly errors, the difference between the teaching trajectory and the actual weld, thermal deformation, penetration, and unstable weld formation during the welding process, which can cause fluctuations in welding quality and lead to welding defects.
　　为了克服焊接过程中各种不确定性因素对精密焊接质量的影响，需要采用信息反馈、智能控制等技术提高现行焊接机器人的适应性或智能化水平，使之能实现初始焊位识别与自主导引、实时焊缝纠偏与跟踪，焊接熔池动态特征信息获取、工艺参数自适应调节和焊缝成形的实时控制，即实现机器人焊接过程的自主智能控制，从而弥补焊接机器人在自动焊接方面的不足。
　　In order to overcome the impact of various uncertain factors on precision welding quality during the welding process, it is necessary to adopt technologies such as information feedback and intelligent control to improve the adaptability or intelligence level of current welding robots, so as to enable them to achieve initial welding position recognition and autonomous guidance, real-time weld deviation correction and tracking, acquisition of dynamic feature information of the welding pool, adaptive adjustment of process parameters, and real-time control of weld formation, That is, to achieve autonomous and intelligent control of the robot welding process, thereby making up for the shortcomings of welding robots in automatic welding.
　　针对铝合金在焊接过程中热积累作用强、恒参数焊接时容易产生各种缺陷的问题，设计了模糊专家控制系统。通过CCD获得熔池的图像以及相应的图像处理软件计算出熔宽的大小，然后该模糊控制器控制焊接热输入，专家系统负责脉冲参数匹配，从而维持熔宽不变，即保证了焊接质量的稳定性，适应于自动化的生产要求。
　　A fuzzy expert control system is designed to solve the problems of strong heat accumulation in the welding process of aluminum alloys and various defects easily generated during constant parameter welding. The image of the weld pool is obtained through CCD and the corresponding image processing software calculates the size of the weld width. Then, the fuzzy controller controls the welding heat input, and the expert system is responsible for pulse parameter matching to maintain the weld width unchanged, which ensures the stability of the welding quality and is suitable for automated production requirements.
　　在钢结构等现场施工中，结构件形状复杂，除常规的圆形、方形的工件外，还有间断不连续的、椭圆形的、外形渐变的工件以及厚壁、大型工件，要想最大限度解决现场的自动化焊接，充分发挥焊接机器人的现场施工利用率，提高焊接效率，可选用直导轨、圆导轨、柔性导轨实现各种复杂曲面的全位置焊接，可以适应不规则焊缝的轨迹跟踪，实现多层多道焊及全位置焊的自动化焊接。
　　In on-site construction such as steel structures, structural components have complex shapes. In addition to conventional circular and square workpieces, there are also discontinuous, elliptical, and tapered workpieces, as well as thick wall and large workpieces. To maximize the automation of on-site welding, fully utilize the on-site construction utilization of welding robots, and improve welding efficiency, straight rails, circular rails Flexible guide rails realize all position welding of various complex curved surfaces, which can adapt to track tracking of irregular welds, and realize automatic welding of multi-layer multi-pass welding and all position welding.