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

Ho Chi Minh Bdi bao nay nghien ciiu thiet ke che tao thii nghiem va van hanh robot han cd khd nang tudong nhan dien moi han cong bat ky trong mat phang sii dung vi dieu khien vd phan tU

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

Bdi bao nay nghien ciiu thiet ke che tao thii nghiem va van hanh robot han cd khd nang tudong nhan dien moi han cong bat ky trong 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 ra moi hdn dong deu, khdng c6 khuyet tat De tdi da md ra mot hUdng di mdi cho viec dp dung robot han tU

dong trong 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

weld-ing robot application into the industry

Keywords: welding robot, automated welding, weld tracking

1 GlCfl THIEU trong cong doan nay dUoc tap trung nghien ciiu

manh me trong 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 trong 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 khi da dUOc de xuat

Tuy nhien, day la mot cong doan nang nhoc, doc Trong bai nghien ciiu nay 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 con ngUdi thii nghiem

TAP CHI CO KHI VIET NAM • S6 12 (Thang 12 nam 2011)

NGHIEN CUfU-TRA0D6l

2 CAU TRUC CUA ROBOT

Hinh 1 la thiet ke cO khi va md hinh thiic

te ciia robot han dUOc che tao thU nghiem, bao

gom cd cac thanh phan sau: module ray dan

hudng, than robot, module cam bien quet dudng

han va module trUOt gan dau han, man hinh hien

thi quy dao han, tu dieu khien va bang dieu khien

bang tay De bao dam do chinh xac va kha nang

tu khda khdng cho phep truyen dong ngUOc (kha

nang tii khda), cac chuyen dong tinh tien, chuyen

dong quet va ban sii dung bo truyen vit me - dai

6c bi Do chinh xac toi da cua hai chuyen dong

doc theo moi ban va phUOng ngang cua dau ban

lan lUOt la 0,2mm va 0,1mm [2]

robot thiic hien hai chuyen dong: chuyen dong doc theo dudng ban va chuyen dong quet toe do cao ciia chum tia laser theo phUOng ngang Dau

dd gan cam bien laser quet ngang qua dUdng ban

de xac dinh vi tri mep ciia dUdng ban (diem 2 va 4) theo nhu hinh 2a, 2b Vi robot vUa quet vUa

di chuyen thiic hien qua trinh ban nen doan 2-4 thiic te cd phUOng cheo trong mat phang, nen tam cua dudng ban dUOc xac dinh la trung diem ciia doan 2-4 (hinh 2c) PhUOng an quet nay cho phep tien hanh qua trinh ban theo hai che do: che do lay mau (sampling) qua trinh quet xac dinh quy dao ban rdi tien hanh ban, dUOc ap dung cho san xuat loat Idn cac san pham giong nhau); va che

do quet-han triic tiep (online scanning): la qua 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 do lay mau cdn cho phep chinh sita quy dao trong trUdng hop quy dao da xac dinh cd nhiing sai so bat thUdng trUdc khi qua trinh ban bat dau [1]

Huong quet ciia chum tia laser

H u o n g quet ctia chum tia laser

" ^

\r

Hinh 1: Thiet ke cd khi ciia robot han (tren)

vd mo hinh thUc te (dUdi)

3 N H A N D I E N M O I HAN

b)

c)

3.1 Phifofng phap nhan biet diicfng han

Hinh 2: Di chuyen ciia chum tia laser denhqn dien

De xac dinh quy dao toan bo dUdng han, mep hdn 2vd4 cg=

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 thanh mdi hi\n, diic biet la doi vdi

moi ban cd be rong h'tn Chuyen ddng nay 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 do (hinh 3), trong dd O

la dudng kinh ciia day ban hoac que ban

ban, nghia k\ cam bien se di chuyen trUdc dau han mot khoang A TrUdc khi tien hanh ban, dau do

va dau hi\n dUOc dUa ve vi tri Home (vi tri ban

dau) (x,,y,) li tpa do 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

^': + i - J

/^sina

Rcosa

)u\ Jai)

i ,'uii! nylic Y

(l>

Hinh 3: Chuyen dong trdn cua dau hdn tao ra quy dao

cong nghe

-0 (.V(), ya): diem

bat dau han

X

Hinh 4: Toa do vn van toe tai mdi diem

ciia quy dao hdn

Doi vdi chuyen ddng theo phUong Y

(theo phUOng han), dong cO bUdc Y se bii trU

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" do khoi ciia he thong dieu khien

mot luong Rcosa PhUOng an dao chieu dUOc

thiic hien bang vitme bi hai chieu (hinh 1) Trong

dd ddng CO quay theo mot chieu xac dinh trong

sudt qua trinh van hanh va viec dao chieu dUOc

thiic hien bang vit me bi cd 2 chieu trai - phai He

thong cho chuyen ddng em, chinh xac, it bi anh

hudng cua quan tinh, tuoi tho cao

So dd khdi ciia he thdng diau khiln dong

CO diroc chi ra d hinh 5

Magnetic ^ ^

sensors \

Power supply 5V

Optical sensors

VidlJukhiln i_

4 HE THONG DIEU KHIEN

4.1 Xac dinh van toe theo hai phiiong:

Xet he toa do trong hinh 4, trong 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

Input ^ I Controller 1

+ • ' '

PID Controller

-~"-o*-Mgch cdng suat H- Bridge

t

Power supply 24V

<

DC Motor X,Y ^

1

Hinh 5: Sa do khoi he thong dieu khien robot

m TAP CHI CO KHI VIET NAM • 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

control-ler [3] Cam bien quang la loai E3X-DA-S do

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 thanh module

PID dieu khien tdc do 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 do dat hoac den dung vi tri can thiet, ddng

thdi cung nhan tin hieu hoi tiep, tinh toan ra sai

lech va tU dd tao tin hieu hieu chinh LUu do dieu

khien dUOc trinh bay trong hinh 7

VBAT VBOOST

Hinh 6: Mach cong sudt H-Bridge [6]

5 H A N THtf NGHIEM VA DANH GIA KET QUA

5.1 Dieu kien thii nghiem:

Dieu kien han thU nghiem dUOc liet ke trong Bang 1 dUdi day

Bang 1: Dieu kien hdn thii nghiem

May han Chieu day thep tam Dien the han Dien ap Dirong kinli day han Van toe cap day Van toe han

M G M R A 2 5 0

2 mm

27 V

500 A 0.8 mm

2 m phut

1 ni phut

BATDAU

t'Au M \ 4 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

X i = > 3 * A X

Yi = Y i * A Y

1

Robot vd oSu hdn

di chiiyin VU

(XI; Yi)

1

i = i » 1

r ' 1 = N ^ sal

eung NgCing robot

K S T T H C I C

Hinh 7; LUu do gidi thuat dieu khien

c ^

NGHIEN CUfU-TRAOOOl

5.2 Ket qua han thii nghiem Bang 2: l^dnh gia khuyet tat moi hdn bang mat

Hinh 8 la ket qua ciia qiui trinh ban thii

nghiem Ket qua thuc nghiem dUo'c danii gia nhU

sau;

\'c do qui' dao ciui duotig hdn: robot di

chuyen deu, on dinh, \'an tdc trung binh theo

dudng ban do 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 trong Bang 2 Mot sd tieu

chi tren chUa dat muc tot nhat do chUa dUpc tdi

Uu bang each dieu chinh cac thdng sd qua trinh

han nhu dien ap, dien the han, tdc dd cap day

Tieu chuan

R6 kill be mat Chay chaii

Do ngau Nirt nong Nut dong dac Lech mep L6 ong

Qua loi

Mo ta khuyet tat

Co 1 16 be mat nhodtromg kinh 0.5mm

Khong phat hien Ngau klioang 2 3 chieu day tam Khong phat hien Khong phat hien Khong phat hien

Co 1 16 be mat

nho daiyng kinh

0.2mm Chieu day loi khoang O.Smm trong chieu dai 5-lOmm

Danh gia

A

0

A

0

0

0

A

A

(;'/)/ chii: O: Tot, A: Chap nhan dUdc

6 KET LUAN

« j ^

Hinh 8: Quy dao moi hdn dUdc xac dinh

tren mdn hinh & mdi hdn thUc te

De tai da hoan thanh dUgfc cac noi dung sau:

Thiet ke ca khi 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

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:

Nghien ciiu nhu cau thiic te cua moi ban

cd quy dao trong khdng gian ba chieu de robot c6 the ban theo mot dUdng cong bat ky trong khong gian

NGHIEN CUfU-TRAO 061

Hoan thien he thdng dieu khien va giao dUpc tien hanh bang mat Can ban thii nghiem d dien sao cho phu hop nhat vdi ngUdi cdng nhan nhieu dieu kien Idiac nhau va mau ban nen dUpc van hanh va nang cao hon dp chinh xac va dp danh gia theo nhieu tieu chuan khac nhau nhU do tin cay phu hop vdi dieu kien san xuat thiic te khuyet tat bang sieu am, do dp ben va dp dai va

Qua trinh danh gia trong bai nghien cUu nay 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)