外文翻譯---焊接機器人應用現(xiàn)狀

1、<p><b>　　附錄一 外文翻譯</b></p><p><b>　　英文原文</b></p><p>　　Weld robot application present condition</p><p>　　According to incomplete statistics, the world'

2、;s industrial robots in service in about nearly half of the industrial robots used in the field of all forms of welding process, welding robot applications, the most popular play, there are two main methods, spot welding

3、 and electric arc welding. We call the welding robot is actually a place in the field of welding production welder in the industrial robot welding task. Some of these welding robots designed as some kind of welding, and

4、in fact most of</p><p>　　It is well known that welding process requires skilled welders have skills, rich experience, stable welding level: it is a poor working conditions, smoke more, heat radiation large,

5、high-risk work. The emergence of industrial robots People naturally think first of people use it to replace manual welding, the welder to reduce the labor intensity, but also can ensure the welding quality and improve th

6、e welding efficiency.</p><p>　　However, welding and other industrial processes are different, such as arc welding process, welding parts by heating and melting and cooling due to local deformation, weld path

7、 will thus change. Hand experience of the welder when welding can be observed under the eyes of the actual location of timely adjustment of the weld torch position, posture and walking speed to adapt to changes in the we

8、ld path. However, the robot must adapt to this change, you must first like people to "see" the change, a</p><p>　　In fact, the industrial robot applications in the field of welding the first automo

9、bile assembly line from the resistance spot welding began. The reason is that the process of resistance spot welding is relatively simple, convenient control, and does not require seam tracking, the robot accuracy and re

10、peatability of control playing a relatively low demand. Spot welding robots in the automotive assembly line of a large number of applications greatly enhance the productivity of the automotive asse</p><p>　　

11、Robot birth from the early 80s of this century, robot technology has gone through a long slow process of development. In 90s, with computer technology, microelectronic technology, the rapid development of network technol

12、ogy, robotics technology has been rapid development. Industrial robot manufacturing level, control the speed and the accuracy, reliability was being improved all the time, while the robot manufacturing costs and prices h

13、ave been declining. In Western society, and the robot prices</p><p>　　It can be seen in Western countries, because labor costs for enterprises to bring considerable pressure, the robot has happened to reduce

14、 the price index for the further application brings opportunity. Reduce staff and increase the robot's equipment investment costs reach a certain balance between the two points when the interest is clearly using the

15、robot than the benefits brought about by a large artificial one hand, it can greatly improve the level of automation of production equipment to imp</p><p>　　As the robot control the speed and accuracy improv

16、ed, especially the development of arc sensor and has been applied in robot welding, arc weld robot trajectory tracking and control to some extent been solved, robotic welding Manufacturing in the automotive comparison fr

17、om the original spot a single vehicle assembly and auto parts will soon develop in the arc welding assembly process. robot arc welding is characterized by the greatest flexibility, you can change at any time by programmi

18、ng the tra</p><p>　　In addition, arc welding robot not only for the automotive industry, but also can be used for arc welding involved in other manufacturing industries such as shipbuilding, rolling stock, b

19、oilers, heavy machinery and so on. Therefore, the scope of application of arc welding robots becoming more widely in the number of great spot on the trend over the robot. </p><p>　　As the car lighter manufac

20、turing technologies, a number of high-strength alloys and light alloys (such as aluminum, magnesium alloy, etc.) in the automotive structural materials in the applications. Welding of these materials often can not solve

21、the traditional welding methods, must be introduction of new welding method and welding process. Including high-power laser welding and friction stir welding, and so the most development potential, therefore, robots and

22、high-power laser welding and frict</p><p>　　And robotic arc welding compared to laser welding seam tracking robot playing the sake of higher accuracy. Under the general requirements of robotic arc welding (i

23、ncluding GTAW and GMAW) weld seam tracking accuracy must be controlled at the electrode or wire diameter of 1 / 2 or less, with the filling yarn in the seam tracking accuracy under the conditions may be relaxed. However,

24、 in terms of laser welding, laser welding spot diameter at the surface is usually less than 0.6, far less than the wi</p><p>　　There is many forms of industrial robots’ structure, commonly used rectangular t

25、ype, cylindrical coordinate type, spherical coordinates, multi-joint coordinate type, telescopic, crawling, etc., depending on the use of welding robots are constantly evolving According to different applications can tak

26、e the form of a different structure, but the most used function is to mimic human multi-articulated arm robots, it is because multi-joint robot arm and maximum flexibility, you can make the gun spatia</p><p>

27、;　　In general, the robot has six joints can basically satisfy the gun position and attitude control of space requirements, of which three degrees of freedom (XYZ) used to control the spatial location of the end of the gu

28、n, the other three degrees of freedom (ABC ) used to control the torch space posture. Therefore, at present most of the welding robot 6 joint style. </p><p>　　For some welding situations, the work piece is t

29、oo large or the space where the shape of what is too complex, so that the welding robot welding gun can not reach the specified location or torch posture, then to 1-3 by adding external axis of ways to increase the robot

30、 degrees of freedom. There are two approaches: First, the robot can move the track installed in the car or gantry rack, and expand the operating space robot itself: the second is to move or rotate the workpiece, the weld

31、ing on the w</p><p>　　Welding robot programming method of teaching is still the online mode (Teach-in) based, but the programmer's interface has been improved a lot than in the past, particularly the ado

32、ption of the LCD graphics display for the new welding robot programming interface more friendly, more easily. However, when programming the robot weld path coordinate position on the key points must still be obtained thr

33、ough the teaching methods, and procedures for the movement into commands for a number of complex sh</p><p>　　First, teaching programming is a rough track to get some weld on a few key points, and then weldin

34、g robot vision sensor (usually the arc sensor or laser vision sensor) automatically track the actual weld path. Although this method still can not do without teaching programming, but to some extent, reduce the intensity

35、 of teaching programming to improve the efficiency of programming itself, but because of the characteristics of arc welding, robot vision sensor does not apply to all forms of welds.</p><p>　　Second, the app

36、roach taken completely off-line programming, the establishment of the robot welding procedures, weld trajectory coordinates of the location of access, and debugging were completed independently on a computer, without the

37、 participation of the robot itself. Robot off-line programming back in there years ago, but because the performance was limited by the computer, offline programming software, mainly in text mode, the robot programmer to

38、be familiar with all the playing and grammar </p><p>　　China's industrial robot from the 80's "Plan" science and technology research started, the current has basically mastered the robotic

39、machine design and manufacturing technology, the control system hardware and software design, kinematics and trajectory planning techniques, producing some of the machines were key components to develop a painting, weldi

40、ng, spot welding, assembly, handling and other robot: Arc welding robot has been used in automobile factory welding line. but, in general, China's</p><p>　　Current production is to be a robot playing the

41、 user's request, re-design single-family single, variety specifications, quantities of small, low degree of component commonality long lead times, cost is not low, and the quality, reliability instability. There is a

42、n urgent need to address the early industrialization of key technologies, the product of a comprehensive plan, do a good job series, universal, modular design, and actively promote the process of industrialization. </

43、p><p>　　Third, the development trend of welding robot </p><p>　　The international robotics communities are increasing research efforts, the generic technology of the robot. From the development tre

44、nd of robot technology, welding robots and other industrial robots, like to keep the intelligent and diverse direction. Specifically, performance in the following aspects: </p><p>　　1.) Structure of robot ma

45、nipulator </p><p>　　The finite element analysis, modal analysis and simulation design, the use of modern design methods to achieve optimal design of the robot operator. </p><p>　　Explore new hig

46、h-strength lightweight materials, further improve the load / weight ratio. For example, the representative of the German company KUKA Robotics, the robot has a parallelogram structure to a parallel open chain structure,

47、expanding the scope of work of the robot, together with the application of lightweight aluminum alloy materials, greatly improving the robot performance. In addition the use of advanced RV reducer and AC servo motor, the

48、 robot manipulator systems almost maintenance</p><p>　　Institution is developing to the modular and reconfigurable. For example, the joint module servo motor, reducer, Trinity detection system: the joint mod

49、ule, link module robot machine constructed with recombinant methods: modular assembly robot products abroad have asked the City. </p><p>　　The robot's structure is more agile, more and more small control

50、 systems, integration is moving in the direction of the two </p><p>　　With parallel mechanism, the use of robotics, high precision measurement and processing, which is CNC robotics technology to develop for

51、the future integration of robot and CNC technology laid the foundation. COMAU Italy, Japan FANUC and other companies have developed such products. </p><p><b>　　譯文</b></p><p><b>

52、;　　焊接機器人應用現(xiàn)狀</b></p><p>　　據(jù)不完全統(tǒng)計，全世界在役的工業(yè)機器人中大約有將近一半的工業(yè)機器人用于各種形式的焊接加工領域，焊接機器人應用中最普遍的主耍有兩種方式，即點焊和電弧焊.我們所說的焊接機器人其實就是在焊接生產(chǎn)領域代替焊工從事焊接任務的工業(yè)機器人.這些焊接機器人中有的是為某種焊接方式專門設計的，而大多數(shù)的焊接機器人其實就是通用的工業(yè)機器人裝上某種焊接工具而構成的。在多任務

53、環(huán)境中，一臺機器人甚至可以完成包括焊接在內的抓物、搬運、安裝、焊接、卸料等多種任務，機器人可以根據(jù)程序耍求和任務性質，自動更換機器人手腕上的工具，完成相應的任務.因此，從某種意義上來說，工業(yè)機器人的發(fā)展歷史就是焊接機器人的發(fā)展歷史。</p><p>　　眾所周知，焊接加工要求焊工要有熟練的操作技能、豐富的實踐經(jīng)驗、穩(wěn)定的焊接水平:它還是一種勞動條件差、煙塵多、熱輻射大、危險性高的工作.工業(yè)機器人的出現(xiàn)使人們自然而

54、然首先想到用它代替人的手工焊接，減輕焊工的勞動強度，同時也可以保證焊接質量和提高焊接效率。</p><p>　　然而，焊接又與其它工業(yè)加工過程不一樣，比如，電弧焊過程中，被焊工件由于局部加熱熔化和冷卻產(chǎn)生變形，焊縫的軌跡會因此而發(fā)生變化。手工焊時有經(jīng)驗的焊工可以根據(jù)眼睛所觀察到的實際焊縫位置適時地調整焊槍的位置、姿態(tài)和行走的速度，以適應焊縫軌跡的變化。然而機器人要適應這種變化，必須首先像人一樣要“看”到這種變化，

55、然后采取相應的措施調整焊槍的位置和狀態(tài)，實現(xiàn)對焊縫的實時跟蹤。由于電弧焊接過程中有強烈弧光、電弧噪音、煙塵、熔滴過渡不穩(wěn)定引起的焊絲短路、大電流強磁場等復雜的環(huán)境因素的存在，機器人耍檢測和識別焊縫所需耍的信號特征的提取并不像工業(yè)制造中其它加工過程的檢測那么容易，因此，焊接機器人的應用并不是一開始就用于電弧焊過程的.</p><p>　　實際上，工業(yè)機器人在焊接領域的應用最早是從汽車裝配生產(chǎn)線上的電阻點焊開始的.原

56、因在于電阻點焊的過程相對比較簡單，控制方便，且不需要焊縫軌跡跟蹤，對機器人的精度和重復精度的控制耍求比較低。點焊機器人在汽車裝配生產(chǎn)線上的大量應用大大提高了汽車裝配焊接的生產(chǎn)率和焊接質量，同時又具有柔性焊接的特點，即只耍改變程序，就可在同一條生產(chǎn)線上對不同的車型進行裝配焊接。</p><p>　　從機器人誕生到本世紀80年代初，機器人技術經(jīng)歷了一個長期緩慢的發(fā)展過程.到了90年代，隨著計算機技術、微電子技術、網(wǎng)絡

57、技術等的快速發(fā)展，機器人技術也得到了飛速發(fā)展.工業(yè)機器人的制造水平、控制速度和控制精度、可靠性等不斷提高，而機器人的制造成本和價格卻不斷下降。在西方社會，和機器人價格相反的是，人的勞動力成本有不斷增長的趨勢。聯(lián)合國歐洲經(jīng)濟委員會(UNECE)統(tǒng)計從1990年至2000年的機器人價格指數(shù)和勞動力成本指數(shù)的變化曲線其中把1990年的機器人價格指數(shù)和勞動力成本指數(shù)都作為參考值100，至2000年，勞動力成本指數(shù)為140，增長了40%;而機器人

58、在考慮質量因素的情況下價格指數(shù)低于20，降低了80%，在不考慮質量因素的情況下，機器人的價格指數(shù)約為40，降低了60%。這里，不考慮質量因素的機器人價格是指現(xiàn)在的機器人實際價格與過去相比較:而考慮質量因素是指由于機器人制造工藝技術水平的提高，機器人的制造質量和性能即使在同等價格的條件下也耍比以前高，因此，如果按過去的機器人同等質量和性能考慮，機器人的價格指數(shù)應該更低.</p><p>　　由此可以看出，在西方國家

59、，由于勞動力成本的提高為企業(yè)帶來了不小的壓力，而機器人價格指數(shù)的降低又恰巧為其進一步推廣應用帶來了契機。減少員工與增加機器人的設備投資，在兩者費用達到某一平衡點的時候，采用機器人的利顯然要比采用人工所帶來的利大，它一方面可大大提高生產(chǎn)設備的自動化水平，從而提高勞動生產(chǎn)率，同時又可提升企業(yè)的產(chǎn)品質量，提高企業(yè)的整體競爭力。雖然機器人一次性投資比較大，但它的日常維護和消耗相對于它的產(chǎn)出遠比完成同樣任務所消耗的人工費用小因此，從長遠看，產(chǎn)品的

60、生產(chǎn)成本還會大大降低。而機器人價格的降低使一些中小企業(yè)投資購買機器人變得輕而易舉.因此，工業(yè)機器人的應用在各行各業(yè)得到飛速發(fā)展。根據(jù)UNECE的統(tǒng)計，2001年全世界有75萬臺工業(yè)機器人用于工業(yè)制造領域，其中38.9萬在日本、19.8萬在歐盟、9萬在北美，7. 3萬在其余國家.至2004年底全世界在役的工業(yè)機器人至少有約100萬。</p><p>　　由于機器人控制速度和精度的提高，尤其是電弧傳感器的開

61、發(fā)并在機器人焊接中得到應用，使機器人電弧焊的焊縫軌跡跟蹤和控制問題在一定程度上得到很好解決，機器人焊接在汽車制造中的應用從原來比較單一的汽車裝配點焊很快發(fā)展為汽車零部件和裝配過程中的電弧焊.機器人電弧焊的最大的特點是柔性，即可通過編程隨時改變焊接軌跡和焊接順序，因此最適用于被焊工件品種變化大、焊縫短而多、形狀復雜的產(chǎn)品.這正好又符合汽車制造的特點.尤其是現(xiàn)代社會汽車款式的更新速度非常快，采用機器人裝備的汽車生產(chǎn)線能夠很好地適應這種變化。

62、</p><p>　　另外，機器人電弧焊不僅用于汽車制造業(yè)，更可以用于涉及電弧焊的其它制造業(yè)如造船、機車車輛、鍋爐、重型機械等等.因此，機器人電弧焊的應用范圍日趨廣泛在數(shù)量上大有超過機器人點焊之勢.</p><p>　　隨著汽車輕量化制造技術的推廣，一些高強合金材料和輕合金材料(如鋁合金、鎂合金等)在汽車結構材料中得到應用.這些材料的焊接往往無法用傳統(tǒng)的焊接方法來解決，必須采用新的焊接方法

63、和焊接工藝。其中高功率激光焊和攪拌摩擦焊等最具發(fā)展?jié)摿σ虼?，機器人與高功率激光焊和攪拌摩擦焊的結合將成為必然趨勢.事實上，像上海大眾等國內最具實力的汽車制造商在他們的新車型制造過程中已經(jīng)大量使用機器人激光焊接。</p><p>　　和機器人電弧焊相比，機器人激光焊的焊縫跟蹤精度耍求更高。根據(jù)一般的要求機器人電弧焊(包括GTAW和GMAW)的焊縫跟蹤精度必須控制在電極或焊絲直徑的1/2以內，在具有填充絲的條件下焊縫

64、跟蹤精度可適當放寬。但對激光焊而言，焊接時激光照射在工件表面的光斑直徑通常在0.6以內，遠小于焊絲直徑(通常大于1.0)，而激光焊接時通常又不加填充焊絲，因此，激光焊接中若光斑位置稍有偏差，便會造成偏焊、漏焊因此，上海大眾的汽車車頂機器人激光焊除了在工裝夾具上采取措施防止焊接變形外，還在機器人激光焊槍前方安裝了德國SCOUT公司的高精度激光傳感器用于焊縫軌跡的跟蹤。</p><p>　　工業(yè)機器人的結構形式很多，

65、常用的有直角坐標式、柱面坐標式、球面坐標式、多關節(jié)坐標式、伸縮式、爬行式等等，根據(jù)不同的用途還在不斷發(fā)展之中焊接機器人根據(jù)不同的應用場合可采取不同的結構形式，但目前用得最多的是模仿人的手臂功能的多關節(jié)式的機器人，這是因為多關節(jié)式機器人的手臂靈活性最大，可以使焊槍的空間位置和姿態(tài)調至任意狀態(tài)，以滿足焊接需要。理論上講，機器人的關節(jié)愈多，自由度也愈多，關節(jié)冗余度愈大，靈活性愈好:但同時也給機器人逆運動學的坐標變換和各關節(jié)位置的控制帶來復雜性

66、.因為焊接過程中往往需耍把以空間直角坐標表示的工件上的焊縫位置轉換為焊槍端部的空間位置和姿態(tài)，再通過機器人逆運動學計算轉換為對機器人每個關節(jié)角度位置的控制，而這一變換過程的解往往不是唯一的，冗余度愈大，解愈多。如何選取最合適的解對機器人焊接過程中運動的平穩(wěn)性很重耍。不同的機器人控制系統(tǒng)對這一問題的處理方式不盡相同。</p><p>　　一般來講，具有6個關節(jié)的機器人基本上能滿足焊槍的位置和空間姿態(tài)的控制要求，其中

67、3個自由度(XYZ)用于控制焊槍端部的空間位置，另外3個自由度(ABC)用于控制焊槍的空間姿態(tài)。因此，目前的焊接機器人多數(shù)為6關節(jié)式的.</p><p>　　對于有些焊接場合，工件由于過大或空間凡何形狀過于復雜，使焊接機器人的焊槍無法到達指定的焊縫位置或焊槍姿態(tài)，這時必須通過增加1-3個外部軸的辦法增加機器人的自由度。通常有兩種做法:一是把機器人裝于可以移動的軌道小車或龍門架上，擴大機器人本身的作業(yè)空間:二是讓工

68、件移動或轉動，使工件上的焊接部位進入機器人的作業(yè)空間。也有的同采用上述兩種辦法，讓工件的焊接部位和機器人都處于最佳焊接位置。</p><p>　　焊接機器人的編程方法目前還是以在線示教方式(Teach-in)為主，但編程器的界面比過去有了不少改進，尤其是液晶圖形顯示屏的采用使新的焊接機器人的編程界面更趨友好、操作更加易。然而機器人編程時焊縫軌跡上的關鍵點坐標位置仍必須通過示教方式獲取，然后存入程序的運動指令中這對

69、于一些復雜形狀的焊縫軌跡來說，必須花費大量的時間示教，從而降低了機器人的使用效率，也增加了編程人員的勞動強度。目前解決的方法有2種:</p><p>　　一是示教編程時只是粗略獲取幾個焊縫軌跡上的幾個關鍵點，然后通過焊接機器人的視覺傳感器(通常是電弧傳感器或激光視覺傳感器)自動跟蹤實際的焊縫軌跡。這種方式雖然仍離不開示教編程，但在一定程度上可以減輕示教編程的強度，提高編程效率但由于電弧焊本身的特點，機器人的視覺傳

70、感器并不是對所有焊縫形式都適用</p><p>　　二是采取完全離線編程的辦法，使機器人焊接程序的編制、焊縫軌跡坐標位置的獲取、以及程序的調試均在一臺計算機上獨立完成，不需要機器人本身的參與。機器人離線編程早在多年以前就有，只是由于當時受計算機性能的限制，離線編程軟件以文本方式為主，編程員需耍熟悉機器人的所有指令系統(tǒng)和語法，還耍知道如何確定焊縫軌跡的空間位置坐標，因此，編程工作并不輕松省時。隨著計算機性能的提高和

71、計算機三維圖形技術的發(fā)展，如今的機器人離線編程系統(tǒng)多數(shù)可在三維圖形環(huán)境下運行，編程界面友好、方便，而且，獲取焊縫軌跡的坐標位置通?？梢圆捎谩疤摂M示教”(virtual Teach-in)的辦法，用鼠標輕松點擊維虛擬環(huán)境中工件的焊接部位即可獲得該點的空間坐標:在有些系統(tǒng)中，可通過CAD圖形文件中事先定義的焊縫位置直接生成焊縫軌跡，然后自動生成機器人程序并下載到機器人控制系統(tǒng).從而大大提高了機器人的編程效率，也減輕了編程員的勞動強

72、度。目前，國際市場上已有基于普通PC機的商用機器人離線編程軟件.如Workspaces, RobotStudio等。圖9所示為筆者自行開發(fā)的基于PC的三維可視化機器人離線編程系統(tǒng)。該系統(tǒng)可針對ABB公司的工</p><p>　　我國的工業(yè)機器人從80年代“七五”科技攻關開始起步，目前己基本掌握了機器人操作機的設計制造技術、控制系統(tǒng)硬件和軟件設計技術、運動學和軌跡規(guī)劃技術，生產(chǎn)了部分機器人關鍵元器件，開發(fā)出噴漆、弧

73、焊、點焊、裝配、搬運等機器人:弧焊機器人已應用在汽車制造廠的焊裝線上.但總的來看，我國的工業(yè)機器人技術及其工程應用的水平和國外比還有一定的距離，如:可靠性低于國外產(chǎn)品:機器人應用工程起步較晚，應用領域窄，生產(chǎn)線系統(tǒng)技術與國外比有差距:應用規(guī)模小，沒有形成機器人產(chǎn)業(yè)。</p><p>　　當前我國的機器人生產(chǎn)都是應用戶的耍求，單戶單次重新設計，品種規(guī)格多、批量小、零部件通用化程度低、供貨周期長、成本也不低，而且質量

74、、可靠性不穩(wěn)定。因此迫切需要解決產(chǎn)業(yè)化前期的關鍵技術，對產(chǎn)品進行全面規(guī)劃，搞好系列化、通用化、模塊化設計，積極推進產(chǎn)業(yè)化進程。</p><p>　　三,焊接機器人發(fā)展趨勢</p><p>　　目前國際機器人界都在加大科研力度，進行機器人共性技術的研究.從機器人技術發(fā)展趨勢看，焊接機器人和其它工業(yè)機器人一樣，不斷向智能化和多樣化方向發(fā)展。具體而言，表現(xiàn)在如下幾個方面:</p>

75、<p>　　1).機器人操作機結構</p><p>　　通過有限元分析、模態(tài)分析及仿真設計等現(xiàn)代設計方法的運用，實現(xiàn)機器人操作機構的優(yōu)化設計。</p><p>　　探索新的高強度輕質材料，進一步提高負載/自重比。例如，以德國KUKA公司為代表的機器人公司，已將機器人并聯(lián)平行四邊形結構改為開鏈結構，拓展了機器人的工作范圍，加之輕質鋁合金材料的應用，大大提高了機器人的性能。此外采用先

76、進的RV減速器及交流伺服電機，使機器人操作機幾乎成為免維護系統(tǒng)</p><p>　　機構向著模塊化、可重構方向發(fā)展。例如，關節(jié)模塊中的伺服電機、減速機、檢測系統(tǒng)三位一體化:由關節(jié)模塊、連桿模塊用重組方式構造機器人整機:國外已有模塊化裝配機器人產(chǎn)品問市。</p><p>　　機器人的結構更加靈巧，控制系統(tǒng)愈來愈小，二者正朝著一體化方向發(fā)展</p><p>　　采用并聯(lián)