机器人焊接过程摄像机及手眼关系标定

建立了摄像机的成像模型,从成像原理角度说明摄像机标定方法,并考虑畸变因素对结果的影响,实现了焊接图像坐标与机器人坐标之间的相互转化。通过对旋转矩阵和平移向量的标定说明机器人手眼关系,了解机器人坐标与机器人位置之间的关系,并建立机器人坐标与机器人末端执行器之间的关系,从而完成从图像坐标到末端执行器坐标转化的整个过程。实验验证了该标定方法的准确性。     

工业机器人实训室的建设与研究

工业机器人广泛应用于包装码垛、焊接、喷涂、切割、打磨和搬运等,高校建立工业机器人实训室,培养应用型人才迫在眉睫。本文介绍了我校工业机器人实训室的布局方案、硬件基础、软件基础及所开设的实训内容。     

焊接烟尘的治理措施分析

焊接存在于现代工业的各个行业,随着现代工业的发展,焊接及相关工艺过程也在同步飞速发展,而相应产生的焊接烟尘等对人体健康有害的污染物质引起了公众的关注,根据目前中国焊接作业的环境现状和焊接工业技术水平,以及焊接过程产生的污染物的特征,对在环境影响评价中如何采取合理的焊接烟尘治理措施进行了分析,根据企业的实际情况,提出相应的治理措施.     

海洋环境钢结构焊接接头腐蚀与防护工艺研究进展

介绍了海洋腐蚀环境的特点,分析了钢结构焊接接头的腐蚀特性。在此基础上,总结了国内外学者关于焊接接头在海洋环境下的腐蚀机制和影响因素等研究成果,明确了焊接接头以电偶腐蚀、应力腐蚀和腐蚀疲劳为主导的电化学腐蚀行为。针对钢结构焊接接头的海洋腐蚀防护要求,总结了当前主要的腐蚀防护方案,如添加合金元素、焊接工艺优化、热处理、表面强化和防腐涂层等。最后,综合当前钢结构焊接接头海洋腐蚀与防护研究现状,提出了在海洋实际工况验证和防护手段不足等方面的问题。     

韩开发出可清除血栓的“血管机器人”

韩国研究人员日前开发出一种可在血管内自由移动并清除血栓的＂血管机器人＂。韩国全南大学日前发表公告说,该大学机器人研究所研制的这种机器人直径约1毫米、长5毫米。研究人员已在迷你猪的血管内成功对这种机器人进行了试验,并取得理想的效果。     

25t多功能惯性摩擦焊机

介绍了自行研制的25t惯性摩擦焊机的组成、功能和主要技术指标,该焊机具备轴向和径向功能,焊接线速度可达20m／s,在该焊机上焊接的高温镍基合金K418与高强钢42CrMo的惯性摩擦焊接头强度〉756MPa,合格率〉95％,铜与钢径向焊接接头抗剪强度〉200MPa。     

智慧加油机器人技术发展现状与展望

传统加油模式工作环境较差且存在风险,而智慧加油机器人无需人工操作,自动完成加油过程,可有效提升加油效率、减少劳动力需求,并规避人工操作风险、降低运营成本。介绍了国内外加油机器人的技术发展现状,对机械结构、安全防护、加注接口、识别定位4项关键技术进行分析归纳,并对未来发展方向进行了展望,即完善智慧加油机器人车型适配度。提出要定期对机器人加油站进行风险评估和安全检测。     

土工离心机多轴机器人系统设计综述

详细地介绍了土工离心机不停机状态下进行试验模拟的重要设备——离心机机器人系统。在总结国内外同类设备的基础上,重点针对近年来中国工程物理研究院总体工程所研制的土工离心机多轴机器人系统进行分析。对该类设备结构设计、电气控制系统设计的关键技术问题和难点进行了介绍。目前中国工程物理研究院总体工程研究所研制的土工离心机多轴机器人最大加载能力可以达到l扭矩±10 N·m,x,y,z方向加载力分别为±2 500,±2 500,±18 000 N,且具备循环加载能力。随着技术的发展,土工离心机机器人系统将在土工离心模型试验过程中发挥更加重要的作用。     

环保市场

新产品·新设备 FFY—Ⅱ系列光纤远距离液(水) 位显示报警仪 上海最新研制成的FFY—Ⅱ系列光纤远距离液(水)位显示报警仪是一种液(水)位监测装置。主要用于工业锅炉的水位指示与报警,也适用于其他中低压密封及开口容器的液位指示与报警。 华力光控焊接面罩 华力光控焊接面罩是现代光、电、新材料等高新技术的结晶。具有自动保护的遮光调节,在焊接的前后,都能清晰地看到焊缝、焊点和工件,在焊接起弧时,能瞬间变暗,而连续焊接时,其视觉效果与略微着色的太阳镜相似。且具有手动精细的调节器,能对不同的焊接电流和焊接材料进行控制,故可节能,操作也方便,可保护眼睛,避免各种职业病的发生。     

工作室模式下高职机电专业机器人制作及编程课程开发与实践

本文阐述了工作室模式下机器人制作与编程课程建设的意义,并分析了"工作室"模式下机器人课程探索与实践的具体方法。实践表明:工作室模式下机器人制作与编程课程充分体现了机电一体化技术专业的核心特色,极大地调动了学生的学习积极性。     

Research evolution on intelligentized technologies for arc welding process

This paper presents some new evolutions of research works in the IRWTL at SJTU on intelligentized technologies for arc welding dynamic process and robot systems, including multi-information sensing of arc welding process, such as characteristic extraction of weld pool image, voltage, current, and sound, arc-spectral features; multi-information fusion algorithms for prediction of weld penetration; intelligentized modeling of welding dynamic process; intelligent control methodology for welding dynamic process; intelligentized technologies for robotic welding, such as guiding and tracking seam technology and intelligent control of weld pool and penetration in robotic welding process; and development of autonomous welding robot system for the special environment. The ideas of intelligentized welding manufacturing technology (IWMT) and intelligentized welding manufacturing engineering (IWME) are presented in this paper for systematization of intending researches and applications on intelligentized technologies for modern welding manufacturing. The studies of intelligentized welding presented in this paper establish the foundation work of intending researches and applications on intelligentized technologies for modern welding manufacturing.     

Double-electrode arc welding process: Principle,variants, control and developments

Double-electrode gas metal arc welding (DE-GMAW) is a novel welding process in which a second electrode, non-consumable or consumable, is added to bypass part of the wire current. The bypass current reduces the heat input in non-consumable DE-GMAW or increases the deposition rate in consumable DE-GMAW. The fixed correlation of the heat input with the deposition in conventional GMAW and its variants is thus changed and becomes controllable. At the University of Kentucky, DE-GMAW has been tested/developed by adding a plasma arc welding torch, a GTAW (gas tungsten arc welding) torch, a pair of GTAW torches, and a GMAW torch. Steels and aluminum alloys are welded and the system is powered by one or multiple power supplies with appropriate control methods. The metal transfer has been studied at the University of Kentucky and Shandong University resulting in the desirable spray transfer be obtained with less than 100 A base current for 1.2 mm diameter steel wire. At Lanzhou University of Technology, pulsed DE-GMAW has been successfully developed to join aluminum/magnesium to steel. At the Adaptive Intelligent Systems LLC, DE-GMAW principle has been applied to the submerged arc welding (SAW) and the embedded control systems needed for industrial applications have been developed. The DE-SAW resulted in 1/3 reduction in heat input for a shipbuilding application and the weld penetration depth was successfully feedback controlled. In addition, the bypass concept is extended to the GTAW resulting in the arcing-wire GTAW which adds a second arc established between the tungsten and filler to the existing gas tungsten arc. The DE-GMAW is extended to double-electrode arc welding (DE-AW) where the main electrode may not necessarily to be consumable. Recently, the Beijing University of Technology systematically studied the metal transfer in the arcing-wire GTAW and found that the desired metal transfer modes may always be obtained from the given wire feed speed by adjusting the wire current and wire position/orientation appropriately. A variety of DE-AW processes are thus available to suit for different applications, using existing arc welding equipment.     

Modeling and simulation of arc: Laser and hybrid welding process

Welding is a fabrication process to join two different materials. Among the many welding processes, the arc and laser welding processes are the most widely used. Great effort is required to understand the physical phenomena of arc and laser welding due to the complex behaviors which include liquid phase, solid phase and, gas phase. So it is necessary to conduct numerical simulation to understand the detailed procedures of welding. This paper will present the various numerical simulation methods of the arc welding processes such as arc plasma, gas tungsten arc welding, gas metal arc welding, laser welding, and laser–arc hybrid welding. These simulations are conducted by the finite element method, finite differential method and volume of fluid method to describe and analyze the various welding processes.     

埋弧自动焊技术在阀门生产中的应用

针对高温高压电站阀门体 座连接焊的“深孔环缝”特点 ,采用埋弧自动焊接方法进行了材料选择和焊接工艺评定实验 ,选择了合适的焊材及工艺并成功地应用于生产。     

B610E不同焊接接头在石油沉积水中的耐蚀性研究

通过室内浸泡、应力腐蚀试验对B610E高强储罐铜所用不同焊接方式在石油沉积水中的耐蚀性进行研究。结果表明,B610E气体保护焊材料的耐蚀性最好,将Q235＋B610E埋弧平焊对接后,由于存在电偶对,耐蚀效果最差。在石油沉积水中,B610E埋横焊具有中等SCC抗力,B610E气体保护焊、B610E气电立焊以及B610E＋Q235埋弧平焊对接具有高的SCC抗力。     

Improvement of welding heat source models for TIG-MIG hybrid welding process

Tungsten inert gas-metal inert gas (TIG-MIG) hybrid welding process is an effective way to improve welding productivity and quality due to advantages of the two processes. Mathematical analysis is crucial to fundamentally understand this synergetic welding process. In this study, based on experimental visualization of arc behaviors, some assumptions are proposed to deduce adaptive plane and volumetric heat source models separately for each involved welding method first. The influence of torch angles on distribution of temperature and geometry of weld bead are calculated and compared with experimental results. It shows that this developed algorithm of heat source can be employed to accurately predict welding process whether the electrode gun is slanted backward or forward to the direction of welding. Then TIG-MIG hybrid welding process is simulated and analyzed without considering the attractive or repulsive force of two arcs. The characteristic of TIG-MIG welding process is discussed compared to single MIG. It lays the foundation for the further research on the interaction of the two arcs during TIG-MIG hybrid welding.     

Plasma arc welding: Process,sensing, control and modeling

This article introduces the basic principles of plasma arc welding (PAW) and provides a survey of the latest research and applications in the field. The PAW process is compared to gas tungsten arc welding, its process characteristics are listed, the classification is made, and two modes of operation in PAW, i.e., melt-in and keyhole, are explained. The keyhole mechanism and its influencing factors are introduced. The sensing and control methodologies of the PAW process are reviewed. The coupled behaviors of weld pool and keyhole, the heat transfer and fluid flow as well as three-dimensional modeling and simulation in PAW are discussed. Finally, a novel PAW process variant, the controlled pulse keyholing process and the corresponding experimental system are introduced.     

Resistance mash welding for joining of copper conductors for electric motors

The automotive industry is developing designs and manufacturing processes for a new generation of electric motors intended for use in hybrid and electric vehicles. This paper is focused on using solid-state welding to join rectangular wires in the fabrication of motor stators. Resistance welding has not typically been applied to copper due to its very high electrical conductivity; however through optimization of the current and pressure profiles, excellent quality copper-to-copper joints have been demonstrated with a technique known as resistance mash welding. A better understanding of resistance mash welding characteristics will help advancements in its application for stators. The limitations of this application will be discussed.     

Microstructure and mechanical properties of alloy C-276 weldments fabricated by continuous and pulsed current gas tungsten arc welding techniques

Effects of switching over from gas tungsten arc welding (GTAW) to pulsed current gas tungsten arc welding (PCGTAW) on the quality of joints produced in Hastelloy C-276 material were investigated. Welding was carried out both by autogenous mode and using ERNiCrMo-3 filler wire. Microstructures of weld joints produced with and without current pulsing were studied using optical and scanning electron microscopy. Microsegregation occurring in GTAW and PCGTAW joints was investigated using energy dispersive X-ray spectroscopy (EDS). Strength and ductility of weld joints produced with and without pulsing were evaluated. The results show that pulsing results in refined microstructure, reduced microsegregation and improved strength of weld joints. Secondary phase(s) noticed in GTA weldments were found to be absent in PCGTA weldments. Autogenous PCGTA weldments were found to be the best in terms of: (i) freedom from microsegregation, (ii) strength and (iii) freedom from unwanted secondary phases.     

Influence of displacement constraints in thermomechanical analysis of laser micro-spot welding process

The evolution of mechanical components into smaller size generating a need for microwelding of these components using laser which offers better control as compared to arc and plasma processing. The present article describes the numerical simulation of laser micro-spot welding using finite element method. A two dimensional Gaussian distributed surface heat flux as a function of time is used to perform a sequentially coupled thermal and mechanical analysis. The model is used for simulating laser micro-spot welding of stainless steel sheet under different power conditions and configurations of mechanical constraints. The temperature dependent physical properties of SS304 have been considered for the simulation and an isotropic strain hardening model has been used. The simulated weld bead dimensions have been compared with experimental results and temperature profiles have been calculated. The maximum deformation of 0.02 mm is obtained with maximum laser power of 75 W. The thermal stress is more inducing factor to temperature induced residual stresses and plastic strain as compared to mechanical constraints. The plastic strain changes significantly by displacement constraints as compared to residual stress.