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研制了一种用于球罐全位置焊接机器人的智能控制系统。采用两点式视觉伺服反馈系统，以预先画出的坡口平行线为机器人的目标运动轨迹，实现机器人在多层多道焊接时的重复自动跟踪。系统选用工业控制级可编程控制器作为核心控制器件，外加自制的电机驱动等辅助电路，实现了对五自由度球罐焊接机器人的柔性磁轮的控制、跟踪机构的控制和摆动机构的控制，并使之协调联动，满足焊接过程的要求。此系统控制下的球罐焊接机器人的主要创新点是，实现了无导轨自动焊接全位置焊缝与多层多道焊接的自动跟踪。焊接工艺评定试验结果表明，此焊接机器人自动跟踪精度高，焊缝质量好，工作稳定可靠，已实现小批量试生产，产品也已用于实际焊接生产。
An intelligent control system for spherical tank full position welding robot was developed. Using two-point visual servo feedback system, the pre-drawn groove parallel line is the robot’s target motion trajectory, so that the robot can automatically and repeatedly track multi-layer multi-pass welding. The system uses industrial control level programmable logic controller as core control device, plus self-made motor drive and other auxiliary circuits to realize the control of the flexible magnetic wheel of the five-DOF spherical tank welding robot, the control of the tracking mechanism and the control of the swinging mechanism, And to coordinate the linkage to meet the welding process requirements. The main innovation of the spherical tank welding robot under the control of this system is to realize the automatic tracking of all-position welding without multi-track automatic welding and multi-layer multi-track welding. Welding process evaluation test results show that the welding robot automatic tracking high precision, weld quality, work stable and reliable, has achieved small batch pilot production, the product has also been used for the actual welding production.