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First, about the welding machine
Since the reform and opening up, China’s national economy has undergone earth-shaking changes. The annual output of steel has reached 500 million tons, becoming the world's largest steel country. Welding is mainly based on steel. At the same time, the export volume of China's electric welding machines has been increasing in recent years, which has promoted the rapid development of China's electric welding machine industry. Looking back, China's electric welding machine industry has a history of more than 50 years. From the initial mechanical control to today's electronic control, the product structure has undergone fundamental changes. The arc welding method has been gradually changed from semi-automatic and automatic welding to manual arc welding, especially the gas-shielded welding method has made great progress. The welding work done by this method has reached more than 30% of the total welding. Since the 1970s, analog-controlled inverter welders have emerged and are rapidly being promoted.
Inverter welding machine has shown great vitality, because its working frequency is high, so the welding machine has the characteristics of small size, light weight, energy saving, material saving, power consumption and dynamic fast, high efficiency, good welder performance, etc. It is gradually becoming the mainstream of arc welding power supply. After years of development, the inverter welding machine has made great progress. With the maturity of the technology and the improvement of product reliability, the inverter welding machine is developing in the direction of large capacity, high efficiency and high performance. Along with this, there are some problems. For example, the high-end welder has a problem that the circuit design is too complicated, which reduces the reliability of the welder. Because of the use of the analog control circuit, the control precision of the welder is unstable and the welder performance is dispersed, which is difficult to guarantee. Consistent quality of mass-produced products, as well as network monitoring and management of welding production. In fact, the shortcomings of the analog control system are mainly limited in the ability to perform complex processing and the number of components, and the parameters of the controller are determined by the parameters of discrete components such as resistors and capacitors. The debugging of the controller is complicated and the flexibility is poor. At the same time, the parameter distribution of the resistors and capacitors affects the consistency and stability of the controller. Faced with the above problems of analog control inverter welding machine, the research and development of digital inverter welding machine was actively promoted, and the digital control instead of analog control is the scientific road for the development of electric welding machine.
Digital welding machine is a relatively independent system, which is different from digital TV, digital camera and other products. Digital TV must be compatible with digital signal networks, digital cameras must be compatible with computer interfaces, and its development has certain standard constraints, which makes the development of most digital products more standardized. However, as an industrial product, the external environment of the digital welding machine is diverse. Even if it is an automatic welding system with a welding robot or a positioner, the standard of the control network is very different. Therefore, digital welders are still difficult to address standard issues at this stage. However, the clarity of the digital welder concept is good for its future development. The so-called digital welding machine is based on the inverter welding machine, using 0/1 encoded digital signal instead of analog signal, applying digital signal processing and digital control technology, which is sophisticated, humanized, efficient, green and network Characteristics. That is to say, only after the digital control takes over the power control, process control and communication control of the welder, it is possible for the digital welder to better meet the needs of future welding production.
In short, the digital welding machine is a high-tech product, which is a comprehensive technical product integrating computer technology, power electronics technology and welding technology. Its core technology requires us to develop it ourselves to have its own intellectual property. What needs to be emphasized here is that after the hardware platform is established, the software is also a key issue. Only the software can be continuously updated to produce the “no-proof welding machineâ€. The level of software is mainly determined by the continuous improvement of process level and process theory and independent innovation.
From the success of digital welding machines abroad, we can see that foreign companies are looking for the entry point and the foothold of the problem from the production practice. Such as: high-speed welding for the needs of the container industry; CMT welding and ACMIG welding for different metal connection requirements; STT welding for spatter-free short-circuit transition welding and pipe bottoming welding; low heat input for long weld butt welding requirements And double wire MIG welding and the like which are produced by reducing deformation.
Based on these problems, foreign manufacturers have developed corresponding welding processes to form special software modules to produce new and characteristic digital inverter welding machines. This point is what we lack. We should make full use of the combination of production, study and research according to the needs of the market and the national conditions, and continuously promote the progress and development of the welding machine technology.
Second, on the welding robot
Since 1919, Mary Shelley created the world's first science fiction novel "Frankenstein" (also translated "Frankenstein"), the novelist has opened up an infinitely magical future for us. From 1927, Westinghouse engineer Wenzley created the first robotic telegraph box. Now, fantasy is becoming a reality step by step.
1. Countries around the world are accelerating robotics research
The developed countries in the world have invested a lot of money to step up research on robots. According to relevant information, South Korea has included intelligent robots in the 10 new growth Engines that determine the economic development of the country in the next decade. The United States regards robots as the focus of high-tech development. A large number of service robots have entered the military market. Japan has established a number of national and enterprise-supported robot research centers, investing a large amount of money for ongoing research. Robot development is also an important support object in the EU's Seventh Framework. It can be seen that in the era of globalization, all developed countries have placed the focus of economic development on high-value-added high-tech industries such as robots, and focused on the development of new industries with high profits, low energy consumption and light pollution.
In the 1990s, intelligent robots for special applications such as mine clearance were created. They have the ability to sense distances through sensors. Then, intelligent robots began to develop into service robots, which can sense speech and images, and even several languages. Production robots are an important part of the future manufacturing industry, and service robots are destined to have broader development potential. From a technical perspective, industrial robots are mostly “fixed†robots (such as welding robots on the production line) that perform repetitive tasks, while service robots are more “mobile†robots that expand to service. According to relevant experts, the robot industry is likely to grow to a larger scale. However, this breakthrough must be based on high-tech development, because mobile robots mostly work under unstructured conditions, that is, their working conditions are often not expected in the prior design. A typical example is Patient care, because of a sudden cough in the patient, can make the general-purpose robot unprepared and make a wrong response. Here, the robot needs to have a whole-body sensing capability. To this end, scientists are using high-tech achievements in micro-sensing to achieve full-surface sensing, such as the "Senskin" researched by American scientists, based on data processing technology, new material technology and micro-sensing technology. The so-called "sensitive skin" that covers the sensitive skin of the robot body will make all kinds of service-oriented intelligent robots truly possible.
Industrialized countries have done a lot of work in the development of humanoid robots, and Chinese universities have also made breakthroughs. The key technologies of robot degree of freedom configuration, classification of gait planning, stability criteria based on zero moment points, classification and application of sensors, and robot control systems are mainly studied. At present, the research of robots in the international scientific community is generally moving in two directions: one is to make the robots more intelligent and functional, and the other is to make the robots more human, that is, more human. The former is the focus in the industrial field.
2. The human-machine intelligence gap will disappear in 2050
Can the intelligence of a computer approach or even exceed human intelligence?
It may take less than 50 years, and the gap between human and computer intelligence will no longer exist. At the recent Intel Information Technology Summit, Intel Chief Technology Officer Justin made the above-mentioned bold predictions. Justin believes that by 2050, technology will bring machine intelligence closer to human intelligence. Currently, robots are mainly used to repeat a single task in a factory. And now the company that is guiding the technology trend is "training" the robot more personal and has the ability to "perceive". Justin demonstrated two prototypes of personal robots developed at Intel Research Labs. One of the robots demonstrates the electric field pre-contact that is placed on the robot's hand. This is a novel way of sensing that fish, not humans, so that the robot can "perceive" the object before it touches the object.
Another demonstration is a completely autonomous mobile-operated robot that uses advanced motion planning, manipulation, perception, and artificial intelligence to recognize faces, comprehend, and execute commands such as "please clean up these messy things." It can be said that from the birth of robots to the early 1980s, robotics experienced a long and slow development process. After the 1990s, with the rapid development of computer technology, microelectronics technology, network technology, cybernetics, and materials science and bionics, robotics technology has also developed rapidly and widely used. The manufacturing level, control accuracy, and reliability of the robot are constantly increasing, and the manufacturing cost and price of the robot are continuously decreasing. In developed countries, contrary to the decline in robot prices, there is a growing trend in human labor costs.
In the figure, the 1990 robot price index and the labor cost index are both used as reference values ​​of 100. By 2000, the labor cost index was 140, an increase of 40%; while the robot has a price index of less than 20 considering the quality factor. Reduced by 80%, the robot price index is about 40, a 60% reduction, regardless of quality factors. Therefore, the application of industrial robots has developed rapidly in developed countries. In Japan, robots became popular before 1980. By the beginning of 2001, more than 1 million industrial robots were installed in the world, of which welding robots accounted for more than 50%. Welding robots are becoming more and more widely used because welding robots have the following characteristics:
(1) Stabilize and improve the quality of welding to ensure its consistency;
(2) Improve labor productivity;
(3) Improve the working conditions of workers;
(4) easy to control product output;
(5) The price of stand-alone equipment continues to decline.
From the current research on welding robot technology at home and abroad, the main focus is on the following aspects:
★ Weld seam tracking technology research ★ Robot sensing technology ★ Robot control system ★ Robot manipulator optimization design ★ Welding power supply for welding robots ★ Research on welding process for robots ★ Research on all-position welding robots ★ Simulation technology research ★ Virtual robots Research ★ Research on coordinated control technology of multiple welding robots and peripheral equipment ★ Multi-agent control technology ★ Robot remote control and monitoring technology
Third, on the intelligentization of welding
1. Prospects for mechanical engineering
(1) From mechanical manufacturing that replaces manual labor to mechanical manufacturing that replaces mental labor (smart manufacturing)
(2) From macro manufacturing to micro manufacturing (micro-nano manufacturing)
(3) From non-ecological manufacturing to ecological manufacturing (green manufacturing)
(4) From inanimate manufacturing to life-making (biological manufacturing)
2. Intelligent manufacturing
Artificial Intelligence is a new technical science that studies and develops theories, methods, techniques, and applications for simulating, extending, and extending human intelligence. It attempts to understand the essence of intelligence and produce a new intelligent machine that responds in a manner similar to human intelligence. Research in this area includes robotics, speech recognition, image recognition, natural language processing, and expert systems. The term "artificial intelligence" was originally coined at the 1956 Dartmouth Conference in the United States. Since then, researchers have developed a number of theories and principles, and the concept of artificial intelligence has expanded. Artificial intelligence is a challenging science. In general, the purpose of artificial intelligence is to make this machine think like a human. In the 21st century, knowledge-based product design, manufacturing, and management will become an important part of the knowledge economy and one of the most important and fundamental features of manufacturing science and technology. It is in this context that intelligentization has been raised and received extensive attention from academia and industry. Intelligent Manufacturing (IM) was first proposed by the United States. It is characterized by the analysis, judgment, reasoning, conception and decision-making through the intelligence and simulation of the intelligent activities of human experts in all aspects of the manufacturing industry in a highly flexible and highly integrated manner, aiming to replace or extend the people in the manufacturing environment. Part of the mental work, and the collection, storage, improvement, sharing, inheritance and development of human experts' manufacturing intelligence. The purpose of intelligent manufacturing is to model the skills of manufacturing workers and human expert knowledge by integrating knowledge engineering, manufacturing software systems, robot vision and robot control technology, so that intelligent machines can be small batches without human intervention. produce.
The main research contents of intelligent manufacturing technology are as follows:
(1) Intelligent Manufacturing Theory and System Design Technology
The products are increasingly personalized and diversified, the product life cycle is shortened, and the update speed is accelerating. The manufacturing mode of the manufacturing enterprise has gradually changed from product-oriented production to customer-oriented production. The operating environment of the manufacturing system is increasingly full of uncertainty, making the traditional hierarchical manufacturing control system difficult. competent. therefore. The handling of complex, frequent changes and disturbances is a key issue that must be considered in today's manufacturing control systems. As a complex mega system, manufacturing control systems place higher demands on automation theory. In recent years, the preliminary research on the basic research of distributed artificial intelligence and its application research in manufacturing system control shows that. Distributed multi-agent systems have become a dynamic alternative to traditional hierarchical hierarchical control structures with their responsiveness and dynamic capabilities.
(2) Intelligent design theory, method and system
Using image analysis and processing and intelligent pattern recognition technology to realize the intelligent recognition of engineering drawings from raster image to vector image; using pattern recognition technology to realize intelligent three-dimensional modeling from the plane projection of parts to three-dimensional graphics; using fuzzy technology and neural network technology Conduct product reliability analysis, optimization design and comprehensive evaluation of design effects; intelligent CAD modeling, finite element analysis and virtual manufacturing based on expert system and neural network.
(3) Intelligent robots and intelligent machines
The third generation of intelligent robots not only has the perception function, but also has certain decision-making and planning capabilities. It can make decisions and plan actions according to people's orders or according to the environment, that is, programming according to tasks. At the same time, it has a sensory system composed of a variety of external sensors, and has its own knowledge base and multi-information processing system. With the continuous development of high-tech such as computer technology, fuzzy control technology, expert system technology, artificial neural network technology and intelligent engineering technology, the ability of industrial robots to learn knowledge and apply knowledge to solve problems will be further improved.
(4) Intelligent scheduling
In order to solve the increasingly complex scheduling problem, it is necessary to solve the structural problems of the scheduling system; the knowledge representation of the scheduling problem and the effective solution strategy; the scheduling knowledge acquisition problem and the effective scheduling optimization algorithm.
(5) Intelligent processing, intelligent detection and control
Using various computational intelligence techniques to identify the machining state (such as tool grinding/damage state) in real time, and adaptively control and decide on abnormal conditions. Realize intelligent detection, prediction and monitoring of processing status; self-learn, self-organize or adaptive control of cutting parameters under optimized (or constrained) targets to realize intelligent control and optimization of machining process; use intelligent industrial robot to realize product assembly and Packaging, material handling, surface coating, welding, high pressure water cutting, etc. In the online intelligent measurement of products: using the machine to simulate the human visual function, the CCD camera takes the detected image and converts it into a digital signal, and then uses advanced computer hardware and software technology to process the digital signal of the image to obtain the various required The feature value of the target image. And thus realizes various functions such as pattern recognition, coordinate calculation, gray scale distribution, etc., non-contact, fast, high-precision measurement of geometric parameters of the product such as dimensional accuracy, shape tolerance, surface roughness, etc., to achieve mass production process Online product measurement, sampling inspection, condition identification and quality control. At the end of the 1980s, China included "intelligent simulation" as the main topic of national science and technology development planning, and has achieved a number of achievements in expert systems, pattern recognition, and robotics. Since then, the Ministry of Science and Technology officially proposed "Industrial Intelligence Engineering." Intelligent manufacturing is an important part of the project. In 1993, the National Natural Science Foundation's key project “Research on the Foundation of Intelligent Manufacturing Technology†was approved. It was implemented in 1994 and was jointly undertaken by Huazhong University of Science and Technology, Nanjing University of Aeronautics and Astronautics, Xi'an Jiaotong University and Tsinghua University. The research content includes intelligent manufacturing basic theory, intelligent unit technology (intelligent design, intelligent process planning, intelligent manufacturing, intelligent numerical control technology, intelligent quality assurance, etc.), intelligent machines (smart robots, intelligent machining centers) and so on. In the new century, international cooperation has been carried out and has achieved gratifying research results. For example, China, Japan and South Korea have carried out joint research in the field of “intelligent robotsâ€.
In summary, we can see that:
Welding workers face the development of intelligent welding - we have a long way to go!
We are full of confidence in the future!