Merilni sistem za kompenzacijo deformacije pločevine pri robotskem varjenju

magistrsko delo

Gregor Levak (Author), Janez Podobnik (Mentor), Aleš Zore (Co-mentor)

Abstract

V industriji se pogosto pojavlja problematika doseganja hitrih in kvalitetnih meritev, ki predstavljajo povratne informacije o kvaliteti izdelka. Pri zelo kompleksnih izdelkih, kjer se zahtevajo ozka tolerančna območja zaradi ustrezne montabilnosti, je zelo pomembna zanesljivost pridobljenih meritev. Geometrijske lastnosti takšnih končnih izdelkov, kjer je pri sestavljanju prisotno varjenje, je odvisna tudi od deformacije materiala pri termični obdelavi spajanja manjših kosov. Oblika zvarjenih kosov je zato na končnem izdelku drugačne oblike, kot jo imajo nezvarjeni kosi, kar lahko predstavlja težavo pri montaži. S pomočjo skenirne naprave smo zato zgradili in ustvarili merilni sistem takšnega kompleksnega izdelka, kot je nosilec kolesa, kjer smo v okviru magistrske naloge analizirali kvaliteto pridobljenih meritev. Merilni sistem je sestavljen iz merilnega in skenirnega programa, ki smo ju podrobneje opisali. Predstavili smo tudi rezultate analize merilnega sistema po metodah MSA procedure 1 in 3 z dodatno analizo primerjave dveh merilnih naprav. Opisali smo tudi izboljšave, ki smo jih naredili za doseganje stabilnejšega in robustnejšega merilnega sistema z izboljšano točnostjo in natančnostjo meritev. Predstavili smo tudi metodologijo definiranja novih odpreškov za namen kompenzacije deformacije pločevine pri varjenju. Metodologijo smo preverili z enostavnim modelom varjenja dveh enakih ploščic. Naredili smo podrobno analizo pridobljenih rezultatov in ugotavljali uporabnost metodologije. Princip definiranja novega odpreška smo tudi uporabili na enem izmed odpreškov nosilca kolesa in oblikovali predlog nove oblike odpreška v obliki CAD modela. S temeljitim razmislekom smo metodologijo tudi nadgradili v računalniško generiranje novega odpreška. Naloga je opremljena z opisnim in slikovnim gradivom. V uvodnem poglavju smo najprej predstavili tematiko zaključnega dela. Nato smo podali podrobnejšo predstavitev uporabljene strojne in programske opreme. V poglavju Metodologija smo predstavili delovanje skenirne naprave, princip skeniranja in način generiranja poligoniziranega objekta. Opisali smo tudi koncepte merilnega programa in v splošnem predstavili načine analize merilnega sistema. V tem poglavju smo opisali tudi idejne koncepte in enačbe za definicijo novega odpreška. V poglavju Rezultati smo predstavili skenirni in merilni program nosilca kolesa, ter vse rezultate in opise analize zgrajenega merilnega sistema. Dodani so tudi rezultati enostavnega modela varjenja dveh ploščic s podrobnimi opisi in analizami. Predstavljeni so tudi rezultati koncepta uporabljenega na realnem odprešku ter rezultati in analize računalniškega generiranja oblike novih odpreškov.

Keywords

skeniranje;odprešek;zvarjenec;robotsko varjenje;virtualno okolje;poligoniziran objekt;GOM;ATOS Scanbox 5120;Matlab;TPV;FAAR WE;UKL2;magisteriji;

Data

Language:	Slovenian
Year of publishing:	2023
Typology:	2.09 - Master's Thesis
Organization:	UL FE - Faculty of Electrical Engineering
Publisher:	[G. Levak]
UDC:	007.52(043.3)
COBISS:	143249155
Views:	24
Downloads:	8
Average score:	0 (0 votes)
Metadata:

Other data

Secondary language:	English
Secondary title:	Measurement system for sheet metal deformation compensation in robotic welding
Secondary abstract:	The problem of achieving fast and high-quality measurements that provide feedback on product quality in industries is very common. In the case of extremely complex products, where a narrow tolerance is required for proper assembly, the reliability of the obtained measurements is very important. The geometric properties of such finished products, where welding is part of the assembly, also depend on the deformation of the material during the thermal treatment of joining smaller pieces. The shape of the welded pieces on the final product is therefore different from the shape of the welded pieces, which can pose a problem during assembly. Therefore, we built and created a measurement system for complex products, such as a wheel carrier, with the help of a scanning device, where we analyzed the quality of the obtained measurements. The measuring system consists of a measuring and scanning program, which we have described in more detail. We also presented the results of the analysis of the measuring system according to MSA procedures 1 and 3, along with an additional analysis comparing the two measuring devices. We also described the improvements that we made to achieve a more stable and robust measuring system with improved accuracy and precision of the measurement results. Furthermore, we also presented a methodology for defining new stamping parts for the purpose of compensating the deformation of sheet metal during welding. We verified the methodology with a simple model of welding two identical plates. We conducted a detailed analysis of the obtained results and determined the methodology’s applicability. We also applied the principle of defining a new stamping part to one of the wheel carrier stamping parts and created a proposal for a new stamping part shape in the form of a CAD model. After careful consideration, we also upgraded the methodology for the new computer-generated stamping part. The thesis is equipped with descriptive and pictorial material. In the first chapter, we started by presenting the topic of the final work. Then we provided a more detailed presentation of the hardware and software that we used. In the Methodology chapter, we presented the operation of the scanning device, the scanning principle and the method of generating a mesh. We also described the concepts of the measuring program and presented the general methods of analysis of the measuring system. In this chapter, we also described the concepts and equations for the definition of a new stamping part. In the Results chapter, we presented the scanning and measuring program for the wheel carrier, as well as all the results and descriptions of the analysis of the built measuring system. In addition, the results of a simple two-plate welding model with detailed descriptions and analyses are included. The results of the concept used on a real stamping part and the results of the analysis of the new computer-generated stamping part shape are also presented.
Secondary keywords:	scanning;stamping part;weldement;robotic welding;virtual environment;mesh;GOM;ATOS Scanbox 5120;Matlab;TPV;FAAR WE;UKL2;
Type (COBISS):	Master's thesis/paper
Study programme:	1000316
Embargo end date (OpenAIRE):	1970-01-01
Thesis comment:	Univ. v Ljubljani, Fak. za elektrotehniko
Pages:	XX, 92 str.
ID:	18085088