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摘    要

针对传统人工焊接效率低下、精度不足、安全性差及工序衔接不畅等问题，本研究以实现焊接工序全流程自动化为目标，设计基于西门子S7-1200 PLC的工业机器人自动化焊接控制系统。该系统是工业焊接生产自动化、标准化的核心控制装置，可破解人工焊接质量不稳定、生产效率低的缺陷，对工业焊接自动化设备的升级改造具有重要实践价值。

研究以西门子CPU 1214C PLC为控制核心，搭配SM 1223数字量模块与TP1200 Comfort HMI人机界面，基于TIA Portal博途软件完成IO地址分配、硬件组态与程序开发；通过OB1主程序、时钟脉冲FB1、控制FB2等程序块设计，实现上电初始化、传送带自动送料、工位光电检测、气缸夹紧定位、机器人双焊缝焊接、位置偏移补偿、焊接计数及系统复位等全流程自动化功能，并对系统多工位协同、时序精准控制等性能进行仿真验证。

本设计的创新点在于，采用时钟脉冲随机数模块实现系统精准时序控制；构建13步闭环自动控制流程，完成送料-夹紧-焊接-复位的连续循环作业；融入位置偏移补偿逻辑提升焊接定位精度；通过HMI界面实现系统运行状态、焊接参数与计数信息的可视化监控。仿真结果表明，系统可稳定完成三工位工件自动上料、双焊缝自动化焊接及循环生产，动作时序精准、工位协同可靠，自动化运行效果达标。

本系统满足工业机器人自动化焊接的生产管控需求，其全流程自动化控制与可视化监控功能有效提升了焊接生产效率与质量，可为工业自动化焊接生产线的设计与实际应用提供技术参考。

关键词：PLC；工业机器人；自动化焊接；时序控制；HMI可视化

Abstract

Aiming at the problems of low efficiency, insufficient precision, poor safety and poor process connection in traditional manual welding, this study designs an automatic welding control system for industrial robots based on Siemens S7-1200 PLC, with the goal of realizing the whole-process automation of welding procedures. As the core control device for automation and standardization of industrial welding production, this system can solve the defects of unstable quality and low production efficiency of manual welding, and has important practical value for the upgrading and transformation of industrial welding automation equipment.

Taking Siemens CPU 1214C PLC as the control core, equipped with SM 1223 digital module and TP1200 Comfort HMI, this study completes IO address allocation, hardware configuration and program development based on TIA Portal; through the design of OB1 main program, clock pulse FB1, control FB2 and other program blocks, it realizes the whole-process automation functions such as power-on initialization, automatic conveyor feeding, station photoelectric detection, cylinder clamping and positioning, robot double-seam welding, position offset compensation, welding counting and system reset, and verifies the performance of the system such as multi-station coordination and precise timing control through simulation.

The innovations of this design are: adopting the clock pulse random number module to realize precise timing control of the system; constructing a 13-step closed-loop automatic control process to complete the continuous cycle operation of feeding-clamping-welding-reset; integrating position offset compensation logic to improve welding positioning accuracy; realizing visual monitoring of system operation status, welding parameters and counting information through HMI interface. The simulation results show that the system can stably complete automatic feeding of three-station workpieces, automatic welding of double welds and cyclic production, with precise action sequence, reliable station coordination and qualified automatic operation effect.

In summary, this system meets the production management and control requirements of industrial robot automatic welding. Its whole-process automatic control and visual monitoring functions effectively improve the efficiency and quality of welding production, and can provide technical reference for the design and practical application of industrial automatic welding production lines.

Keywords: PLC; Industrial Robot; Automatic Welding; Timing Control; HMI Visualization

目    录

摘    要............................................................... I

Abstract................................................................ II

第1章 绪论........................................................ 1

1.1 研究背景............................................... 1

1.2 研究目的及意义................................... 1

1.2.1 研究目的.................................... 1

1.2.2 研究意义.................................... 2

1.3 国内外研究现状................................... 2

1.3.1 国外研究现状............................ 2

1.3.2 国内研究现状............................ 3

1.4 课题主要研究内容............................... 3

第2章 自动化焊接控制系统总体方案设计.... 4

2.1 自动化焊接控制系统原理................... 4

2.2 控制系统方案的确定........................... 4

第3章 自动化焊接控制系统硬件设计............ 6

3.1 PLC选型................................................ 6

3.2 输入/输出设备选型.............................. 7

3.2.1 输入设备选型............................ 7

3.2.2 输出设备选型............................ 7

3.3 硬件接线设计....................................... 8

3.4 电源模块选型....................................... 9

第4章 自动化焊接控制系统软件设计.......... 10

4.1 PLC外部输入/输出点(I/O)................. 10

4.2 控制系统流程设计............................. 11

4.3 系统接线图设计................................. 12

4.4 梯形图设计......................................... 13

第5章 系统运行与调试.................................. 17

5.1 通讯设定............................................. 17