CN1218806C - Arc welding robot control platform with visual welding seam automatic tracing function - Google Patents
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Abstract
The present invention relates to a control platform for an arc welding robot with the function for automatically tracing visual weld seams, which comprises a controller, a robot, a computer, a laser and a camera head fixed at the end of the robot, wherein the controller is used for controlling the motion of the robot; the robot moves a weld gun to perform the welding operation under the control of the controller; the computer is used for calculating different parameters of the robot and controlling the motion of the robot by the controller; plane luminous beams are emitted to welded work pieces by the laser; the camera head collects images formed because the plane luminous beam generated by the laser irradiate on joint grooves of the welded pieces and transfers the collected images to a computer to be processed by a video line. The control platform has an open structural system. The control platform can control various types of industrial robots, servo controllers and video devices, can flexibly control the industrial robots, and can conveniently add or change the hardware configuration of the industrial robots to realize different functions to enable the existing robot production to further meet the requirements of small batches and multiple types of the modern industrial production.
Description
Technical field
The present invention relates to the general-purpose industrial robot control system, particularly have the Arc Welding Robot Control platform of the automatic following function of vision weld joint.
Background technology
The basic structure of traditional industry arc welding robot system as shown in Figure 1, A1 is a controller, R1 is an industrial robot, H1 is a welding gun, G1 is a workpiece to be welded.The groundwork mode that this system takes is that teaching is reproduced, and promptly before welding job, manual control machine device people's terminal welding gun is along weld movement, and the position of each motor tracing point of record is calculated position while welding and finished weld task with this in moving process.One of shortcoming of this operating type is that teaching work is loaded down with trivial details, takies more man-hour, and when weld seam was more irregular, this defective was especially outstanding.Another shortcoming is the adaptability that lacks the butt welded seam change in location.For example, if the position while welding of a collection of workpiece is not in full accord, will carry out the position teaching to workpiece one by one so.Compare with general industry automation mechanized operation mechanism and transfer robot, arc welding robot not only requires high to motion control, need track position relation, movement velocity and posture of welding torch between high-precision welding gun and the workpiece simultaneously.Raising workpiece machining accuracy, strict control robot teaching track not only can improve manufacturing cost, and the restriction scope of application.Therefore,, make the arc welding robot system have the adaptability of butt welded seam change in location, must make arc welding system possess the soldering joint automatic tracking function in order to enhance productivity.
Weld seam vision tracking transducer mainly is divided into three kinds of modes: structured light formula, laser scan type and directly take arc type.Also there are many incomplete places in the vision control system of at present existing arc welding robot, does not possess opening, can not satisfy the requirement that robot discerns under circumstances not known, handles problems.(writing " intelligent solder technology ", National Defense Industry Press, 2001.5) referring to Wu Lin, Chen Shanben etc.
Summary of the invention
The purpose of this invention is to provide a kind of Arc Welding Robot Control platform with the automatic following function of vision weld joint.
For achieving the above object, have the Arc Welding Robot Control platform of the automatic following function of vision weld joint, comprising:
Controller is used to control the motion of robot;
Robot, under the control of described controller, mobile welding gun welds, and it is characterized in that also comprising:
Computer is used for calculating robot's various parameters, by the motion of controller control robot;
Laser instrument sends planar light beam to welded piece;
Be fixed on two cameras of robot end, gather the planar light beam that produces by laser instrument and shine the image that the joint bevel place of welded piece forms, and the image of being gathered is sent to computer by video line handles.
The present invention has realized the soldering joint automatic tracking function of arc welding robot, can enhance productivity greatly; The present invention has open structural system, can control polytype industrial robot, servo controller, video equipment (comprising video frequency collection card and CCD camera), can control industrial robot more neatly, increase or change its hardware configuration more easily, realize different functions, make existing robots produce the requirement that further adapts to the many kinds of modern industry production small lot; The present invention also can be used as a kind of experiment porch, by the control software of layer exploitation thereon based on different operating system, can be to can only experimentizing by the various control strategies of Computer Simulation in the past, for the research and the exploitation of futurity industry robot provides a kind of experiment porch.
Description of drawings
Fig. 1 is the configuration connection layout of traditional arc-welding industrial robot control system;
Fig. 2 is the arc welding robot vision platform configuration connection layout with the automatic following function of vision weld joint based on the opened industrial robot controller;
Fig. 3 is an opened industrial robot controller internal drive part connection layout;
Fig. 4 is the connection layout of two CCD cameras and two-way capture card.
The specific embodiment
The difference of the present invention and prior art (Fig. 1) is:
Increased external PC I1, made the user work out and to revise control program according to the actual needs of oneself.
Disposed two CCD camera D1 and D2 that are fixed in the robot end, and a generating laser L1, with generating structure light.
Technological core of the present invention also is the opened industrial robot controller is applied to robotic vision system, connects two CCD cameras (can add optical filter) by computer, and by opened industrial robot controller control laser beam emitting device.Fig. 2 is the concrete line schematic diagram of this control platform, and the I1 among the figure is an industrial computer; A2 is the opened industrial robot controller; D1 and D2 are the CCD camera (can add optical filter) that is fixed on the robot end, and data wire is connected to the video port of the video frequency collection card among the A2, and the pose of its pose random device robot end changes and changes; L1 is a generating laser (can add optical filter), and it links to each other with A2 by a light adjusting and controlling device (C6 among Fig. 3), and the adjusting of light intensity realizes by A2.
The operation principle of Fig. 2 is as follows: computer links to each other with the CCD camera by the video frequency collection card that is inserted on its pci bus, and capture card is dual input, can select different cameras for use according to different needs.For finishing the automatic tracing task of vision weld joint, at first send planar light beam by C7 control laser instrument L1 by controller, camera D1 and D2 gather the pencil of planes that is produced by laser instrument and shine the image that the joint bevel place of workpiece G2 forms, and be sent to computer by video line, pass through image processing process such as filtering, image binaryzation, image thinning and fitting a straight line then, obtain the various characteristic parameters of image.By the matching relationship of two camera image and the camera inside and outside parameter of demarcating in advance, extract the needed various information such as pose, size of notch again.According to resulting information, go out the movement locus of robot by specific algorithmic rule, decompose each joint then.Computer passes to open architecture robot controller A2 to the kinematic parameter in each joint, the AC servo motor that the driving signal of the servo bag output in the controller can driven machine people R2, and the automatic tracing task of vision weld joint is finished in the motion of control robot.The position in each joint of R2 obtains by the code-disc that is installed on the joint motor.It is very big that the sampled images effect of CCD camera is influenced by light intensity, so design A2 has the light source output intensity of one tunnel output control laser instrument L1, if the image effect that D2 and D3 sampling obtain is undesirable, system can regulate the light intensity of L1 automatically according to actual needs.
Fig. 3 is an open architecture robot controller internal drive part line graph, C1 is multi-axis motion controller PMAC2-PC (being called for short PMAC) among the figure, it can be inserted on the slot of the isa bus on the industrial computer, C2 (the second code-disc converter) and C3 (the first code-disc converter) are YASKAWA absolute encoder converter ACC-8D-OPTION9, C4 (the first Signal Matching converter), C5 (secondary signal adaption converter) and C6 (the 3rd Signal Matching converter) are Signal Matching converter ACC-8E, and C7 is a voltage regulator circuit; C2, C3, C4, C5, C6 and C7 are installed in A2 inside; The J1 port of C1 is connected with the P6 mouth of C2, and JMAC2, JMAC3 are connected with the JMACH mouth of C4, C5 and C6 respectively with the JMAC4 port; The J2 port of C2 links to each other with the J1 port of C4, and the J1 of C3, J2 port are connected with the J1 port of C5 and C6 respectively; Servo bag S1, S2, S3, S4, S5 and S6 drive AC servo motor M1, M2, M3, M4, M5 and M6 respectively; The EO port of servo bag S1 and S2 is connected respectively to P2 and the P3 port of C2, and the EO port of servo bag S3, S4, S5 and S6 is connected respectively to P1, the P2 of C3, P3 and P4 port; The CI port of servo bag S1 and S2 is connected respectively to TB3 and the TB5 port of C4, and the CI port of servo bag S3 and S4 is connected respectively to TB3 and the TB5 port of C5, and the CI port of servo bag S5 and S6 is connected respectively to TB3 and the TB5 port of C6; The TB4 port of C6 links to each other with C7; C7 links to each other with laser instrument L1.
The operation principle of Fig. 3 is as follows:
Send voltage control signal by operating in the control program of working out on the industrial computer, send the JMAC port of C4, C5 and C6 to by the JMAC2 on the C1, JMAC3 and JMAC4 port, transform through digital-to-analogue by C4, C5 and C6 again and send servo bag S1, S2, S3, S4, S5 and S6 to, and then form the driving pulse of AC servo motor M1, M2, M3, M4, M5 and M6.
The variation of the position in each joint of robot is to produce by the absolute encoder that is installed on the AC servo motor.Give S1, S2, S3, S4, S5 and S6 earlier by the code-disc signal that M1, M2, M3, M4, M5 and M6 produce, the EO port by them passes to absolute encoder converter C2 and C3 again; C3 passes to C2 with the code-disc absolute position signal on the one hand, and C2 passes the absolute position signal of C2 and C3 back PMAC again; C2 and C3 are converted to increment signal with the absolute encoder signal on the other hand, and C2 passes to C4 with this signal, and C3 passes to C5 and C6 respectively with increment signal; When needed, C4, C5 and C6 pass to PMAC with increment signal again by JMAC port separately; By isa bus, PMAC uploads industrial computer with the absolute position reading of each motor more at last.Computer has just obtained the code wheel reading of AC servo motor like this, just can understand these code-disc data by computer program, to determine the position and the motion state in each joint of robot.
The adjustment of illuminating ray intensity also realizes by controller, computer is given C1 according to regulation voltage number of situation output of camera sampled images, C1 sends this signal to C4, the analog voltage signal of the 0～6V of TB4 port output of C4 is given voltage regulator circuit C7, the output of C7 is entered as linear change according to it, therefore, can regulate the brightness of L1.
Fig. 4 is the connection layout of two CCD cameras and two-way capture card.Camera is connected to two-way image pick-up card C8 by video transmission line; C8 is connected with Computer I 1 by pci bus.Its operation principle is as follows: camera powers up back work, constantly produces the PAL mode video signal of modulation, and these signals are sent to capture card.Under the control of application software, these vision signals are processed into image data format by capture card, and are transferred to calculator memory, and application program is reads image data from internal memory, and carry out next step processing.
The present invention adopts binocular vision, planar structure photoimaging technology, the weld seam location and the following function of arc welding robot have been realized, the major advantage of the Arc Welding Robot Control platform with the automatic following function of vision weld joint that is proposed is as follows: adopt binocular vision technology, overcome the difficulty of blocking that monocular vision may cause; Adopt structured light, avoided the insoluble arc-welding light of passive vision interference problem; The opened industrial robot controller is applied in the vision system, adopt open structure, the user on the one hand can be according to the needs flexible customization hardware configuration of oneself, can on this controls the basis of platform, carry out secondary development on the other hand, finish the not available task of some original systems.
Embodiment:
This control platform has been realized the AC servo motor to robot, the control of tunable laser by circuit shown in Figure 3.In an embodiment, built by an industrial robot, an opened industrial robot controller, two CCD cameras, a video frequency collection card and the arc welding robot vision platform that laser instrument constitutes with the automatic following function of vision weld joint.Industrial computer can adopt ADVANTECH-610, adopt peace river YASKAWA MOTOMAN SK10 humanoid robot body as the control object, servo bag adopts a day intrinsic safety river YASKAWACACR-SR15SZ1SD-Y214 type single shaft to drive servo bag respectively, S, L, U, R, B and six joints of T of being used for the driven machine people, camera adopts SONY Digital Hyper HAD colour imagery shot (can add optical filter), video frequency collection card to select the OK-C80/M capture card of pci bus for use, and laser instrument adopts semiconductor laser (can add optical filter).
The present invention is a device of realizing the soldering joint automatic tracking of industrial robot.
At first send planar light beam by C7 control laser instrument L1 by controller, gather the pencil of planes that produces by laser instrument at camera D1 and D2 and shine the image that the joint bevel place of workpiece G2 forms, and be sent to computer by video line, pass through image processing process such as filtering, image binaryzation, image thinning and fitting a straight line then, obtain the various characteristic parameters of image.By the matching relationship of two camera image and the camera inside and outside parameter of demarcating in advance, extract the needed various information such as pose, size of notch again.According to resulting information, go out the movement locus of robot by specific algorithmic rule, decompose each joint then.Computer passes to open architecture robot controller A2 to the kinematic parameter in each joint, the AC servo motor that the driving signal of the servo bag output in the controller can driven machine people R2, and the automatic tracing task of vision weld joint is finished in the motion of control robot.
The present invention adopts the opened industrial robot controller to replace the robot controller of traditional structure sealing, has realized the automatic following function of vision weld joint by the opened industrial robot controller.This invention makes the user of robot need not butt welded seam pointwise teaching, just can formulate the job task of arc welding robot automatically, can enhance productivity greatly.In addition, because therefore structure opening can improve the user to the ROBOT CONTROL ability easily for robot increases the function that does not possess when some dispatch from the factory.This creation increases its adaptive capacity to circumstances not known for the production efficiency that improves the arc-welding industrial robot, expands the application of robot in industrial production and has important effect.
Claims (5)
1. Arc Welding Robot Control platform with the automatic following function of vision weld joint comprises:
Controller is used to control the motion of robot;
Robot, under the control of described controller, mobile welding gun welds, and it is characterized in that also comprising:
Computer is used for calculating robot's various parameters, by the motion of controller control robot;
Laser instrument sends planar light beam to welded piece;
Be fixed on two cameras of robot end, gather the planar light beam that produces by laser instrument and shine the image that the joint bevel place of welded piece forms, and the image of being gathered is sent to computer by video line handles.
2. by the described control platform of claim 1, it is characterized in that described camera links to each other with computer by the video frequency collection card that is inserted on the pci bus.
3. by the described control platform of claim 1, it is characterized in that regulating described laser beam intensity and comprise:
Described computer is given multi-axis motion controller according to regulation voltage number of camera sampled images situation output,
The Signal Matching converter receives voltage-regulation from multi-axis motion controller and counts signal, and the output analog voltage signal is given voltage regulator circuit;
The output of voltage regulator circuit is according to the input linear change, to regulate the brightness of laser instrument.
4. by the described control platform of claim 1, it is characterized in that described controller comprises:
The voltage control signal that multi-axis controller, receiving computer send;
The Signal Matching converter receives the voltage control signal from multi-axis controller;
Servo bag receives the signal through the digital-to-analogue conversion of Signal Matching converter;
AC servo motor receives the signal of servo packet generation.
5. by the described control platform of claim 4, it is characterized in that also comprising:
Be installed in the absolute encoder on the AC servo motor, produce the code-disc signal;
AC servo motor receives the code-disc signal, and the code-disc signal is passed to the absolute encoder converter;
The code-disc converter, on the one hand, the first code-disc converter is passed to the second code-disc converter with the code-disc absolute position signal, and the second code-disc converter is all passed the absolute position signal of the second and first code-disc converter back multi-axis controller again; On the other hand, second and the first code-disc converter is converted to increment signal with the absolute encoder signal, the second code-disc converter is passed to the first Signal Matching converter with this signal, and the first code-disc converter is passed to the second and the 3rd Signal Matching converter respectively with increment signal;
At last, by isa bus, multi-axis motion controller is uploaded computer with the absolute position reading of each motor again.
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