JPH11146387A - Welding state remote supervisory system and its method - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a welding state remote supervisory system and its method by which a welding state is remotely supervised accurately in almost real time. SOLUTION: Two ND filters, each having a different light transmissivity, are provided respectively at the front side of a 1st camera 1 and of a 2nd camera 2. Both the cameras 1, 2 photograph a welded part. An image of an arc photographed by the 1st camera 1 and an image other than the arc such as molten pool and groove photographed by the 2nd camera 2 are synthesized. The synthesized image is displayed on a color monitor 6.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a welding status remote monitoring device and a welding status remote monitoring method for displaying and monitoring a welding status on an image.

[0002]

2. Description of the Related Art Conventionally, it has been conventionally performed to photograph a welded portion using a camera, display an acquired image on a monitor, and remotely monitor a welding condition. However, in the weld,
Some parts, such as an arc part and other parts, whose optical conditions are remarkably different, especially around the luminance, coexist. Therefore, if the aperture is adjusted so that it is suitable for photographing the arc part and the welded part is photographed, the amount of light in the part other than the arc part becomes extremely insufficient, making it difficult to monitor the welding condition. When the weld is adjusted and photographed, the image becomes bright and blurred as a whole due to the influence of the arc, and the required part shines white due to blooming and smear, which also makes it difficult to monitor the welding state.

Therefore, the welding status remote monitoring device described in Japanese Patent Application Laid-Open No. 8-150475 monitors a current value and a voltage value sent from a welding power source and shoots an arc portion at a timing when an arc is generated. On the other hand, the imaging of the weld pool or groove other than the arc portion is performed at a timing when the arc is not generated or extremely small, and the arc image, the weld pool image, and the groove image captured in this manner are combined into a single image. To be displayed on a monitor.

[0004]

In the conventional welding status remote monitoring device, the current value and the voltage value sent from the welding power source are monitored, and when a timing suitable for capturing each of them is reached, We shoot the arc, the molten pool, and the groove. However, in other words, the portion of the composite image where the above timing does not arrive is that the previous image remains without being updated. Therefore, the image on the monitor lacks a quick response to a change in the welding condition, and it is difficult to perform accurate and reliable remote monitoring.

There has also been proposed a welding condition remote monitoring apparatus in which a filter having an increased amount of attenuation with respect to transmitted light only at a central portion thereof is provided on the front of a camera, and an arc portion is photographed through the central portion of the filter. However, in such a welding condition remote monitoring device, when the arc portion deviates from the center of the filter, the welding condition cannot be effectively monitored. There is a problem that it is not suitable for remote monitoring of welding.

SUMMARY OF THE INVENTION The present invention has been made to solve the above-mentioned conventional disadvantages, and an object of the present invention is to provide a welding system capable of performing accurate and reliable remote monitoring of a welding condition with almost real-time response. It is an object to provide a situation remote monitoring device and a welding situation remote monitoring method.

[0007]

SUMMARY OF THE INVENTION Accordingly, a welding condition remote monitoring device according to the first aspect of the present invention is provided with a plurality of cameras 1, each of which is installed so as to photograph a welded portion and has different optical conditions suitable for photographing each other. 2 and each of these cameras 1, 2
An image processing unit 5 for processing and synthesizing an image indicating the welding condition from the image information captured in step 1 and an image display unit 6 for displaying the synthesized image.

In the welding condition remote monitoring device according to the first aspect of the present invention, a welded portion in which portions having significantly different optical conditions are mixed can be viewed almost in real time in a single image. Monitoring becomes possible.
It should be noted that the “synthesis” mentioned above has a broad meaning not only when a plurality of images are simply added, but also includes various types of synthesis processing such as fitting and arithmetic synthesis.

A welding condition remote monitoring device according to claim 2 is
It is characterized by comprising a camera 1 adjusted to be suitable for recognition of an arc portion of a welded portion, and a camera 2 adjusted to be suitable for recognition of a welded portion other than an arc portion such as a groove or a molten pool. And

In the welding condition remote monitoring device according to the second aspect, the arc portion and the portion other than the arc portion such as the groove and the molten pool can be viewed almost in real time on a single image. And accurate and reliable remote monitoring of welding conditions including

Further, in the welding condition remote monitoring apparatus according to the third aspect, each of the cameras 1 and 2 has optical conditions suitable for recognition adjusted by using filters 7 and 8 for attenuating transmitted light. And

By using a plurality of cameras 1, 2, each of the cameras 1, 2 can be mounted with filters 7, 8 to adjust optical conditions suitable for photographing. In the welding condition remote monitoring device according to the third aspect, the filters 7, 8
Since the conditions suitable for photographing are adjusted using, the above conditions can be largely changed with a simple configuration, and the implementation thereof can be facilitated.

According to a fourth aspect of the present invention, there is provided a remote control apparatus for monitoring a welding condition, wherein a control unit for performing a welding control such as a welding position control based on the synthesized image information is provided.

Here, the control section may be provided with a microcomputer or the like to automatically perform welding control as described in claim 5, or may be provided with a handle or the like and manually perform welding control. It may be something.

In the welding condition remote monitoring device according to the fourth and fifth aspects, since the welding control is performed based on the image information synthesized in advance, it is possible to reduce the amount of information processing required for the control.

According to a sixth aspect of the present invention, there is provided a remote monitoring apparatus for a welding condition, wherein the first camera is adjusted so as to be suitable for recognizing an arc portion of a welded portion, and a filter for passing only a laser light band.
Is arranged on the front side and adjusted so as to be suitable for recognition of a welding line such as a groove in a welding portion, and an image of an arc portion taken by the first camera 1 and taken by the second camera 2 It is characterized by comprising an image processing unit 5 for processing and synthesizing the image of the weld line thus formed, and an image display unit 6 for displaying the synthesized image.

In the welding condition remote monitoring apparatus according to the sixth aspect, a belt-like laser beam is obliquely applied to the welding line, and the welding line such as a groove is controlled by a laser broken line generated due to the presence of the groove. In this case, the laser broken line and the arc portion can be remotely monitored simultaneously and in real time on a single image. Further, a composite image of the laser broken line and the arc portion formed at this time can also be used for scanning control such as a groove.

According to a seventh aspect of the present invention, there is provided a method for remotely monitoring a welding condition, wherein a filter for attenuating transmitted light is disposed on a front surface of the first camera, and the filter is adjusted so as to be suitable for recognition of an arc portion of a welded portion.
A second camera 2 having a filter 8 having a different attenuation amount of transmitted light from the filter 7 disposed on the front surface thereof and adjusted so as to be suitable for recognition of a portion other than an arc portion such as a groove or a molten pool in a welded portion.
And the first camera 1
The image processing unit 5 processes and synthesizes the image of the arc portion photographed in step 2 and the image other than the arc portion photographed by the second camera 2, and displays the synthesized image on the image display unit 6. I have.

According to the welding condition remote monitoring method of the seventh aspect, the arc portion and the portion other than the arc portion such as a groove or a molten pool can be viewed almost in real time on a single image. Accurate and reliable remote monitoring of welding conditions including copying and the like is possible.

[0020]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Next, specific embodiments of a remote monitoring apparatus and a remote monitoring method according to the present invention will be described in detail with reference to the drawings.

FIG. 3 is a diagram showing a schematic configuration of the welding status remote monitoring device. Two cameras 1 and 2 are attached to the camera holder 3. These two cameras 1, 2
Is a CCD color camera having the same configuration, the output side of which has two camera control units (CCU).
4, 4 are connected. This CCU4 is camera 1,
It has a function of converting the potential charged in the two CCD elements into a video signal. The video signals formed by the CCUs 4 and 4 are transferred to the image processing unit 5 next. The image synthesized by the image processing unit 5 is further transferred to a color monitor (image display unit) 6 and displayed on a CRT.

FIG. 4 is a transparent side view showing the internal structure of the camera holder 3. The two cameras 1 and 2 arranged side by side in the camera holder 3 are provided with transmitted light attenuating filters (hereinafter, referred to as ND filters) 7 and 8 on the front surfaces thereof. The ND filters 7 and 8 have a function of attenuating transmitted light, but the ND filter 7 attached to the first camera 1 disposed on the upper side has a transmittance of about 0.3%. On the other hand, the ND filter 8 attached to the second camera 2 arranged on the lower side has a transmittance of about 8%. The two cameras 1 and 2 have their respective central parts on axes 13 and 1.
4 rotatably supported. And the shaft 1
The adjustment screw 11 and the lock screw 12
Are provided. By operating the adjusting screw 11 among them, the cameras 1 and 2 can be rotated about the axes 13 and 14, whereby the difference in the optical axis angle between the cameras 1 and 2 can be adjusted. By fastening the lock screw 12, the optical axis angle can be fixed. A blower fan 10 is provided at the rear end of the camera holder 3.
Is attached. The blower fan 10 is for preventing an increase in noise mixed in an output signal due to a rise in the temperature of the cameras 1 and 2. Further, a protective glass 9 is attached to the front side of the camera holder 3. Openings (not shown) are formed on both left and right sides of the protective glass 9, and the air generated by the blower fan 10 is blown out from the openings to prevent fumes from adhering to the protective glass 9. Has become. Each camera 1, 2
In addition to the ND filters 7 and 8, a filter (not shown) for color adjustment is attached to the front surface of the.

FIG. 2 is a flowchart showing the procedure of image processing / combining performed by the image processing section 5. However, before performing this procedure, the camera 1 and 2 need to be aligned. That is, for example, the same object can be photographed by the cameras 1 and 2 by removing the ND filters 7 and 8, and the images photographed by the cameras 1 and 2 by operating the adjustment screw 11 are almost the same. It is to be the thing of. Then, the angle and the like of the camera holder 3 are further adjusted so that the welded portion is located at the center of the image. Here, the welded portion refers to a portion including a welding position and its periphery, and includes an arc portion, a molten pool, a groove, and the like.

After the positioning of the cameras 1 and 2 is completed, the image processing / combining procedure is executed. First, in step S1, the ND filter 7 having a transmittance of about 0.3%
An image is input via the CCU 4 from the first camera 1 provided with. The image input at this time is shown in FIG. Since this is an image photographed through the ND filter 7 having an extremely low transmittance, an arc portion is photographed in the center of the image, and the other portions are blackened. On the other hand, in step S2, an image is input via the CCU 4 from the second camera 2 having the ND filter 8 having a transmittance of about 8%. The image input at this time is shown in FIG.
This is shown in FIG. Since this is an image photographed through the ND filter 8 having a light transmittance nearly 30 times higher than that of the ND filter 7, the molten pool and the groove are clearly displayed, while the arc portion is an image flying white. Has become.

Next, in step S3, the image shown in FIG. 1A is binarized using a predetermined threshold level. Then, an image is formed in which the arc portion having a luminance equal to or higher than the predetermined value is white and the other portions are black. Then, the white portion among them becomes a mask region for the image (FIG. 1A) captured in step S2. That is, by taking the exclusive OR (EXOR) of the image captured in step S2 and the binary image formed in step S3, the arc portion of the image shown in FIG. Means that an image having no change is obtained in step S4. Then, in the following step S5, the image obtained in step S4 and the image (FIG. 1A) captured in step S1 are combined. Then, the arc portion of the image captured in step S1 is inserted into the black masked portion of the image obtained in step S4, and an image as shown in FIG. 1C is formed. Therefore, in this image, both the image of the arc portion taken by the first camera 1 and the image of the molten pool and the groove taken by the second camera 2 are clearly displayed.

In the welding condition remote monitoring device and the welding condition remote monitoring method, the image of the arc portion taken by the first camera 1 and the image of the molten pool and the groove taken by the second camera 2 are processed and synthesized. The composite image is displayed on the color monitor 6 for monitoring. According to the above method, the image of the arc portion and the images of the molten pool and the groove can be taken almost simultaneously and continuously. Therefore, the arc portion and the portions other than the arc portion such as the groove and the molten pool can be viewed on the single color monitor 6 in real time. Therefore, it is possible to perform accurate and reliable remote monitoring as to whether or not welding control such as groove line profiling control is proceeding as expected. In the above,
ND with different transmittance from each other using two cameras 1 and 2
Filters 7 and 8 are attached to the respective cameras, whereby the optical conditions suitable for photographing are different between the cameras 1 and 2. In order to photograph both the arc portion and the other portion with a single camera at any time, a special camera must be used so that the shutter speed or the aperture can be changed instantaneously and extremely widely. Therefore, by performing the above, the camera 1 to be installed,
Although the number of units increases, the cost can be reduced.

Further, welding control such as welding position control can be performed by using the composite image as shown in FIG. 1 (c). This welding control can be performed by an automatic control such as a groove line scanning control by a control unit configured using a microcomputer or the like. In this case, the control unit may perform the control based on the pre-combined image, so that the information processing amount required for the control can be reduced and the configuration of the control unit can be simplified. Further, the welding control can be performed by manual control such that an operator operates a handle or the like to adjust a welding position while watching an image on the color monitor 6. In this case, the handle and the mechanism for moving the welding position in accordance with the operation of the handle correspond to the control unit. In this case as well, the operator only needs to adjust the welding position based on the pre-combined image, so that the information processing amount required for the operator is reduced, and the work can be facilitated. In any of the above cases, control can be performed based on an image presented in real time, so that accurate and reliable welding control can be performed.

Although the specific embodiments of the present invention have been described above, the present invention is not limited to the above embodiments, and can be implemented with various modifications within the scope of the present invention. In the above description, the ND filters 7 and 8 having different light transmittances are provided on the front surfaces of the cameras 1 and 2 so that the optical conditions suitable for photographing are different between the cameras 1 and 2. In the same manner as described above, the first camera 1 is adjusted to be suitable for photographing the arc portion, while the second camera 2 is adjusted to be suitable for photographing in the infrared region so that the optical conditions suitable for the respective photographing are different. Is also good. By doing so, an image in which the temperature distribution of the welded portion and the arc portion are combined can be obtained. For example, in butt welding of thin plates, when the intended position is shifted, the temperature of one thin plate to be welded rapidly rises, and the temperature of the other thin plate suddenly drops. Therefore, it is possible to remotely and accurately monitor whether or not the groove line tracing control or the like is proceeding as expected by an image obtained by synthesizing the temperature distribution of the welded portion and the arc portion. Further, it is possible to remotely monitor the heat input control based on the temperature distribution. Further, the composite image can be used for welding position control and heat input control.

Further, for example, the first camera 1 is adjusted to be suitable for photographing the arc portion in the same manner as described above, while a band-pass filter for passing only the laser light band is attached to the front of the second camera 2. May be adjusted so as to be suitable for photographing a laser beam, and the optical conditions suitable for each photographing may be made different. In this manner, when a belt-shaped laser beam is radiated obliquely to the welding line, and the welding line such as a V-shaped groove is controlled by the laser folding line generated due to the presence of the groove, the laser bending line and the arc are controlled. Parts can be monitored simultaneously and in real time on a single monitor 6. Further, the composite image of the laser broken line and the arc portion formed at this time can also be used for scanning control of a V-shaped groove.

Further, in the above description, the arc portion is photographed by the first camera 1 disposed on the upper side in the camera holder 3, but this is performed by photographing the arc portion by the second camera 2 disposed on the lower side. Alternatively, three or more cameras may be used to photograph the welded portion to form a composite image.

[0031]

According to the welding condition remote monitoring device of the first aspect, the welding portion in which portions having significantly different optical conditions are mixed can be viewed almost in real time with a single image. Remote monitoring becomes possible.

In the welding condition remote monitoring device according to the second aspect, the arc portion and the portion other than the arc portion such as the groove and the molten pool can be viewed almost in real time on a single image. And accurate and reliable remote monitoring of welding conditions including

Further, in the welding condition remote monitoring device according to the third aspect, since conditions suitable for recognition are adjusted using a filter, the above conditions can be largely changed with a simple configuration, and the implementation thereof is facilitated. Becomes possible.

In the welding condition remote monitoring device according to the fourth and fifth aspects, since the welding control is performed based on the image information synthesized in advance, the amount of information processing required for the control can be reduced.

According to a sixth aspect of the present invention, the welding condition remote monitoring device irradiates a strip-like laser beam obliquely to the welding line, and controls the scanning of the welding line such as the groove by the laser broken line generated due to the presence of the groove. In this case, the laser broken line and the arc portion can be remotely monitored simultaneously and in real time on a single image.
Further, a composite image of the laser broken line and the arc portion formed at this time can also be used for scanning control such as a groove.

According to the welding condition remote monitoring method of the seventh aspect, the arc portion and the portion other than the arc portion such as a groove or a molten pool can be viewed almost in real time on a single image, so that the groove line is traced. It is possible to perform accurate and reliable remote monitoring of welding conditions including the above.

[Brief description of the drawings]

FIG. 1 shows images obtained by a welding status remote monitoring apparatus or a welding status remote monitoring method according to the present invention, wherein (a) is an image of an arc portion, and (b) is an image of a weld pool, a groove or the like. And (c) is a composite image.

FIG. 2 is a flowchart illustrating a procedure for forming the composite image.

FIG. 3 is a schematic configuration diagram of the welding status remote monitoring device.

FIG. 4 is a transparent side view showing the inside of a camera holder of the welding status remote monitoring device.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 1st camera 2 2nd camera 5 Image processing part 6 Color monitor 7 ND filter 8 ND filter

 ──────────────────────────────────────────────────続 き Continuing on the front page (72) Inventor, Toshimitsu Araki 118, Futatsuka, Noda-shi, Chiba Kawasaki Heavy Industries Noda Plant (72) Inventor Hideo Kawahara 118, Futatsuka, Noda-shi, Chiba Kawasaki Heavy Industries Noda Plant ( 72) Inventor Takao Kanamaru 118 Notsuka, Noda City, Chiba Prefecture Kawasaki Heavy Industries Noda Factory Co., Ltd. 118 Futatsuka Noda City Kawasaki Heavy Industries Noda Plant (72) Inventor Kenji Iwashima 118 Futatsuka Noda City Chiba Prefecture Kawasaki Heavy Industries Noda Plant

Claims (7)

[Claims] 1. A plurality of cameras, each of which is installed so as to photograph a welded part and has different optical conditions suitable for photographing, and an image indicating a welding condition is obtained from image information photographed by each of these cameras. A welding status remote monitoring device, comprising: an image processing unit for processing and combining; and an image display unit for displaying the combined image. 2. A camera comprising: a camera adjusted to be suitable for recognition of an arc portion of a welded portion; and a camera adjusted to be suitable for recognition of a portion other than an arc portion such as a groove or a molten pool in a welded portion. The welding status remote monitoring device according to claim 1, wherein: 3. The welding status remote monitoring apparatus according to claim 2, wherein each of the cameras has a filter adapted to attenuate transmitted light to adjust optical conditions suitable for recognition. 4. The welding status remote monitoring device according to claim 3, further comprising a control unit for performing welding control such as welding position control based on the synthesized image information. 5. The remote monitoring apparatus according to claim 4, wherein the control section automatically performs a groove line scanning control. 6. A first camera adjusted to be suitable for recognizing an arc portion of a welded portion, and a filter for passing only a laser light band disposed on the front surface, and recognizing a welding line such as a groove in the welded portion. A second camera adjusted to suit the
An image processing unit for processing and synthesizing the image of the arc portion photographed by the camera and the image of the welding line photographed by the second camera, and an image display unit for displaying the synthesized image. To monitor the welding status. 7. A first camera in which a filter for attenuating transmitted light is arranged on the front surface and adjusted to be suitable for recognition of an arc portion of a welded portion, and a filter having a different attenuation amount of transmitted light from the filter. The second part is adjusted to be suitable for recognition of parts other than arc parts such as grooves and weld pools among welded parts.
The image of the arc portion photographed by the first camera and the image other than the arc portion photographed by the second camera are processed and combined by the image processing unit, and the combined image is taken. A remote monitoring method for a welding condition, wherein the method is performed by displaying the image on an image display unit.