CN101256399A - Double DSP built-in control system for visual feedback during soldering process - Google Patents

Double DSP built-in control system for visual feedback during soldering process Download PDF

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Publication number
CN101256399A
CN101256399A CNA2007103043174A CN200710304317A CN101256399A CN 101256399 A CN101256399 A CN 101256399A CN A2007103043174 A CNA2007103043174 A CN A2007103043174A CN 200710304317 A CN200710304317 A CN 200710304317A CN 101256399 A CN101256399 A CN 101256399A
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module
dsp
image processing
welding
processing module
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CNA2007103043174A
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孙振国
黄操
刘鹏飞
陈强
徐绪炯
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HUAHENG WELDING APPARATUS TECHNOLOGY Co Ltd KUNSHAN CITY
Tsinghua University
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HUAHENG WELDING APPARATUS TECHNOLOGY Co Ltd KUNSHAN CITY
Tsinghua University
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Priority to CNA2007103043174A priority Critical patent/CN101256399A/en
Publication of CN101256399A publication Critical patent/CN101256399A/en
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Abstract

The invention discloses a double DSP embedded type welding process visual feedback control system for welding seam tracking and welding quality control in welding automation, comprising a DSP image processing module, a DSP feedback control module, a power and reset module, a visual interface module, an analog video coding module and a USB control module. The DSP image processing module extracts the eigenvalues of a welding region image transmitted from the video interface module and transmits to the DSP feedback control module, the DSP feedback control module outputs corresponding signals according to the eigenvalues, and finishes close-loop control of welding seam tracking and welding quality. By this invention, welding seam tracking and welding seam shaping control can be carried out without a host computer.

Description

Double DSP built-in control system for visual feedback during soldering process
Technical field
Patent of the present invention belongs to field of welding devices, is specifically related to a kind of real-time double DSP built-in control system for visual feedback during soldering process of controlling of welding process monitoring, weld joint tracking and appearance of weld that is used to realize the welding process robotization.
Background technology
Vision sensor based on the industrial CCD video camera contains much information because of it has, the measuring accuracy height, with characteristics such as workpiece is contactless, be widely used in picture control, weld joint tracking and the appearance of weld closed-loop control of welding process.Vision sensor in use is not vulnerable to the influence of magnetic blow or wire bending, but need overcome arc light in the welding process, flue dust, interference such as splash.In addition, the pattern-recognition and the real-time requirement thereof of features such as groove, electric arc, molten bath have all proposed higher requirement to image process method, precision and speed.This just requires to have following characteristics based on the welding process feedback control system of vision sensor:
1, architecture is simple, space structure is little, system accessibility is good;
2, fast operation, control performance are good, can be rapidly and accurately to welding arc this is non-linear, the time varying duty carry out FEEDBACK CONTROL;
3, can carry out welding process monitoring, weld joint tracking or appearance of weld FEEDBACK CONTROL.
Existing control system for visual feedback during soldering process adopts desk-top industrial control computer as image processor mostly, with hard disk as data storage medium, employing based on the image pick-up card of pci bus with the analog video image digitizing, change into the simulation controlled quentity controlled variable or directly adopt numeral to export to driver by the digital controlled signal of DA transition card, and constitute feedback control system thus computer output.The Weld Seam Tracking Control system that for example yellow army sweet smell is introduced in " research of pipeline welding vision track control system ", adopt Meteor-II/Standard image pick-up card and CCD camera to realize the collection of welded seam area image, utilize the weld image algorithm for pattern recognition to detect the deviation of arc welding gun head and axis of a weld in real time on computers, send this departure to PLC system implementation tracking Control." a kind of spiral pipe seam tracking system " and the Min Qingkai of Liu Song based on computer vision, the safe one-tenth of Hino " welding robot intelligent process and control " also all adopts desk-top industrial control computer as image processor, makes up the welding process feedback control system.This feedback control system be unable to do without huge desk-top industrial control computer, the architecture complexity, and the accessibility of control system is poor, can't carry out off-line welding control.
Along with the development of DSP technology, some welding Visual Feedback Control systems based on DSP have also appearred.From the documents and materials of having published, they all adopt a slice DSP to finish Flame Image Process and two processor active tasks of FEEDBACK CONTROL simultaneously, for example left small echo has been introduced a kind of based on the DSP vision sensor in " based on the seam tracking system of DSP " literary composition, be used to not have submerged arc welding that arc light disturbs, seam tracking system, it adopts a slice TMS320C6711 model DSP and the preposition model of a slice is CPLD composing images acquisition process and the display module of EPM71285, wherein DSP both had been used for Flame Image Process and also had been used for control signal output, be difficult to make the full-time concurrent working of Flame Image Process and FEEDBACK CONTROL, limited the dynamic responding speed of system.
In addition, existing welding Visual Feedback Control system is owing to be subjected to the restriction of space, resource and interface, fail DSP image processing module, DSP feedback control module, power supply and reseting module, video interface module, analog video coding module, USB control module etc. are become one, fail to realize simultaneously analog and input, output the digital video picture signal, and in single feedback control system, realize multiple functions such as welding process monitoring, weld joint tracking and appearance of weld control simultaneously.
In sum, existing welding process visual sensing system has the following disadvantages: (1) generally adopts desk-top industrial control computer to carry out image acquisition and processing, architecture complexity, accessibility are poor: (2) adopt single DSP operation architecture, arithmetic speed is slow, can't satisfy the requirement of high-quality welding process FEEDBACK CONTROL on precision and speed; (3) integrated level is little, and function singleness fails to realize the integrated of multiple function such as welding process monitoring, weld joint tracking and appearance of weld control in real time.
Summary of the invention
The objective of the invention is in order to overcome the deficiency of prior art, adopt the embedded lamination brick pattern design of two DSP, not only divorced from computer carries out work on system architecture, and with the DSP Flame Image Process, the real-time FEEDBACK CONTROL of welding process DSP, video interface, the analog video coding, numerous functional modules such as USB interface control are integrated in the less space, a kind of compact conformation is provided, integrated multiple functional module is in one, Visual Feedback Control system based on the processing of double DSP built welding image, at system accessibility, aspects such as control real-time and function applicability are better than prior art, can be widely used in CO 2, welding process monitoring, weld joint tracking and appearance of weld in the multiple welding techniques such as MIG, TIG control in real time.
A kind of double DSP built-in control system for visual feedback during soldering process of the present invention's design, comprise the DSP module, power supply and reseting module, video interface module, analog video coding module and USB control module, it is characterized in that, described DSP module is two, one of them is the DSP image processing module, another is the DSP feedback control module, described video interface module, the welding region image that is used for the industrial CCD camera is obtained sends the DSP image processing module to, described DSP image processing module is handled this image, extraction is used for the characteristic parameter of weld joint tracking or the real-time control of appearance of weld, and described characteristic parameter is sent to the real-time feedback control module of DSP, the real-time feedback control module of described DSP is adjusted the welding gun pose in real time or is adjusted source of welding current parameter according to the characteristic parameter that is obtained, data image signal after described DSP image processing module will be handled is divided into two-way output, one the tunnel exports to the industry monitoring device through described analog video coding module carries out the welding process monitoring, another road outputs to through described USB control module and stores on the computing machine and show, the real-time feedback control module of described DSP, video interface module, the analog video coding module, the DSP image processing module links to each other, the USB control module, 6 modules of power supply and reseting module divide 3 layers to integrate.
Described DSP image processing module is positioned at the centre position, the real-time feedback control module of described DSP, video interface module, the identical port of analog video coding module employing are arranged and are linked to each other with the DSP image processing module, and USB control module, power supply and the identical port of reseting module employing are arranged and linked to each other with the DSP image processing module.
Described DSP image processing module extracts and defeated characteristic parameter comprises the position deviation of welding gun and weld seam or is used for the appearance of weld fusion penetration of control in real time, molten wide, it is core processor that described DSP image processing module adopts TMS320DM642, extend out two 48LC4M32B random access memory and 1 AM29LV033C power down can keep storer, wherein, two random access memory are used for the welding region image that buffer memory imports into and the intermediate variable of processing procedure, power down can keep storer to be used to preserve algorithm routine, can break away from the host computer bootstrapping and be written into operation when system powers on or reset.
The real-time feedback control module of described DSP adopts TMS320LF2812, the weld joint tracking or the real-time controlling features parameter of appearance of weld that provide according to the DSP image processing module, export 3 groups of control signals, wherein press every group one tunnel velocity setting pwm signal, one tunnel direction of motion DIRECTION signal respectively for two groups, one the tunnel enables the output of ENABLE signal, control two-way direct current or stepper motor respectively and be used for welding-torch horizontal and vertical pose adjustment, export 3 road pwm signals to the source of welding current, be respectively applied for the real-time control of weldingvoltage, electric current and wire feed rate for other one group.
The present invention has the following advantages and effect:
(1), adopt embedded lamination modular construction design, realized that welding process feedback control system breaking away industrial computing machine independently carries out work, reduced system bulk and system architecture complexity, improved the accessibility of feedback control system;
(2), adopted two DSP structures, be respectively applied for the control of parameter extraction of welding region characteristics of image and weld joint tracking and appearance of weld, effectively improved the data processing speed and the dynamic response performance of system;
(3), a plurality of modules such as the integrated analog input of video signal, simulation output, numeral input, numeral output, make system have stronger function applicability;
(4), adopt the CPLD technology, realized support to the different video signal input sources;
(5), can preset corresponding technological specification parameter at different welding techniques, realize that welding process monitoring, weld joint tracking and appearance of weld control in real time.
Description of drawings
Below in conjunction with drawings and Examples patent of the present invention is described further, but patent of the present invention is not limited to shown in the accompanying drawing.
Fig. 1 double DSP built-in control system for visual feedback during soldering process structural drawing;
The three-dimensional explosive view of Fig. 2 double DSP built-in control system for visual feedback during soldering process;
Fig. 3 double DSP built-in control system for visual feedback during soldering process tomograph.
Embodiment
Below in conjunction with description of drawings the specific embodiment of the present invention.
As shown in Figure 1, patent of the present invention comprises several parts such as DSP image processing module, DSP feedback control module, analog video coding module, USB control module and video interface module.Wherein the DSP image processing module adopts the TI high-performance image process chip TMS320DM642 of company, has extended out the RAM of two 16M on the CE0 of its EMIF bus space, is used for the temporary large nuber of images digital signal of obtaining from video port.Simultaneously, on the CE1 space of its EMIF, extended out the FLASH storer of a 4M.The FLASH storer is used for preserving the image processing program algorithm after the power down, realizes that DSP powers on the back program from loading, and realizes following the tracks of thereby break away from host computer.The DSP image processing module has been drawn all videos interface (totally three) of TMS320DM642, and adopts same-interface to arrange and arrange.
The DSP feedback control module adopts the TMS320LF2812 of TI as logic control element, because it has had the built-in FLASH storer, need not to extend out the FLASH storer, in order to obtain more multiprogram running memory space, guarantee complicated control algolithm operate as normal, module has extended out the RAM of 512K.The DSP feedback control module is drawn three groups of Electric Machine Control lines, and every group of control line comprises 3 control signals, can adapt to the feedback and tracking demand of many control variable.The DSP feedback control module is by hyperchannel buffer memory serial port (McBSP) and DSP image processing module images characteristic.
Power supply and reseting module adopt two high-power switchgear power supply chips, as input, are converted to 1.4V and 3.3V power supply with the 5V power supply respectively, stable working power are provided for the kernel and the peripheral hardware of DSP image processing module.Because resetting of DSP needs special electrifying timing sequence, power supply and reseting module are integrated TPS3307 resets chip, the DSP in control image processing module and the feedback control module carries out the active homing operation.
Video interface module is made up of analog video decoder module and digital visual interface module, can distinguish according to the difference of the industrial CCD camera output signal of reality and select for use.
The analog video decoder module adopts the SAA7115 chip, and the parity field analog video signal of analogue camera output is sampled obtains digital video signal output, and imports the DSP image processing module into by video interface.Because the analog video decoder module relates to analog and digital signal, in order to prevent the interference between simulating signal and the digital signal, this module is the 3.3V power supply of using system power supply and reseting module output not, and adopts inside modules TPS76833 switching power source chip that the 5V power supply of input is converted to numeral and the simulation part parallel circuit that 3.3V analog power and 3.3V digital power are supplied with this module respectively respectively.In order to prevent the interference between the analog-and digital-power supply, add magnetic bead between the analog-and digital-power supply and isolate and add a large amount of electric capacity afterflows and filtering.
The digital visual interface module uses 4 DS90LV048A to change 15 road LVDS signals, and in order to adapt to different video formats, 15 way word vision signals do not have directly to insert the video port of DSP image processing module, but the CPLD of process a slice EPM240T100.By changing or the digital signal of input carried out preliminary processing and delivered to corresponding video image mouth the signal format of input to CPLD programming.
The analog video coding module adopts SAA7121 that the digital video signal of DSP image processing module by video port output is converted to the CVBS simulating signal and outputs on N system or the PAL-system monitor and show.Identical with the analog video decoder module, because this module relates to analog and digital interface, therefore adopted the independent current source power supply, and adopted analog-and digital-isolated from power.
The USB control module adopts the CY7C68013 chip.It has expanded the I of a 24WC256 2C electrically-erasable storer is used to store the USB firmware program, and the bootstrapping that realizes powering on is configured to the USB Peripheral Interface, finishes the USB communication with computing machine.CY7C68013 is by the high-speed peripheral interface (HPI) of DSP image processing module, under the computing cost that does not expend image processing module DSP, read data image signal in the internal memory by the DMA passage, thereby realize that host computer is to digital collection of video signal function.
Described DSP feedback control module, analog video decoder module, digital visual interface module, analog video coding module adopt identical interface shape, can realize exchanging easily dismounting on three video ports of described DSP image processing module expansion.Wherein analog video decoder module, digital visual interface module and analog video coding module are optional module.These modules are not the necessary modules of system's operate as normal, when reality is used, can select to install these modules according to different applicable cases and realize specific video collection and output.
Fig. 2 is the three-dimensional explosive view of system, DSP feedback control module (102), analog video decoder interface module (104), analog video coding module (105) adopt identical port to arrange and DSP image processing module (101) joins, and USB control module (106), power supply and reseting module (103) adopt identical port to arrange and DSP image processing module (101) joins.
Fig. 3 is the three-dimensional assembly drawing of system, and this three stacked assembling structures make native system have less overall space volume (170mm * 57mm * 40mm).
The principle of work of patent of the present invention and the course of work:
According to the camera of different output modes, different video interface/decoder modules is installed, promptly digital camera is installed the digital visual interface module, and analogue camera is installed the analog video decoder module.The welding image scene is converted to the video data of specific format through video interface/decoder module after by the collection of digital-to-analog camera, imports the DSP image processing module into by video port.The DSP image processing module does not have buffer memory among the RAM that image information is imported into expansion in computing loss ground by the DMA passage, processor carries out the feature extraction computing of cache image synchronously simultaneously, and is transferred to the DSP feedback control module by hyperchannel buffer memory serial port (McBSP).The DSP feedback control module is finished weld joint tracking closed-loop control and welding quality closed-loop control according to image feature value output control signal corresponding.
This device is based on Embedded Double DSP structure, and integrated multifunction module in smaller size smaller has realized that the disengaging host computer independently carries out weld joint tracking and molten wide, fusion penetration control.Owing to this apparatus structure compactness, integrated level height, can expand and adaptability is strong, volume is little, improve the accessibility and the adaptability of welding control system.

Claims (4)

1. double DSP built welding process visual feedback system, comprise DSP module, power supply and reseting module, video interface module, analog video coding module and USB control module, it is characterized in that, described DSP module is two, one of them is the DSP image processing module, and another is the DSP feedback control module.Described video interface module, the welding region image that is used for the industrial CCD camera is obtained sends the DSP image processing module to, described DSP image processing module is handled this image, extraction is used for the characteristic parameter of weld joint tracking or the real-time control of appearance of weld, and described characteristic parameter is sent to the real-time feedback control module of DSP, the real-time feedback control module of described DSP is adjusted the welding gun pose in real time or is adjusted source of welding current parameter according to the characteristic parameter that is obtained, data image signal after described DSP image processing module will be handled is divided into two-way output, one the tunnel exports to the industry monitoring device through described analog video coding module carries out the welding process monitoring, another road outputs to through described USB control module and stores on the computing machine and show, the real-time feedback control module of described DSP, video interface module, the analog video coding module, the DSP image processing module links to each other, the USB control module, 6 modules of power supply and reseting module divide 3 layers to integrate.
2. double DSP built-in control system for visual feedback during soldering process according to claim 1, it is characterized in that, described DSP image processing module is positioned at the centre position, the real-time feedback control module of described DSP, video interface module, the identical port of analog video coding module employing are arranged and are linked to each other with the DSP image processing module, and USB control module, power supply and the identical port of reseting module employing are arranged and linked to each other with the DSP image processing module.
3. double DSP built-in control system for visual feedback during soldering process according to claim 1 and 2, it is characterized in that, described DSP image processing module extracts and defeated characteristic parameter comprises the position deviation of welding gun and weld seam or is used for the appearance of weld fusion penetration of control in real time, molten wide, it is core processor that described DSP image processing module adopts TMS320DM642, extend out two 48LC4M32B random access memory and 1 AM29LV033C power down can keep storer, wherein, two random access memory are used for the welding region image that buffer memory imports into and the intermediate variable of processing procedure, power down can keep storer to be used to preserve algorithm routine, can break away from the host computer bootstrapping and be written into operation when system powers on or reset.
4. double DSP built-in control system for visual feedback during soldering process according to claim 3, it is characterized in that, the real-time feedback control module of described DSP adopts TMS320LF2812, the weld joint tracking or the real-time controlling features parameter of appearance of weld that provide according to the DSP image processing module, export 3 groups of control signals, wherein press every group one tunnel velocity setting pwm signal respectively for two groups, one tunnel direction of motion DIRECTION signal, one the tunnel enables the output of ENABLE signal, control two-way direct current or stepper motor respectively and be used for welding-torch horizontal and vertical pose adjustment, export 3 road pwm signals to the source of welding current, be respectively applied for weldingvoltage for other one group, the real-time control of electric current and wire feed rate.
CNA2007103043174A 2007-12-27 2007-12-27 Double DSP built-in control system for visual feedback during soldering process Pending CN101256399A (en)

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Cited By (12)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN101961819A (en) * 2009-07-22 2011-02-02 中国科学院沈阳自动化研究所 Device for realizing laser welding and seam tracking and control method thereof
CN102060234A (en) * 2010-10-26 2011-05-18 常州超媒体与感知技术研究所有限公司 Tire crane traveling track video correction device and method
CN102346002A (en) * 2010-07-30 2012-02-08 江苏泰达机电设备有限责任公司 Antiaircraft gun continuous shooting command simulation route generating system
CN102922094A (en) * 2012-10-09 2013-02-13 上海工程技术大学 Ultra-small size welding seam tracking method based on heat input
CN103817401A (en) * 2014-02-20 2014-05-28 深圳市佳士科技股份有限公司 Method and system for realizing current type limited bipolar PWM (pulse-width modulation) output by combining DSP (digital signal processor) with CPLD (complex programmable logic device)
CN104070264A (en) * 2014-06-23 2014-10-01 江苏科技大学 Groove-width-varying rotating arc narrow gap MAG welding self-adaptive swing device and method thereof
CN104808582A (en) * 2015-04-27 2015-07-29 广东工业大学 Embedded digital controller based on FPGA and control method of embedded digital controller
CN108672893A (en) * 2018-05-21 2018-10-19 天津工业大学 A kind of control method of asymmetry angle joint penetration form and fusion penetration
CN110369832A (en) * 2019-08-01 2019-10-25 太原科技大学 A kind of screw thread welded tube forming process Intelligent Adjustment System and method
CN112534365A (en) * 2018-08-09 2021-03-19 Abb瑞士股份有限公司 Device comprising a process control system and at least one process module, associated method, computer program product and data processing apparatus
CN115877808A (en) * 2023-01-30 2023-03-31 成都秦川物联网科技股份有限公司 Industrial Internet of things for machining thin-sheet workpieces and control method
US12025966B2 (en) 2018-08-09 2024-07-02 Abb Schweiz Ag Apparatus comprising a process control system and at least one process module, related method, computer program product, and data processing device

Cited By (18)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN101961819A (en) * 2009-07-22 2011-02-02 中国科学院沈阳自动化研究所 Device for realizing laser welding and seam tracking and control method thereof
CN101961819B (en) * 2009-07-22 2013-10-30 中国科学院沈阳自动化研究所 Device for realizing laser welding and seam tracking and control method thereof
CN102346002A (en) * 2010-07-30 2012-02-08 江苏泰达机电设备有限责任公司 Antiaircraft gun continuous shooting command simulation route generating system
CN102346002B (en) * 2010-07-30 2013-10-23 江苏泰达机电设备有限责任公司 Antiaircraft gun continuous shooting command simulation route generating system
CN102060234A (en) * 2010-10-26 2011-05-18 常州超媒体与感知技术研究所有限公司 Tire crane traveling track video correction device and method
CN102060234B (en) * 2010-10-26 2012-12-26 常州超媒体与感知技术研究所有限公司 Tire crane traveling track video correction device and method
CN102922094A (en) * 2012-10-09 2013-02-13 上海工程技术大学 Ultra-small size welding seam tracking method based on heat input
CN103817401A (en) * 2014-02-20 2014-05-28 深圳市佳士科技股份有限公司 Method and system for realizing current type limited bipolar PWM (pulse-width modulation) output by combining DSP (digital signal processor) with CPLD (complex programmable logic device)
CN104070264A (en) * 2014-06-23 2014-10-01 江苏科技大学 Groove-width-varying rotating arc narrow gap MAG welding self-adaptive swing device and method thereof
CN104808582A (en) * 2015-04-27 2015-07-29 广东工业大学 Embedded digital controller based on FPGA and control method of embedded digital controller
CN108672893A (en) * 2018-05-21 2018-10-19 天津工业大学 A kind of control method of asymmetry angle joint penetration form and fusion penetration
CN112534365A (en) * 2018-08-09 2021-03-19 Abb瑞士股份有限公司 Device comprising a process control system and at least one process module, associated method, computer program product and data processing apparatus
CN112534365B (en) * 2018-08-09 2024-05-28 Abb瑞士股份有限公司 Apparatus, associated methods, computer program products, and data processing devices including a process control system and at least one process module
US12025966B2 (en) 2018-08-09 2024-07-02 Abb Schweiz Ag Apparatus comprising a process control system and at least one process module, related method, computer program product, and data processing device
CN110369832A (en) * 2019-08-01 2019-10-25 太原科技大学 A kind of screw thread welded tube forming process Intelligent Adjustment System and method
CN110369832B (en) * 2019-08-01 2020-11-27 太原科技大学 Intelligent adjusting system and method for spiral welded pipe forming process
CN115877808A (en) * 2023-01-30 2023-03-31 成都秦川物联网科技股份有限公司 Industrial Internet of things for machining thin-sheet workpieces and control method
US11906949B2 (en) 2023-01-30 2024-02-20 Chengdu Qinchuan Iot Technology Co., Ltd. Industrial Internet of Things, control methods, and storage medium for sheet workpiece processing

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