CN102284769A - System and method for initial welding position identification of robot based on monocular vision sensing - Google Patents
System and method for initial welding position identification of robot based on monocular vision sensing Download PDFInfo
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Abstract
The invention provides a system for the initial welding position identification of a robot based on monocular vision sensing. The system comprises a welding robot, a monocular vision sensing system and a master control computer, wherein the monocular vision sensing system is used for shooting a scene containing a weld joint of a workpiece and transmitting an acquired image to the master control computer through a video wire; and the master control computer is used for receiving a shooting enabling signal sent by the welding robot, further controlling the monocular vision sensing system to take a picture of the weld joint scene, processing the taken picture and guiding the welding robot to reach an initial point of the weld joint according to the processing result. Through the monocular vision sensing system, the shooting and the processing of the image can be performed on the workpiece to be welded more flexibly and conveniently. The complex steps of mounting and calibrating a binocular vision sensor are omitted and the limitation that the contact type sensing can only be used for the workpieces in regular shapes can be further avoided.
Description
Technical field
The present invention relates to a kind of arc welding robot guiding control system and method, relate in particular to a kind of initial welding position recognition system and method for arc welding robot.
Background technology
In welding process, traditional teaching reproduction pattern welding robot is very strict to the stability requirement of welding operating condition, lack flexible during welding, weld seam programming efficiency to complicated shape is lower, and can not realize detecting in real time control to the welding dynamic process, can't satisfy high-quality and high accuracy welding requirements complicated weldment.In order to overcome of the influence of various uncertain factors to welding quality, require welding robot system will have the function of real-time detection and adjustment control, by welding robot being assembled various sensing devices, make its to external world environment have certain perception, thereby can be very necessary according to the variation of external environment condition autonomous adjustment work track and state.Along with the development of electronic technology, computer technology, numerical control and various welding sensing technologies,, the Study of intelligent of welding robot provides powerful support for for providing technical.
At present, the sensing mode that is applied on the welding robot is varied.Among these method for sensing and since the visual sensing mode have contain much information, noncontact, fast, high accuracy and automaticity advantages of higher, be subjected to liking of numerous Welders author.Become at present the research focus of robot welding sensor aspect.The visual sensing technology on welding robot, use more be carry out that the weld seam vision is followed the tracks of and welding process Based Intelligent Control such as penetration control aspect research, at present both at home and abroad the research comparative maturity be the weld seam vision tracking mode that adopts laser or structured light.This sensing mode belongs to the category of active vision, need add specific light source.Because its course of work is reliable, lower to the working environment requirement, in industrial production, obtained at present using more widely.But it also exists, and information content is abundant inadequately, function singleness, weak point that volume is bigger.So, at present international and domesticly have many experts and scholars adopting ordinary light source or utilizing the passive vision sensing mode of arc light to study.
When a certain weld task adopts welding robot to finish, for any task, at first all requires to make welding gun accurately to move to the weld seam initial point position, and the attitude of adjusting welding gun make it to satisfy welding process requirement, prepare to begin welding and moves.The process of this guiding is crucial for satisfactorily finishing of a weld task, and it is the first step of whole welding action and for the automaticity that improves welding robot, realizes that the autonomous welding function of welding robot is very necessary.
Though the visual sensing method is widely used on welding robot, at present for the searching of the weld seam original position of no initial position message, identification and rare to the research of the guiding aspect of welding robot.The day intrinsic safety river company of robot of visible report produces and has the welding robot of welding starting point detection function at present, what but it adopted is touch sensor, owing to be subjected to the restriction of sensing mode, be only applicable to angle welding and have the weld seam form of groove greatly, contact must clearly be convenient at the edge of weld seam, and requirement must move to robot near the welding starting point, it can only welding near the starting point than the zonule in begin to seek, can not realize seeking on a large scale the function of initial welding position.Document " Xu Peiquan, Tang Xinhua etc.; based on the visual sensing system Review Study [(periodical) welding] of robot welding; Shanghai; welding engineering research institute of Shanghai Communications University; 2005 " is summed up: when using contact-sensing, because robot has carried out the search course and increased the production cycle, welding point also must contain an edge that can be found by sensor.In addition, document " Guo Zhenmin, base and the initial welding position guiding research of the welding robot of visual servo [doctorate paper], Harbin; Harbin Institute of Technology, 2002 " was once studied the guiding problem of robot the method that adopts the motion image sequence analysis.But he has adopted the method for additional marking point, and is provided with the test constraints of comparison strictness, and test effect is not very good, and differs bigger with the actual production conditions of industry spot.
Summary of the invention
The present invention is directed to above-mentioned deficiency of the prior art and needs, a kind of robot initial welding position recognition system and method based on the monocular vision sensing is provided, guide robot to move to the technical problem of path of welding starting point accurately thereby solve.
To the invention provides a kind of robot initial welding position recognition system in order solving the problems of the technologies described above, to comprise based on the monocular vision sensing:
Can treat the welding robot that welder's part welds, after it moves to the relevant position, send and take the permission signal to main control computer;
The monocular vision sensor-based system is used for the scene that comprises the workpiece weld seam is taken, and the image of being gathered is sent to main control computer by video line;
Main control computer, it receives the shooting permission signal that welding robot sends, and controls monocular vision sensor-based system butt welded seam scene then and takes pictures, and captured photo is handled, and guides welding robot to arrive the weld seam starting point according to result.
Further, describedly thank to the robot initial welding position recognition system of device based on the monocular vision sensing, also comprise: secondary light source is fixedly mounted on the welding robot robot end joint.
Further, described robot initial welding position recognition system of thanking to device based on the monocular vision sensing, it is characterized in that, described main control computer is provided with slot, described monocular vision sensor-based system comprises interconnective vision sensor, image pick-up card, and described vision sensor is the monocular vision sensor and is fixedly mounted on the welding robot human body.
Described further robot initial welding position recognition system of thanking to device based on the monocular vision sensing, it is characterized in that, described vision sensor comprises: ccd video camera, mirror system and sensor stand, described ccd video camera, mirror system all are fixed on the sensor stand, mirror system comprises first order reflection mirror and mirror support, the first order reflection mirror is arranged on the mirror support, first order reflection mirror and horizontal direction adjustable angle, the first order reflection mirror collects image and reflexes to ccd video camera.
Describedly further thank to the robot initial welding position recognition system of device based on the monocular vision sensing, it is characterized in that described main control computer is provided with kernel control module, this kernel control module comprises:
Image capture module is in order to gather near the picture signal the initial welding position of workpiece to be welded and it is carried out transfer of data;
Welding position is sought module, in order to seek the initial welding position and the calculation deviation amount of position deviation workpiece in picture signal;
Welding position correction module is in order to calculate workpiece horizontal coordinate correction according to this searching result and departure and to control robot and rectify a deviation.
Simultaneously, the present invention also provides a kind of and thanks to the robot initial welding position recognition methods of device based on the monocular vision sensing, comprises the steps:
After step 1, welding robot move to the relevant position, send and take the permission signal to main control computer;
Step 2, visual sensing system are taken the scene that comprises the workpiece weld seam, and the image of being gathered is sent to main control computer by video line;
Step 3, main control computer receive the shooting permission signal that welding robot sends, then controlling monocular vision sensor-based system butt welded seam scene takes pictures, and captured photo handled, guide welding robot to arrive the weld seam starting point according to result.
Further, describedly thank to the robot initial welding position recognition methods of device, it is characterized in that described step 3 specifically comprises the steps: based on the monocular vision sensing
Image acquisition step is gathered near the picture signal of the initial welding position of workpiece to be welded and it is carried out transfer of data;
Welding position is sought step, seeks the initial welding position and the calculation deviation amount of position deviation workpiece in picture signal;
Welding position correction step calculates workpiece horizontal coordinate correction and controls robot and rectify a deviation according to this searching result and departure.
Compared with prior art, the present invention has following beneficial effect: the present invention has satisfied the requirement of polytype industrial robot local intelligence for the guiding of welding robot monocular vision provides system platform.By the monocular vision sensor-based system, the welder's part for the treatment of that can be more flexible carries out image taking and processing.Save the complex steps that binocular vision sensor is installed and demarcated, and avoided contact-sensing can only be used for the limitation of regular shape workpiece.In the presence of secondary light source, obtain the second best in quality workpiece weld image to be welded, for good condition has been established in subsequent image processing and guiding work.Quicken the speed of the initial welding position guiding of welding robot, increased the range of application of the initial welding position guiding of welding robot.
Description of drawings
Fig. 1 is the GMAW robot welding guidance system block diagram based on the monocular vision sensing;
Fig. 2 is a vision sensor light path schematic diagram of the present invention;
It is that the pixel coordinate system of robot motion's coordinate system and video camera camera plane concerns floor map that Fig. 3 is one;
The specific embodiment
Below in conjunction with accompanying drawing embodiments of the invention are elaborated: present embodiment is being to implement under the prerequisite with the technical solution of the present invention, provided detailed embodiment and concrete operating process, but protection scope of the present invention is not limited to following embodiment.
As shown in Figure 1, the initial welding position recognition system of the GMAW of robot based on the monocular vision sensing of present embodiment comprises: welding robot, monocular vision sensor-based system, main control computer, secondary light source, wherein:
Welding robot is used to treat welder's part and welds, and after it moves the relevant position, sends and takes the permission signal to main control computer; In the relevant position described in this specific embodiment can be the fixing position of workpiece height to be welded relatively.
Monocular monocular vision sensor-based system is used for the scene that comprises the workpiece weld seam is taken, and the image of being gathered is sent to main control computer by video line;
Main control computer, it receives the shooting permission signal that welding robot sends, and controls monocular vision sensor-based system butt welded seam scene then and takes pictures, and captured photo is handled, and guides welding robot to arrive the weld seam starting point according to result.
Secondary light source, be extra add in order to improve the small-power cold light source of scene image quality, be fixedly mounted on the welding robot robot end joint.
Described welding robot comprises, welding robot human body and be installed in instrument on the welding robot robot end joint, and this instrument specifically can be a welding gun.In this specific embodiment, tool coordinates system centre point arrives the weld seam starting point, and then welding robot begins welding job.
Described monocular vision sensor-based system comprises vision sensor, image pick-up card, and image pick-up card is installed in the main control computer PCI slot, links to each other with vision sensor by video line.Described vision sensor is the monocular vision sensor and is fixedly mounted on the welding robot human body.
Described vision sensor comprises: ccd video camera, mirror system and sensor stand.Ccd video camera, mirror system all are fixed on the sensor stand, mirror system comprises first order reflection mirror and mirror support, the first order reflection mirror is arranged on the mirror support, first order reflection mirror and horizontal direction adjustable angle, the first order reflection mirror collects image and reflexes to ccd video camera, and whole vision sensor is fixed to by sensor stand on the GMAW welding torch in terminal joint of welding robot.
Described main control computer comprises a common computer that comprises serial ports, PCI slot.Serial ports in order to and robot between communication, the PCI slot is in order to install image pick-up card.The kernel control module of whole system is installed on the main control computer.
Described kernel control module comprises:
Image capture module is in order to gather near the picture signal the initial welding position of workpiece to be welded and it is carried out transfer of data;
Welding position is sought module, in order to seek the initial welding position and the calculation deviation amount of position deviation workpiece in picture signal;
Welding position correction module is in order to calculate workpiece horizontal coordinate correction according to this searching result and departure and to control robot and rectify a deviation.
The concrete course of work is: before welding beginning, described image capture module carries out near the initial welding position picture signal collection and transmission to the workpiece to be welded of position deviation; Welding position is sought horizontal departure amount 1 and the horizontal departure amount 2 that module is sought the initial welding position of workpiece and calculated initial welding position according to preceding described picture signal, (owing to any one point on the horizontal plane can be represented with two-dimentional Di Kaer coordinate (also being rectangular co-ordinate), so the deviation in the horizontal plane between any two points can make up description with the gap of coordinate figure projection on two coordinate directions in these 2 o'clock, and two departures are also just arranged).The horizontal departure amount of indication is meant the poor of initial welding position of current workpiece and the initial welding position horizontal level of standard in this specific embodiment, the determining of the initial welding position of standard determines that with a point fixing in the video camera camera plane this fixing point can be understood as the intersection point of video camera photocentre and camera plane.Described welding position correction module is according to preceding described horizontal departure amount 1 and horizontal departure amount 2, calculate the horizontal coordinate correction 1 and the horizontal coordinate correction 2 of initial welding position, described horizontal coordinate correction is obtained through Coordinate Conversion by the horizontal departure amount, described Coordinate Conversion is to be determined by the relative position between described signal pattern coordinate system and the robot tool coordinate system and direction, and horizontal coordinate correction 1 and horizontal coordinate correction 2 are sent to robot rectifies a deviation.In the horizontal plane as shown in Figure 3, two coordinate systems are arranged, one is robot motion's coordinate system, one is the pixel coordinate system of video camera camera plane, origin position difference between two coordinate systems, X/Y direction difference, parasang are also different, but the point that photographs in the pixel coordinate system and this position in robot motion's coordinate system can be set up relation one to one.
The initial welding position of standard, present known a point position, but the b point is the actual initial welding position that obtains, can obtain its physical location in the robot motion plane by the position in the pixel coordinate system in camera plane of b and a so, so just the gap of initial welding position in pixel coordinate system can be converted to the gap in the robot motion plane, the Coordinate Conversion of deviation that Here it is.
When the present invention works, before welding job begins, walk workpiece relative altitude to be welded fixed position place of welding robot, take the signal that allows by the serial communication transmission of welding robot and main control computer and inform the main control computer kernel control module, main control computer is taken the scene that comprises the weld seam path by IMAQ card control vision sensor, this scene is to be taken under the irradiation of the auxiliary cold light source of the small-power that is installed in welding robot robot end joint, and image pick-up card picture signal that shooting is obtained sends back to the main control computer kernel control module then.Kernel control module is sought by carry out initial welding position in the picture signal that collects, calculate the numerical information that obtains initial welding position, and by carrying out calculating the departure of initial welding position in the vision sensor coordinate system then with reference to calculating the position of initial welding position in the vision sensor coordinate system with the staking-out work of finishing in advance.At last, core control mould calculates in the welding robot coordinate system by above-mentioned departure, the correction of workpiece horizontal coordinate also sends to robot by serial communication, make the welding robot motion of rectifying a deviation, robot tool coordinate central point is moved to the starting point of workpiece weld seam to be welded.After above job step is finished, will carry out welding job to workpiece, finish or continue the welding job of next workpiece until welding job according to the robot welding path that prior teaching is finished.The weld seam of the workpiece to be welded described in this specific embodiment is a level, towards fixing and be changeless with respect to the height of vision sensor.
The present invention simultaneously also provides a kind of and thanks to the robot initial welding position recognition methods of device based on the monocular vision sensing, comprises the steps:
After step 1, welding robot move to the relevant position, send and take the permission signal to main control computer;
Step 2, monocular vision sensor-based system are taken the scene that comprises the workpiece weld seam, and the image of being gathered is sent to main control computer by video line;
Step 3, main control computer receive the shooting permission signal that welding robot sends, then controlling monocular vision sensor-based system butt welded seam scene takes pictures, and captured photo handled, guide welding robot to arrive the weld seam starting point according to result.
Described step 3 specifically comprises the steps:
Image acquisition step is gathered near the picture signal of the initial welding position of workpiece to be welded and it is carried out transfer of data;
Welding position is sought step, seeks the initial welding position and the calculation deviation amount of position deviation workpiece in picture signal;
Welding position correction step calculates workpiece horizontal coordinate correction and controls robot and rectify a deviation according to this searching result and departure.
Described welding position is sought horizontal departure amount 1 and the horizontal departure amount 2 that step is sought the initial welding position of workpiece and calculated initial welding position according to preceding described picture signal, described horizontal departure amount is meant the poor of initial welding position of current workpiece and the initial welding position horizontal level of standard, the determining of the initial welding position of standard determines that with a point fixing in the video camera camera plane this fixing point can be understood as the intersection point of video camera photocentre and camera plane.
Described welding position correction step is specially:
According to preceding described horizontal departure amount 1 and horizontal departure amount 2, calculate the horizontal coordinate correction 1 and the horizontal coordinate correction 2 of initial welding position, described horizontal coordinate correction is obtained through Coordinate Conversion by the horizontal departure amount, described Coordinate Conversion is to be determined by the relative position between described signal pattern coordinate system and the robot tool coordinate system and direction, and horizontal coordinate correction 1 and horizontal coordinate correction 2 are sent to robot rectifies a deviation.
Present embodiment is the important foundation platform that makes up the GMAW of robot local intelligence welding system, on this basic platform, can further develop welding robot system with more composite guide control functions or guiding tracking integrated control functions, improved the Control Welding Process ability of user, had important effect expanding the application of robot in the Automation of Welding field to arc welding robot.
Claims (11)
1. the robot initial welding position recognition system based on the monocular vision sensing comprises: can treat the welding robot that welder's part welds, after it moves to the relevant position, send and take the permission signal to main control computer; It is characterized in that, also comprise:
The monocular vision sensor-based system is used for the scene that comprises the workpiece weld seam is taken, and the image of being gathered is sent to main control computer by video line;
Main control computer, it receives the shooting permission signal that welding robot sends, and controls monocular vision sensor-based system butt welded seam scene then and takes pictures, and captured photo is handled, and guides welding robot to arrive the weld seam starting point according to result.
2. the robot initial welding position recognition system based on the monocular vision sensing according to claim 1 is characterized in that, also comprises:
Secondary light source is fixedly mounted on the welding robot robot end joint.
3. the robot initial welding position recognition system based on the monocular vision sensing according to claim 1, it is characterized in that, described main control computer is provided with slot, described monocular vision sensor-based system comprises interconnective vision sensor, image pick-up card, and described vision sensor is the monocular vision sensor and is fixedly mounted on the welding robot human body.
4. the robot initial welding position recognition system based on the monocular vision sensing according to claim 3, it is characterized in that, described vision sensor comprises: ccd video camera, mirror system and sensor stand, described ccd video camera, mirror system all are fixed on the sensor stand, mirror system comprises first order reflection mirror and mirror support, the first order reflection mirror is arranged on the mirror support, first order reflection mirror and horizontal direction adjustable angle, the first order reflection mirror collects image and reflexes to ccd video camera.
5. the robot initial welding position recognition system based on the monocular vision sensing according to claim 1 is characterized in that described main control computer is provided with kernel control module, and this kernel control module comprises:
Image capture module is in order to gather near the picture signal the initial welding position of workpiece to be welded and it is carried out transfer of data;
Welding position is sought module, in order to seek the initial welding position and the calculation deviation amount of position deviation workpiece in picture signal;
Welding position correction module is in order to calculate workpiece horizontal coordinate correction according to this searching result and departure and to control robot and rectify a deviation.
6. the robot initial welding position recognition methods based on the monocular vision sensing is characterized in that, comprises the steps:
After step 1, welding robot move to the relevant position, send and take the permission signal to main control computer;
Step 2, visual sensing system are taken the scene that comprises the workpiece weld seam, and the image of being gathered is sent to main control computer by video line;
Step 3, main control computer receive the shooting permission signal that welding robot sends, then controlling monocular vision sensor-based system butt welded seam scene takes pictures, and captured photo handled, guide welding robot to arrive the weld seam starting point according to result.
7. the robot initial welding position recognition methods based on the monocular vision sensing according to claim 6 is characterized in that described step 3 specifically comprises the steps:
Image acquisition step is gathered near the picture signal of the initial welding position of workpiece to be welded and it is carried out transfer of data;
Welding position is sought step, seeks the initial welding position and the calculation deviation amount of position deviation workpiece in picture signal;
Welding position correction step calculates workpiece horizontal coordinate correction and controls robot and rectify a deviation according to this searching result and departure.
8. the robot initial welding position recognition methods based on the monocular vision sensing according to claim 7, it is characterized in that, described welding position is sought horizontal departure amount 1 and the horizontal departure amount 2 that step is sought the initial welding position of workpiece and calculated initial welding position according to preceding described picture signal, and described horizontal departure amount is meant the poor of initial welding position of current workpiece and the initial welding position horizontal level of standard.
9. the robot initial welding position recognition methods based on the monocular vision sensing according to claim 8 is characterized in that, the initial welding position of described standard be the intersection point of video camera photocentre and camera plane.
10. the robot initial welding position recognition methods based on the monocular vision sensing according to claim 8 is characterized in that, described welding position correction step is specially:
According to preceding described horizontal departure amount 1 and horizontal departure amount 2, calculate the horizontal coordinate correction 1 and the horizontal coordinate correction 2 of initial welding position, described horizontal coordinate correction is obtained through Coordinate Conversion by the horizontal departure amount, described Coordinate Conversion is to be determined by the relative position between described signal pattern coordinate system and the robot tool coordinate system and direction, and horizontal coordinate correction 1 and horizontal coordinate correction 2 are sent to robot rectifies a deviation.
11. the robot initial welding position recognition methods based on the monocular vision sensing according to claim 10 is characterized in that, the described relevant position of step 1 is the fixing position of workpiece height to be welded relatively.
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