CN103149134A - Welding dust monitoring method based on backlight image - Google Patents
Welding dust monitoring method based on backlight image Download PDFInfo
- Publication number
- CN103149134A CN103149134A CN2013100676255A CN201310067625A CN103149134A CN 103149134 A CN103149134 A CN 103149134A CN 2013100676255 A CN2013100676255 A CN 2013100676255A CN 201310067625 A CN201310067625 A CN 201310067625A CN 103149134 A CN103149134 A CN 103149134A
- Authority
- CN
- China
- Prior art keywords
- image
- gray
- light source
- electric arc
- monitoring method
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Granted
Links
Images
Landscapes
- Investigating Or Analysing Materials By Optical Means (AREA)
Abstract
The invention provides a welding dust monitoring method based on a backlight image. A lens set is used for focusing light generated by a background light source on the end part of a welding wire; a light filter is arranged at the opposite side of the background light source to filter electric arcs and strong light generated by the background light source; a clear electric arc smoke dust image is formed on the light filter; the electric arc smoke dust image is continuously shot to obtain continuous electric arc smoke dust pictures, the smoke dust pictures aretransmitted to a computer image processing unit; the upper part region and the side part region of the pictures are selected and a gray value of each pixel in the region is read; a average gray-value of the region is calculated; an instantaneous smoke dust gray value can be shot by subtracting a background gray value by the average gray-value; and a smoke dust concentration at a shooting moment can be obtained according to a pre-established relation curve of the smoke dust gray value and the smoke dust concentration.
Description
Technical field
The invention belongs to the weld fumes monitoring technical field, relate to and a kind of the volume of smoke that produces in arc welding is carried out the real-time concentration the method for monitoring.The present invention specifically obtains the soot image of arc welding by technique for taking backlight, utilize image analysis technology to carry out Real-Time Monitoring to the dust concentration that produces.
Background technology
No matter be welding rod or the solid welding wire of shielded welding and the flux-cored wire of covered arc welding, all can produce volume of smoke in its electric arc welding process, environment and human body are caused very big harm.Therefore, effectively monitoring its fume amount, is that arc welding is polluted the basis of implementing control.The main method of collecting weld fumes and weighing that still adopts is monitored weld fumes, to estimate its flue dust generation to the impact of environment but up to now.There are the shortcomings such as equipment volume is large, the dust deposition acquisition time is long in the method, and can only collect the flue dust total amount in certain weld interval, generation and the situation of change that can't reflect in real time flue dust in welding process are difficult to satisfy the demand to the quick Real-Time Monitoring of weld fumes.
Some researchers also attempt adopting laser scattering method to monitor the information of weld fumes, but this monitoring method mainly is applicable in air monitoring, pollute in the basicly stable situation of particle concentration in atmosphere.For the flue dust that produces in welding, it is in continuous change procedure, and the dust concentration apart from the electric arc diverse location is also different, and laser scattering method only can be measured the flue dust situation in laser beam scattering very among a small circle, is difficult to adopt this method that the flue dust total amount that produces is monitored.Simultaneously, the method is also higher to the installation accuracy requirement of pick-up unit, and the accuracy of measurement is affected by environment very large, is difficult to adapt to the actual industrial detection demand of weld fumes.
Along with the development of modern times welding manufacturing technology, the inevitable direction that becomes development for real time environment evaluation and the monitoring technology of weld fumes.Only have this omnidistance on-line monitoring technique, could carry out Real-Time Monitoring to the environmental pollution that causes due to reasons such as different lot numbers, storage environment, raw material sources, and then realize effective environmental impact assessment.
Summary of the invention
The purpose of this invention is to provide a kind of weld fumes monitoring method based on backlight image, so that the fume amount that produces in electric arc welding process is carried out Real-Time Monitoring.
Weld fumes monitoring method based on backlight image provided by the invention comprises:
1) background light source is set, the light that the scioptics group produces described background light source focuses on the welding wire end, produce the bias light overlapping with welding wire electric arc, and the light intensity of described bias light is greater than the light intensity of electric arc;
2) offside at background light source arranges optical filter, and the high light that produces to filter electric arc and background light source forms electric arc flue dust image clearly on optical filter;
3) described electric arc flue dust image is taken continuously, obtained continuous electric arc soot image;
4) by data transmission, soot image is transferred to the Computer Image Processing unit;
5) select the top of image and lateral region as the zone that obtains dust concentration, the Computer Image Processing unit reads the gray-scale value of each pixel in this zone, calculates this regional average gray;
6) with average gray subtracting background gray-scale value, obtain taking instantaneous flue dust gray-scale value, the flue dust gray-scale value of setting up in advance according to the Computer Image Processing unit and the relation curve of dust concentration can obtain taking instantaneous dust concentration.
Wherein, can adopt two kinds of methods to obtain described background gray levels.A kind of method is the gray-scale value gray-scale value as a setting in smoke dust zone in the electric arc soot image of taking; Another kind method is to only have background light source, taking when igniting electric arc without the electric arc image, with its gray-scale value gray-scale value as a setting.
At first the present invention is that a kind of technique for taking backlight of employing obtains the image about flue dust.
Owing to can producing very strong arc light in electric arc welding process, if directly take electric arc itself, can only see bright electric arc, and can't obtain the image about flue dust.Therefore, the present invention is at distance electric arc certain position place, place a light intensity greater than the background light source of arclight, as laser, xenon lamp, carbon arc lamp etc., the scioptics group is carried out optically focused, make the high light cover of its generation to electric arc, then the opposite side at background light source adopts optical filter to filter the high light of electric arc and background light source.At this moment, can stop the high light of background light source due to flue dust, will produce different light transmission capacities, the image of mating plate is after filtration taken, will obtain the image of flue dust.
During shooting, should regulate approximately 1～2 meter of the distance that makes background light source and welding wire end, and background light source, lens combination, end of welding must be deployed on the sustained height plane.Start background light source, the relative position of regulating lens combination focuses on, and makes the divergent shape pointolite scioptics group of background light source emission gather position, welding wire end, forms very strong bias light.
For guaranteeing that background light source can accurately focus on the end of welding wire, can also be provided with governor motion at the stiff end of welding wire, be used for auxiliary adjustment and carry out the focusing of background light source.
Security protection when taking considers, can also be between welding wire and lens combination, between welding wire and optical filter, protective shield be set, and logical light window is offered in position corresponding to welding wire end on protective shield, and on logical light window, logical light microscopic sheet is installed.Like this, a side protective plate can protect the arc heat radiation and splash to the damage of collector lens group, and the opposite side protective shield can protect the arc heat radiation and splash to the damage of camera system.
After obtaining the soot image of taking continuously, the present invention is by image analysis method, the zone of determining to obtain fume amount from the flue dust image.
The present invention observes by lot of experiments, and the flow feature of the flue dust that produces in electric arc welding process is analyzed, and finds that all flue dust that produce all can be under the effect of arc force and air-flow, to top and the lateral flow of welding arc.Therefore, as long as determine instantaneous fume amount through coboundary and lateral edges in the flue dust image, generation that just can the Real-Time Monitoring flue dust.Select coboundary and lateral edges as surveyed area, be that also this region distance arcing distance is far away, the flowing velocity of flue dust is basicly stable, is subjected to the impact of instantaneous blow force of arc less.Therefore, the present invention adopts the zone of imagery zone top and each 1mm * 1mm of side～2mm * 2mm as the zone that obtains fume amount.Selecting the zone of size like this, be in order to guarantee that flue dust is " process " surveyed area, rather than " stop " is in this zone, with the raising accuracy of detection.
At last, it is the calibration foundation that the present invention adopts background gray levels, determines the calibration rank of the fume amount of different gray scale flue dust impact, and the gray-scale value of image selection area digital image is added up.
The zone that the present invention will obtain fume amount is divided into again several zonules.According to Lambert-beer's law, there are following relational expression in the gradation of image that forms after the light transmission flue dust and its fume amount (concentration):
In formula, α is granule absorbance, and it is relevant with diameter, refractive index and the incident wavelength of particle; C is dust concentration; L is the distance that light passes through flue dust, I and I
0Be respectively by the light intensity after flue dust and original light intensity, its ratio is directly proportional to the gray scale of soot image.
When soot dust granule was more uniform and stable, α was constant, and L is usually fixing, so dust concentration C and I/I
0, namely the gray scale of soot image is relevant.
By detecting the gray-scale value of the regional flue dust of each junior unit, just can determine the concentration of flue dust, accumulation at last can obtain the flue dust total amount of a certain instantaneous generation.
According to filming frequency, after obtaining the fume amount size of a certain moment generation, then by the analysis to continuously shot images, just can obtain the weld fumes amount over time, realize the real-time quantitative of weld fumes is detected.
According to monitoring method provided by the invention, adopt continuous camera technique to obtain different instantaneous soot images, by analyzing every width image, can obtain different instantaneous flue dust generations.For example, adopting filming frequency is the consecutive image shooting of 1000 hardwood/seconds, will obtain the flue dust variable quantity of every 1ms.In addition, the filming frequency parameter preferably and the soot image analyzed area is big or small mates, and filming frequency is high, and the soot image analyzed area is just smaller, and vice versa.By parameter matching, can satisfy the requirement of different flue dust accuracy of detection and speed, realize that effectively weld fumes detects in real time.
Description of drawings
Fig. 1 is that the present invention carries out the structure drawing of device of shooting backlight to weld fumes.
In figure, the 1-background light source; The 2-lens combination; 3-electric arc; 4-welding wire end; The 5-weld fumes; The 6-optical filter; The 7-video camera; The 8-soot image.
Fig. 2 is the image at the weld fumes moving direction that does not photograph in the same time.
Fig. 3 is that the soot image surveyed area is chosen schematic diagram.
Fig. 4 is that certain model welding rod flue dust detects the multiple image of taking continuously.
Fig. 5 is certain model welding rod flue dust generation detection curve that surveillance map 4 images of the present invention obtain.
Fig. 6 is that certain model flux-cored wire flue dust detects photographic images.
Fig. 7 is certain model flux-cored wire flue dust generation detection curve that surveillance map 6 images of the present invention obtain.
Embodiment
As shown in Figure 1, in distance welding wire end 4 approximately 2 meters positions place an extremely strong background light source 1(laser, xenon lamp, carbon arc lamp etc.), one group of lens combination 2 is placed between background light source 1 and welding wire end 4, regulates that background light source 1, lens combination 2 and welding wire end 4 are placed on the sustained height plane.
Start background light source, the relative position of regulating lens combination focuses on, and by regulating, the divergent shape pointolite that makes background light source produce gathers position, welding wire end, forms very strong bias light.Finely tune by the governor motion of regulating the setting of welding wire stiff end at last, make the bias light focusing effect in the welding wire end.
Both sides in the welding wire end, between welding wire and lens combination, between welding wire and optical filter, protective shield is set respectively, two side protective plates are installed logical light microscopic sheet and are protected at the arc position windowing on window.
The electric arc 3 that ignites according to arc stiffness, selects suitable optical filter 6 to be arranged on the opposite side of background light source 1, to filter the high light of electric arc 3 and background light source 1.Weld fumes 5 can produce different light transmission capacities owing to stopping high light, at this moment will form the image of weld fumes on optical filter 6.According to brightness and the sharpness of image, adjust background light source intensity, until obtain to have the electric arc image of clear soot image.
After adjusting is completed, start video camera 7, obtain the electric arc soot image 8 under continuous bias light shooting.By data transmission, soot image is transmitted graphics processing unit into computing machine.
According to the observation, find that the arc welding flue dust can be under the effect of arc force and air-flow, to welding arc top and lateral flow (as Fig. 2).Therefore, the coboundary in selection soot image 8 and lateral edges are as the zone of monitoring flue dust generation.As shown in Figure 3, adopt grey scale change in the scope of imagery zone top and side each 1mm left and right to come the size of Real-Time Monitoring fume amount, the 1mm zone of coboundary and lateral edges is divided into again several zonules along its length.
After determining between detection zone, according to the image information of obtaining, the location positioning of pixel in image array corresponding to each junior unit in this is interval, utilize graphics processing unit to extract the corresponding gradation data of respective pixel point in data matrix, read the gray-scale value of subregion junior unit, be averaged and obtain average gray value.
Adopt the gray scale of smoke dust photographic images to be the calibration foundation, read the gradation data value of background image, with the gradation data value of average gray value subtracting background image, can obtain removing the instantaneous soot image instant cleaning liquid gray-scale value of shooting of background.
Utilize the gray-scale value of foundation in advance and the relation curve of dust concentration, the clean gray-scale value that adopts detection to obtain can calculate takes instantaneous dust concentration.
According to the soot image of continuous shooting, repeat above-mentioned steps, calculate continuously different instantaneous dust concentration delta datas.Determine with filming frequency the time interval that each instantaneous picture is corresponding, as the time abscissa axis, as axis of ordinates, draw out continuous dust concentration change curve with dust concentration with this, obtain the time dependent intuitive analysis result of dust concentration, realize the real-time quantitative of weld fumes is detected.
Application examples 1
Real-time detection to certain model welding rod flue dust generation
Adopt the present embodiment weld fumes monitoring method, at first the gray-scale value after selected background light source filters is gray-scale value as a setting, take continuously the electric arc of this welding rod, obtain several flue dust photos (Fig. 4) under backlight, obtain on this basis the gray-scale value of each flue dust district's monitoring in every photos, remove background gray levels, the monitoring smoke dust real-time change curve that obtains at last as shown in Figure 5.
Application examples 2
Real-time detection to certain model flux-cored wire flue dust generation
Monitoring smoke dust process to flux-cored wire is identical with application examples 1.Just when adopting shooting backlight, need to adjust backlight intensity and optical filtering degree according to actual conditions, obtain flue dust photo clearly.Fig. 6 is for taking continuously several flue dust photos that obtain lower this flux-cored wire backlight, and Fig. 7 is the real-time change curve of the monitoring smoke dust that obtains.
Claims (8)
1. weld fumes monitoring method based on backlight image comprises:
1) background light source is set, the light that the scioptics group produces described background light source focuses on the welding wire end, produce the bias light overlapping with welding wire electric arc, and the light intensity of described bias light is greater than the light intensity of electric arc;
2) offside at background light source arranges optical filter, and the high light that produces to filter electric arc and background light source forms electric arc flue dust image clearly on optical filter;
3) described electric arc flue dust image is taken continuously, obtained continuous electric arc soot image;
4) by data transmission, soot image is transferred to the Computer Image Processing unit;
5) select the top of image and lateral region as the zone that obtains dust concentration, the Computer Image Processing unit reads the gray-scale value of each pixel in this zone, calculates this regional average gray;
6) with average gray subtracting background gray-scale value, obtain taking instantaneous flue dust gray-scale value, the flue dust gray-scale value of setting up in advance according to the Computer Image Processing unit and the relation curve of dust concentration can obtain taking instantaneous dust concentration;
Wherein, described background gray levels is the gray-scale value in smoke dust zone in image, or takes the gray-scale value without the electric arc image.
2. monitoring method according to claim 1, is characterized in that described background light source is laser, xenon lamp or carbon arc lamp.
3. monitoring method according to claim 1, described background light source, lens combination, the end of welding section of it is characterized in that is positioned on the sustained height plane.
4. monitoring method according to claim 1, is characterized in that between described background light source and welding wire apart from 1～2 meter.
5. monitoring method according to claim 1 is characterized in that between welding wire and lens combination, be provided with protective shield between welding wire and optical filter, and described protective shield has logical light window at welding wire end correspondence position.
6. monitoring method according to claim 5, is characterized in that being equipped with on described logical light window logical light microscopic sheet.
7. monitoring method according to claim 1, is characterized in that being provided with at the stiff end of welding wire the governor motion that focuses on for the auxiliary adjustment background light source.
8. monitoring method according to claim 1, is characterized in that the dust concentration area size of obtaining of described selection is 1mm * 1mm～2mm * 2mm.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN201310067625.5A CN103149134B (en) | 2013-03-04 | 2013-03-04 | A kind of weld fumes monitoring method based on backlight image |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN201310067625.5A CN103149134B (en) | 2013-03-04 | 2013-03-04 | A kind of weld fumes monitoring method based on backlight image |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| CN103149134A true CN103149134A (en) | 2013-06-12 |
| CN103149134B CN103149134B (en) | 2016-02-17 |
Family
ID=48547339
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CN201310067625.5A Expired - Fee Related CN103149134B (en) | 2013-03-04 | 2013-03-04 | A kind of weld fumes monitoring method based on backlight image |
Country Status (1)
| Country | Link |
|---|---|
| CN (1) | CN103149134B (en) |
Cited By (5)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN104198695A (en) * | 2014-09-28 | 2014-12-10 | 杨伟群 | Method for analyzing developing result of colloidal gold test strip |
| CN110542657A (en) * | 2019-09-09 | 2019-12-06 | 新疆大学 | biomolecule concentration detection device and method |
| CN111398103A (en) * | 2020-03-31 | 2020-07-10 | 北京工业大学 | Method for measuring particles in light beam in laser welding based on sandwich model constrained plume |
| CN112730174A (en) * | 2020-12-17 | 2021-04-30 | 华南理工大学 | Method for monitoring concentration of spheroidal particles in crystallization process in real time |
| CN112924344A (en) * | 2021-01-22 | 2021-06-08 | 中煤科工集团重庆研究院有限公司 | Monitoring system and method for acquiring underground coal mine dust concentration based on image |
Citations (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US20030086084A1 (en) * | 2001-11-02 | 2003-05-08 | Graham Ross | Device and methods of inspecting soldered connections |
| CN1963663A (en) * | 2006-12-07 | 2007-05-16 | 上海交通大学 | Photography system for welding process of compound heat reservoir in carbon dioxide laser-melting argon-arc welding |
| EP2359980A2 (en) * | 2010-02-23 | 2011-08-24 | Robert Bosch GmbH | Laser beam welding device and method for testing same |
-
2013
- 2013-03-04 CN CN201310067625.5A patent/CN103149134B/en not_active Expired - Fee Related
Patent Citations (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US20030086084A1 (en) * | 2001-11-02 | 2003-05-08 | Graham Ross | Device and methods of inspecting soldered connections |
| CN1963663A (en) * | 2006-12-07 | 2007-05-16 | 上海交通大学 | Photography system for welding process of compound heat reservoir in carbon dioxide laser-melting argon-arc welding |
| EP2359980A2 (en) * | 2010-02-23 | 2011-08-24 | Robert Bosch GmbH | Laser beam welding device and method for testing same |
Non-Patent Citations (3)
| Title |
|---|
| 李俊岳等: "以激光为背光的高速摄影", 《天津大学学报》 * |
| 李桓等: "基于激光散射法的焊接烟尘粒径测量", 《电焊机》 * |
| 杨运强等: "焊接电弧高速摄影技术及其同步装置", 《电焊机》 * |
Cited By (5)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN104198695A (en) * | 2014-09-28 | 2014-12-10 | 杨伟群 | Method for analyzing developing result of colloidal gold test strip |
| CN110542657A (en) * | 2019-09-09 | 2019-12-06 | 新疆大学 | biomolecule concentration detection device and method |
| CN111398103A (en) * | 2020-03-31 | 2020-07-10 | 北京工业大学 | Method for measuring particles in light beam in laser welding based on sandwich model constrained plume |
| CN112730174A (en) * | 2020-12-17 | 2021-04-30 | 华南理工大学 | Method for monitoring concentration of spheroidal particles in crystallization process in real time |
| CN112924344A (en) * | 2021-01-22 | 2021-06-08 | 中煤科工集团重庆研究院有限公司 | Monitoring system and method for acquiring underground coal mine dust concentration based on image |
Also Published As
| Publication number | Publication date |
|---|---|
| CN103149134B (en) | 2016-02-17 |
Similar Documents
| Publication | Publication Date | Title |
|---|---|---|
| CN103149134B (en) | A kind of weld fumes monitoring method based on backlight image | |
| JP4706978B2 (en) | Fluid measurement system and computer program | |
| CN104374677B (en) | Measuring device and method for dust concentration | |
| WO2021132017A1 (en) | Particle measurement device | |
| CN102937583B (en) | Pearl smooth-finish online automatic grading device based on monocular multi-view machine vision | |
| CN102601131B (en) | A kind of billet surface quality on-line detecting device | |
| CN103424406A (en) | Image method measuring device and method for gas-liquid two-phase flow in pipelines | |
| CN113313713B (en) | Method and system for online detection of burrs of lithium battery pole piece | |
| CN106645197A (en) | Online detection system for detecting particles on surface of precise optical element and application method | |
| WO2010085655A2 (en) | Cytometer with automatic continuous alignment correction | |
| CN102455171A (en) | Method for detecting geometric shape of back of tailor-welding weld and implementing device thereof | |
| JP2013029496A (en) | Device evaluating depth of element in three-dimensional scene | |
| CN103997610A (en) | Night-vision camera device and focusing method thereof | |
| CN106568577A (en) | Optical athermalization design detection system and detection method | |
| CN102353518A (en) | Device and method for detecting quality of lattice point of printed light guide plate | |
| CN203011419U (en) | An optical axis parallelism digital calibration instrument for multiple optical sensors | |
| CN105606628A (en) | Optical lens detecting system and method | |
| Neubecker et al. | Automatic inspection for surface imperfections: requirements, potentials and limits | |
| CN202256106U (en) | Anti-interference imaging acquisition system for aggregate grading on-site test | |
| CN110389090B (en) | Large-aperture reflector surface particle pollutant sub-pixel size calibration method | |
| CN116990303A (en) | Pole piece edge defect detection device and pole piece edge defect detection method | |
| CN203405417U (en) | Device for measuring gas-liquid two-phase flow in pipeline through image method | |
| CN110389088B (en) | On-line monitoring method for particle pollutants on surface of large-diameter reflector | |
| GB2390674A (en) | Imaging flame monitor for measuring multiple characteristic parameters | |
| CN201957149U (en) | Image acquisition device for mineral mixture |
Legal Events
| Date | Code | Title | Description |
|---|---|---|---|
| C06 | Publication | ||
| PB01 | Publication | ||
| C10 | Entry into substantive examination | ||
| SE01 | Entry into force of request for substantive examination | ||
| C14 | Grant of patent or utility model | ||
| GR01 | Patent grant | ||
| CF01 | Termination of patent right due to non-payment of annual fee |
Granted publication date: 20160217 |
|
| CF01 | Termination of patent right due to non-payment of annual fee |