CN103273171A - Visual tracking monitoring system and method in automatic corrugated thin plate fillet weld welding - Google Patents
Visual tracking monitoring system and method in automatic corrugated thin plate fillet weld welding Download PDFInfo
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Abstract
The invention discloses a visual tracking monitoring system and method in automatic corrugated thin plate fillet weld welding. The visual tracking monitoring system and method in the automatic corrugated thin plate fillet weld welding comprises a welding gun, a system installing frame, a welding technological parameter adjuster, a vision device I, a vision device II, an image data processor, a welding gun drive device, a tracking drive device and a controller. The vision device I and the vision device II are respectively connected with the image data processor; the image data processor is respectively connected with the controller and the welding technological parameter adjuster; the controller is respectively connected with the welding gun drive device and the tracking drive device. According to the visual tracking monitoring system and method in the automatic corrugated thin plate fillet weld welding, binocular vision devices are adopted, the front vision device II is used for leading the movement of the welding gun, the direct-sight vision device I monitors a weld pool and welding joints before the weld pool and conducts adjustment on welding gun track deviation caused by factors such as thermal welding deformation and welding wire bending.
Description
Technical field
The present invention relates to the welding of sidewall corrugated plating, relate in particular to vision tracking and monitoring system and method in the automatic welding of corrugated sheet angle welding.
Background technology
In actual welding is produced, because there is the abnormal error of blanking processing and assembling in workpiece to be welded, can produce workpiece thermal deformation, wire bending and welding arc blow, welding mechanism movement warp etc. in the welding process and be difficult to the expectation problem in advance, may cause slit to be welded width to differ and cause that welding gun departs from the weld seam center for the treatment of, so desirable automatic welding process should remain weld seam crack track and the wide automatic tracking, monitoring of seam, dynamically in good time adjusts welding gun movement locus and welding condition accordingly.
The existing automatic recognition and tracking method of weld seam according to various principles adopts corresponding sensor to realize, as direct copy, arc sensor, laser sensor, ultrasonic sensor etc. both at home and abroad.These sensors are applied in some automatic welding jigs, and its characteristics and applicable situation respectively have difference.Because fit-up gap track and the gap length of weldment are irregular, some method was difficult to use during corrugated sheet angle weldings such as container were welded automatically, though the method that has has the effect of application not satisfactory.For example existing enterprise adopts the method for laser ranging to carry out weld joint tracking, by rangefinder according to be incident upon treat the weld seam dead ahead or directly over laser point draw two-dimensional coordinate, with the approximate assembling slit track (so precision is not high) that replaces of this track of putting, guide welding gun to move accordingly.Because the welding arc light has serious interference to laser, so laser can only be at the projection at a distance of distance welding zone (measuring point be apart from about half meter far away of welding gun), there is leading error in current relatively the putting at welding position of this measuring point, welding gun still may be offset in the welding process in this scope, so still need manually to carry out the welding torch position adjustment.The patent " based on the container corrugated plate welding track monitoring device of laser ranging " of the applications such as Tian Xincheng of the existing Shandong University of this method, " based on container corrugated plate welding track monitoring and the control system of laser ranging ".
In recent years, step into commercial Application gradually based on the recognition and tracking technology of vision sensor, wherein the most extensive employing be to obtain laser point or line is being treated the welding zone projected image and extracted its characteristic point and the method for indirect identification weld seam.Because of welding arc light serious interference, so laser can only be in the projection at a distance of distance welding zone, the method is not good for applications such as narrow groove or square groove weld seam, complicated position weld seams, and has leading error.Another kind method is to obtain the welding zone image, therefrom the Direct Recognition weld seam.The problem that this method exists is that the dynamic light intensity of this district's arc light is extremely strong, and the general industry camera is difficult to this district's direct imaging in addition, because the visual field is confined in the welding zone territory, can not be predicted by the butt welded seam track, thereby can not be planned the welding gun path.
The corrugated plating angle welding particularly side plate angle welding monitoring tracking of container is the difficult problem that enterprise uses automatic welding jig always; workpiece to be welded thin (1.6mm); weld seam long (tens meters); the fit-up gap changes greatly (0～6mm); speed of welding fast (1.5m/min); there is protective gas to fill the air; the weld seam complications; thermal deformation causes the fit-up gap that uncertain skew takes place in the welding process; there is hard arc in the welding process; interference such as the welding slag that splashes; particularly utilize vision sensor need big working substance apart from and space after the angle welding assembling is narrow and small, these complex environments make the especially suitable difficulty of corrugated plating curvilinear angle weld joint tracking monitoring of angle welding.
Summary of the invention
Shortcoming and deficiency that the present invention exists in order to overcome prior art provide vision tracking and monitoring system and method in the automatic welding of a kind of corrugated sheet angle welding.The present invention is mainly used in container, passenger train, subway and light rail with the welding of sidewall corrugated platings such as passenger vehicle.
The present invention adopts following technical scheme:
Vision tracking and monitoring system during a kind of corrugated sheet angle welding is welded automatically comprises welding gun, also comprises system's installing rack, welding condition adjuster, and
Be used for obtaining the sighting device I of molten bath and slit, bonding pad image thereof;
Be used for obtaining the preposition sighting device II for the treatment of welding zone assembling seam image;
For the treatment of the preposition welding assembling seam centrode for the treatment of welding zone and stitch wide, coupled district, center, molten bath slit center offset and welding when the wide image data processor of proparea seam;
Be used for drive welding gun and sighting device I and carry out the welding gun drive unit of Y-direction motion;
The tracking drive unit that be used for driving the sighting device II, the welding gun drive unit carries out Z-direction motion and Y-direction motion;
Be used for control welding gun drive unit, follow the tracks of the controller that drive unit moves;
Described system installing rack comprises guide rail, chute and chute driver, orthogonal L shaped installing rack and perpendicular shape installing rack, and described perpendicular shape installing rack is installed on the guide rail by chute and chute driver;
Described welding gun is installed on the welding gun drive unit;
Described sighting device II is installed in the right-hand member of crossbearer in the L shaped installing rack;
Described sighting device I is fixed on the welding gun drive unit, and servo-actuated with welding gun;
Described tracking drive unit is installed on the perpendicular shape installing rack, and described sighting device II, welding gun drive unit are fixed with following the tracks of drive unit by the perpendicular frame in the L shaped installing rack, and carries out Z-direction, Y-direction motion simultaneously with the tracking drive unit;
Described sighting device I, sighting device II are connected with image data processor respectively, and described image data processor is connected with the welding condition adjuster with controller respectively, and described controller is connected with welding gun drive unit, tracking drive unit respectively;
Being directions X with the welding bench length direction, is the Z direction perpendicular to the direction on welding bench plane, with face XZ vertical direction be Y-direction.
The center, visual field of described sighting device I, sighting device II differs a ripple cycle.
Described sighting device I comprises dimmer arrangement, filtering apparatus, secondary light source and industrial camera I successively, and described secondary light source links to each other in X-direction with the molten bath at the projection hot spot of base plate.
Described sighting device II comprises industrial camera II and laser line generator, described laser line generator is positioned at the right side of industrial camera II, the projection line of described laser line generator on base plate is parallel with Y-axis, and be arranged in the visual field of industrial camera II, described laser line generator at the projection oblique line on the corrugated plating also in the visual field of industrial camera II.
Described guide rail is placed along directions X.
Described tracking drive unit comprises Y-direction drive unit and Z-direction drive unit.
Described Y-direction drive unit is by guide rail, the Y-direction driver, and the guide rail platform constitutes.
Described Z-direction drive unit is by guide rail, the Z-direction driver, and the guide rail platform constitutes.
Vision tracking and monitoring method during a kind of corrugated sheet angle welding is welded automatically comprises the steps:
(1) stitches before the weldering, follow the tracks of drive unit and the welding gun drive unit resets, welding gun is got back to work coordinate system XYZ initial point;
(2) the sighting device II is by the drive of chute and chute driver, move along the guide rail directions X, after the assembling slit between corrugated plating and the base plate enters into the visual field of industrial camera II, the industrial camera II is obtained laser line generator emission laser rays at the projection line image of corrugated plating and base plate, and sends image data processor to;
(3) image data processor calculates the place ahead assembling to be welded slit track and assembling gap width according to the projection line image, and gap width to be assembled is sent to the welding condition adjuster, and assembling to be welded slit track sends to controller;
(4) the welding condition adjuster is planned corresponding parameter to be welded according to seam width to be assembled;
(5) controller is followed the tracks of the Y-direction motion of Y-direction drive unit realization welding gun, sighting device I, sighting device II in the drive unit according to assembling to be welded slit TRAJECTORY CONTROL, the Z direction motion of Z-direction drive unit realization welding gun, sighting device I, sighting device II in the drive unit is followed the tracks of in control, and welding gun is moved along seam track;
(6) after the assembling slit between corrugated plating and the base plate and molten bath enter into sighting device I visual field, the sighting device I is obtained the image of molten bath, secondary light source hot spot and interior ripple side plate lower edge and plate upper surface profile, and sending to image data processor, image data processor obtains welding when the wide and center line left side, the relative slit of the molten bath central point A terminal B side-play amount of proparea seam according to image; And the wide welding condition adjuster that sends to of the seam that will work as the proparea, the relative B point of A point side-play amount is sent to controller;
(7) controller is according to the adjustment amount of step (6), and control welding gun drive unit realizes that the Y-direction of welding gun, sighting device I moves, and realizes fine setting, and the welding condition adjuster is adjusted current welding condition according to wide when weld zone, proparea seam simultaneously.
Welding condition comprises electric current, voltage, wire feed rate and speed of welding in the described step (7).
Three-dimensional track and seam that the present invention online real-time continuous extraction the place ahead assembling broken line to be welded stitches are wide, give controller and welding condition adjuster with the corresponding data real-time Transmission, slightly plan for realization welding gun path and welding condition; Online real-time continuous is extracted the wide and seam relative molten bath side-play amount of current welding zone seam, obtain position adjustment amount and the welding condition adjustment amount of welding gun, give controller and welding condition adjuster with the corresponding data real-time Transmission, be used for realizing that the welding gun track is finely tuned in real time and welding condition is adjusted in real time.
Beneficial effect of the present invention:
(1) efficient height of the present invention, welding quality is good, the present invention adopts the vision system of forward type to seek the welding starting point automatically and is identifying the dog-leg path tracking of assembling to be welded slit, the place ahead and gap width in the weldering automatically, the guiding welding gun moves and is scheduled to welding condition, the monitoring of recycling direct-viewing type vision system, the sweating heat distortion, the weld width variation that wire bending etc. cause and the side-play amount of molten bath phase butt welded seam, the guiding welding gun carries out positional deviation correction and adjusts welding condition in real time, the weld seam dog-leg path that elimination or minimizing corrugated sheet angle welding are welded in the particularly automatic welding of MAG automatically distinguishes inaccurate, weldering pre-structure form error and rigging error, the caused weldquality problems of reason such as sweating heat distortion, realize intelligent-tracking monitoring and self adaptation feedback in the corrugated sheet broken line angle welding automation welding, before avoiding or reducing weldering, in the weldering, the postwelding personal monitoring, monitoring, fine setting, the repair welding workload improves welding quality and efficient;
(2) operation mechanism of flexibility, adaptability is good, and the present invention has designed three controlled motions of monitoring device and welding gun according to the tortuous weld seam of corrugated plating and fillet welding position feature, can monitor each position of weld seam; (3) versatility is good, can realize weld seam recognition and the tracking of the weldment of slab, thin plate and various grooves, weld seam recognition of the present invention and tracking system are treated the specific limited that welding work pieces does not have material, shape, size, identification and the tracking of ripple weld seam and angle welding both can be used for, also can be used for automatic identification and the tracking of straight weld, treat the weldment thickness of slab and reach whether bevel does not all have restriction;
(4) the intelligent degree of the present invention is higher, does not need manually to reach zero in welding process to adopt complicated anchor clamps auxiliary, and only the weldment for the treatment of that need assemble moves to position to be welded at production line, just can realize automatic welding;
(5) simple to operate, the automaticity height, it is low, nuisanceless to measure cost, and the hardware and software of weld seam recognition of the present invention and tracking system is all quite simple, low cost of manufacture; Different workpiece to be welded only need be positioned at the effective moving range of platform and effective identification range just can be identified and be followed the tracks of fast, realize welding automatically; Operation can realize the automation of higher degree easily; Need not to consume intermediate medium in the use, measure with low cost; Alleviate greatly that arc light, flue dust, gas etc. improve the welding work condition to the injury of human body in the welding production process.
Description of drawings
Fig. 1 is structural representation of the present invention;
Fig. 2 is that A among Fig. 1, B two parts are installed the coordinate graph of a relation, and (a) front view (b) is vertical view, (c) is side view;
Fig. 3 is the structure chart of system's installing rack among Fig. 1;
Fig. 4 is workflow diagram of the present invention;
Fig. 5 (a) is image graph in the RST coordinate system among Fig. 2, (b) is image graph in the R ' S ' T ' coordinate system among Fig. 2;
Fig. 6 (a) is theoretical and practical set seam coincidence pattern, and (b) be theoretical and practical set is stitched the figure that does not overlap, and (c) is that wide and center position figure is stitched in assembling.
Shown in the figure:
The 1-image data processor, 2-welding bench, 3-corrugated plating, the 4-dimmer arrangement, 5-filtering apparatus, 6-secondary light source, 7-industrial camera I, 8-chute and chute driver, 9-system installing rack, 10-industrial camera II, 11-laser line generator, 12-guide rail, the 13-controller, 14-welding condition adjuster, 15-molten bath, 16-secondary light source hot spot, 17-welding gun, 18-welding gun drive unit, 19-Y is to drive unit, and 20-Z is to drive unit, and the 21-line laser is at ripple side plate projection line, the 22-line laser is at the base plate projection line, the 23-base plate, the theoretical weld seam of 24-, 25-sighting device I, 26-sighting device II, 27-follows the tracks of drive unit.
The specific embodiment
Below in conjunction with embodiment and accompanying drawing, the present invention is described in further detail, but embodiments of the present invention are not limited thereto.
Embodiment
The work coordinate system XYZ of welding gun in the present embodiment, be directions X with welding bench 2 length directions, direction perpendicular to the welding bench plane is the Z direction, with face XZ vertical direction be Y-direction, initial point is summit, the welding bench lower left corner, and described welding gun moves from left to right, and described XOY plane overlaps on the surface in theory with base plate 23 to be welded, industrial camera I coordinate system RST, initial point O
1, the coordinate of described industrial camera II 10 is UVW, initial point O
2, above-mentioned three coordinate systems can be changed mutually.
As shown in Figure 1, vision tracking and monitoring system during a kind of corrugated sheet angle welding is welded automatically, comprise welding gun 17, also comprise system's installing rack 9, welding condition adjuster 14, sighting device I 25, sighting device II 26, image data processor 1, welding gun drive unit 18, tracking drive unit 27, controller 13;
As shown in Figure 3, described system installing rack 9 comprises guide rail 12, chute and chute driver 8 and orthogonal L shaped installing rack and perpendicular shape installing rack, and described perpendicular shape installing rack is installed on the guide rail 12 by chute and chute driver 8;
Described welding gun 17 is installed on the welding gun drive unit 18;
Described sighting device II 26 is installed in the right-hand member of crossbearer in the L shaped installing rack;
Described sighting device I 25 is fixed on the welding gun drive unit 18, and servo-actuated with welding gun 17;
Described tracking drive unit 27 is installed in and erects on the shape installing rack, and described sighting device II 26, welding gun drive unit 18 are fixed with following the tracks of drive unit 27 by the perpendicular frame in the L shaped installing rack, and carries out Z-direction, Y-direction motion simultaneously with tracking drive unit 27;
Described sighting device I 25, sighting device II 26 are connected with image data processor 1 respectively, described image data processor 1 is connected with welding condition adjuster 14 with controller 13 respectively, and described controller 13 is connected with welding gun drive unit 18, tracking drive unit 27 respectively; Described guide rail 12 is placed along directions X, realizes that welding gun 17, sighting device I 25, welding gun drive unit 18 move by the directions X of chute 8 along guide rail 12.
Described tracking drive unit comprises Y-direction drive unit 19 and Z-direction drive unit 20.
Y-direction drive unit 19 is by guide rail, the Y-direction driver, and the guide rail platform constitutes, and Z-direction drive unit 20 is by guide rail, the Z-direction driver, the guide rail platform constitutes.
Being directions X with the welding bench length direction, is the Z direction perpendicular to the direction on welding bench plane, with face XZ vertical direction be Y-direction.
The center, visual field of described sighting device I 25, sighting device II 26 differs a ripple cycle.
Described sighting device I 25 comprises dimmer arrangement 4, filtering apparatus 5, secondary light source 6 and industrial camera I successively.Described dimmer arrangement 4, filtering apparatus 5 are installed in before the industrial camera I camera lens, and industrial camera I, secondary light source 6 all are θ with the Z axle in the YZ parallel surface
1Angle lapping is tiltedly installed, secondary light source 6 is between welding gun 17 and industrial camera I 7, secondary light source 6 is according to the place ahead of 15 to the molten bath, its hot spot 16 and molten bath 15 that is incident upon on the base plate 23 links to each other in X-direction, comprise local ripple side plate lower edge and plate upper surface (being the slit between the two) in the hot spot 16, set up industrial camera I image coordinate system RST, the initial point O of described coordinate system RST
1Be the imaging surface center of industrial camera I, the T axle is the optical axis of industrial camera I, and the T axle is a smaller θ with the Z axle in the XZ plane
2Angle lapping is oblique, blocks the hot spot imaging to avoid welding gun 17 and secondary light source 6.Shown in Fig. 2 (a) and (b), (c), the RST coordinate system is rotated counterclockwise θ around the S axle
2Angular transformation is coordinate system R ' S ' T ', and described R ' S ' T ' coordinate system can be changed mutually with XYZ coordinate system, and R ' is parallel with X, and S ', T ' are rotated counterclockwise θ around R '
1Parallel with Y, Z respectively behind the angle.
Assembling slit between corrugated plating 3 and base plate 23 enters into the visual field, welding gun 17 begins welding, the industrial camera I is obtained molten bath, secondary light source hot spot 16 and is positioned at the image that wherein assembles the slit, shown in Fig. 5 (a) and (b), by image data processor 1 image in this RS plane is made θ
2Angle lapping tiltedly is corrected in the R'S' plane, identification molten bath 15 patterns and extract its central point A and proparea, molten bath hot spot in the sideline, slit, calculate image slot width δ
1And width center line; Definition B is the point in close molten bath on the center line, extracts B dot image coordinate, can calculate R', the S' of 2 of A, B to image coordinate difference DELTA r' and Δ s', according to the picture system parameter of prior demarcation, by δ
1Calculate the wide L of actual seam
1, by Δ r' and calibrating parameters calculate its Δ x
1To value (center, molten bath A be about to be soldered to a B in the distance of directions X), being converted to Y, Z axial projection and calibrating parameters by Δ s' obtains center, molten bath A and the Y, the Z-direction offset y that are about to be soldered to slit central point B
1, Δ z
1Stitch wide and offset data and send welding condition modulator 14, controller 13 respectively to, be used for the bias of welding condition and welding gun phase butt welded seam is adjusted.
Described sighting device II 26 comprises industrial camera II 10 and laser line generator 11, and described laser line generator 11 is positioned at the right side of industrial camera II, and described right side is the X-axis positive direction, and industrial camera II10, laser line generator 11 all are θ with the Z axle in the YZ parallel surface
1Angle lapping is tiltedly installed, and also to be the θ angle lapping oblique with the Z axle in the XZ plane for laser line generator 11, so that laser line generator 11 is at the projection line 22 of base plate 23 upper surfaces and can be in the visual field of industrial camera II at the projection oblique line 21 on the ripple side plate 3.
Set up industrial camera II image coordinate system UVW, the initial point O of described coordinate system UVW
2Be the imaging surface center of industrial camera II, the W axle is the optical axis of industrial camera II, and shown in Fig. 2 (a) and (b), (c), the W axle is θ with the Z axle in the YZ plane
1Angle lapping is oblique.U is parallel with X, and V, W are rotated counterclockwise θ around U
1Parallel with Y, Z respectively behind the angle.
The projection line of laser rays on ripple side plate 3 and base plate 23 of laser line generator 11 emissions obtained by the industrial camera II.If contact with base plate 23 on the base of the position ripple side plate 3 that laser rays shines, then line laser is crossing at two plate contact points at the projection line 21 on the corrugated plating and the projection line 22 of line laser on base plate, intersection point M(N) namely assemble the point of sewing on, its image coordinate value u
MTo X-axis conversion, v
MNamely obtain this X that treats solder joint, Y, Z-direction coordinate figure x to Y, the conversion of Z axial projection and consideration picture system calibrating parameters
M, y
M, z
M, send controller to and be used for planning welding gun path; If base or base plate 23 at this position corrugated plating 3 do not contact because of distortion.Then have a gap width, the laser side is thrown the end points N that the end points M of line 21 and the end throws line 22 and is not directly intersected, and handles the image coordinate (u of ordering according to M and N in the UV plane of delineation through image
M, v
M) and (u
N, v
N) calculating image coordinate difference DELTA u and Δ v at 2, Δ v is the picture traverse δ in slit herein at the component of theory assembling suture normal direction
2, according to each coordinate system relation among the picture system parameter of prior demarcation and Fig. 2, by δ
2Calculate the wide L of actual seam
2, get δ
2Mid point C is by its image coordinate value (u
C, v
C) convert and consideration picture system calibrating parameters to XYZ coordinate system, namely obtain X, Y, Z-direction coordinate figure x that C is ordered
C, y
C, z
C, send data to controller 13 and welding condition adjuster 14, be used for path and technological parameter and slightly plan.Because sighting device II phase Butt welding gun 17 has big lead, the Monitoring Data of above-mentioned assembling seam position and width is the predicted value of a period of time before welding gun 17 does not also reach, when welding gun 17 is gone to this future position from current location, also the weld seam error that thermal deformation, arc blow etc. cause may take place, therefore need to monitor and guide fine setting with the sighting device I.。
Vision tracking and monitoring method during a kind of corrugated sheet angle welding is welded automatically as shown in Figure 4 comprises the steps:
(1) weld before, controller sends instruction, sighting device I, sighting device II, welding gun drive unit 18, follow the tracks of drive unit 27 and reset at directions X along guide rail with system's installing rack 9, sighting device I, sighting device II, welding gun 17 are realized resetting of Y-direction, Z direction by following the tracks of drive unit 27, sighting device I and welding gun 17 are replied the Y-direction initial position at welding gun drive unit 18, and namely welding gun is positioned at coordinate system XYZ initial point; Then, with expecting welding bench on corrugated plating 3 to be welded and the base plate 23, compress with anchor clamps and carry out coarse positioning spot welding, so far finish the weld seam assembling.
(2) system's installing rack is under the drive of chute and chute driver 8, move along the guide rail directions X, after the assembling slit between corrugated plating 3 and the base plate 23 enters into the visual field of industrial camera II, the industrial camera II is obtained laser line generator emission laser rays at the projection line image of corrugated plating 3 and base plate 23, and sends image data processor to.Shown in Fig. 6 (a) and (b), (c), if the edge of corrugated plating and base plate applying herein, then laser side throwing line 21 intersects intersection point M(N with end throwing line 22) namely assemble the point of sewing on, be positioned on the theoretical weld seam 24; If edge and the base plate of corrugated plating do not fit herein, then there is a gap width, it is directly crossing that the laser side is thrown the end points N that the end points M of line 21 and the end throws line 22, the image coordinate (u of ordering according to M and N in the UV plane
M, v
M) and (u
N, v
N), simply with the image coordinate value (u of these 2 line mid points as seam wide mid point C, its C
C, v
C) suc as formula 1-1
Image coordinate (the u of ordering according to M and N
M, v
M) and (u
N, v
N) calculating image coordinate difference DELTA u and Δ v at 2, Δ v is the picture traverse δ in slit herein at the component of theory assembling suture normal direction
2, according to according to the UVW picture system calibrating parameters of demarcating in advance (mm/ pixel), calculate the wide L of actual seam
2Suc as formula 1-2
L
2=δ
2* calibration coefficient,
α is ripple weld seam broken line and X-axis angle among the formula 1-2
According to the spatial relation between image coordinate system UVW and the work coordinate system XYZ, can stitch wide mid point C in coordinate system XYZ spatial location suc as formula 1-3
The three-dimensional coordinate of seam track C is transferred to controller 13, assembling gap width L
2Be transferred to welding condition adjuster 14.Controller 13 sends instruction, follows the tracks of drive unit 27 and drives welding gun 17 by the Y-direction drive unit and realize that Y-directions move, and drives welding gun 17 by Z direction drive unit and realizes that the Z directions move, thereby welding gun 17 is moved along seam track; Welding condition adjuster 14 is according to the wide L of seam
2Planning welding condition (welding current, voltage etc.).
(3) the assembling slit between corrugated plating and base plate and molten bath enter into sighting device I, industrial camera I is by dimmer arrangement, filtering apparatus, obtain molten bath 15 and secondary light source hot spot 16 and sideline, interior slit image thereof, by image data processor, image in this RS plane is made θ
2Angle lapping tiltedly is corrected in the R'S' plane, extracts the coordinate figure A'(r' of molten bath 15 central point A
A, s'
A) and proparea, molten bath hot spot in the sideline, slit, obtain gap width L by image data processor
1With the gap width center line, according to each coordinate system relation among the picture system parameter of prior demarcation and Fig. 2 (a) and (b), (c), by δ
1Calculate the wide L of actual seam when the proparea
1Suc as formula 1-4
L
1=δ
1* calibrating parameters 1-4
Definition B extracts B dot image coordinate B'(r for the point in close molten bath on the wide center line of seam
B', s'
B), R', the S' that can calculate 2 of A, B namely obtain 2 distances at directions X of A, B to image coordinate difference DELTA r' and Δ s'(Δ r'* calibration coefficient), obtain Y, the Z-direction offset y that molten bath central point A is about to be soldered to slit central point B relatively by Δ s' to Y, the conversion of Z axial projection
1, Δ z
1Suc as formula 1-5
Stitch wide and offset data and send welding condition modulator 14, controller 13 respectively to, be used for the bias of welding condition and welding gun phase butt welded seam is adjusted, adapting to actual gap width changes and the broken line break-in, obtain the continuous whole weld seam, eliminate or minimizing postwelding manual amendment workload.
Above-described embodiment is preferred implementation of the present invention; but embodiments of the present invention are not limited by the examples; other any do not deviate from change, the modification done under spiritual essence of the present invention and the principle, substitutes, combination, simplify; all should be the substitute mode of equivalence, be included within protection scope of the present invention.
Claims (8)
1. the vision tracking and monitoring system during a corrugated sheet angle welding is welded automatically comprises welding gun, it is characterized in that, also comprises system's installing rack, welding condition adjuster, and
Be used for obtaining the sighting device I of molten bath and slit, bonding pad image thereof;
Be used for obtaining the sighting device II of prefix area assembling seam image;
Be used for to obtain to treat the welding assembling slit centrode of welding zone and stitch wide, center, molten bath and coupled weld seam center offset and weld seam when the wide image data processor of seam in proparea;
Be used for drive welding gun and sighting device I and carry out the welding gun drive unit of Y-direction motion;
The tracking drive unit that be used for driving the sighting device II, the welding gun drive unit carries out Z-direction motion and Y-direction motion;
Be used for control welding gun drive unit, follow the tracks of the controller that drive unit moves;
Described system installing rack comprises guide rail, chute and chute driver, orthogonal L shaped installing rack and perpendicular shape installing rack, and described perpendicular shape installing rack is installed on the guide rail by chute;
Described welding gun is installed on the welding gun drive unit;
Described sighting device II is installed in the right-hand member of crossbearer in the L shaped installing rack;
Described sighting device I is fixed on the welding gun drive unit, and servo-actuated with welding gun;
Described tracking drive unit is installed on the perpendicular shape installing rack, and described sighting device II, welding gun drive unit are fixed with following the tracks of drive unit by the perpendicular frame in the L shaped installing rack, and carries out Z-direction, Y-direction motion simultaneously with the tracking drive unit;
Described sighting device I, sighting device II are connected with image data processor respectively, and described image data processor is connected with the welding condition adjuster with controller respectively, and described controller is connected with welding gun drive unit, tracking drive unit respectively;
Being directions X with the welding bench length direction, is the Z direction perpendicular to the direction on welding bench plane, with face XZ vertical direction be Y-direction.
2. the vision tracking and monitoring system during corrugated sheet angle welding according to claim 1 is welded automatically is characterized in that the center, visual field of described sighting device I, sighting device II differs a ripple cycle.
3. the vision tracking and monitoring system during corrugated sheet angle welding according to claim 2 is welded automatically, it is characterized in that, described sighting device I comprises dimmer arrangement, filtering apparatus, secondary light source and industrial camera I successively, and described secondary light source links to each other in X-direction with the molten bath at the projection hot spot of base plate.
4. the vision tracking and monitoring system during corrugated sheet angle welding according to claim 2 is welded automatically, it is characterized in that, described sighting device II comprises industrial camera II and laser line generator, described laser line generator is positioned at the right side of industrial camera II, the projection line of described laser line generator on base plate is parallel with Y-axis, and be arranged in the visual field of industrial camera II, described laser line generator at the projection oblique line of corrugated plating in the visual field of industrial camera II.
5. the vision tracking and monitoring system during corrugated sheet angle welding according to claim 1 is welded automatically is characterized in that described guide rail is placed along directions X.
6. the vision tracking and monitoring system during corrugated sheet angle welding according to claim 1 is welded automatically is characterized in that described tracking drive unit comprises Y-direction drive unit and Z-direction drive unit.
7. application rights requires the monitoring method of the vision tracking and monitoring system in the automatic welding of one of 1-6 described corrugated sheet angle welding, it is characterized in that, comprises the steps:
(1) carry out before the weld seam, welding gun drive unit, tracking drive unit reset, welding gun is got back to work coordinate system XYZ initial point;
(2) the sighting device II is under the drive of chute and chute driver, move along the guide rail directions X, after the assembling slit between corrugated plating and the base plate enters into the visual field of industrial camera II, the industrial camera II is obtained laser line generator emission laser rays at the projection line image of corrugated plating and base plate, and sends image data processor to;
(3) image data processor is according to the projection line image, and it is wide to calculate the place ahead assembling seam track to be welded and assembling seam, and with the wide welding condition adjuster that sends to of seam to be assembled, assembling seam track to be welded sends to controller;
(4) the welding condition adjuster is wide according to seam to be assembled, plans corresponding parameter to be welded;
(5) controller is followed the tracks of the Y-direction motion of Y-direction drive unit realization welding gun, sighting device I, sighting device II in the drive unit according to assembling seam TRAJECTORY CONTROL to be welded, the Z direction motion of Z-direction drive unit realization welding gun, sighting device I, sighting device II in the drive unit is followed the tracks of in control, and welding gun is moved along seam track;
(6) after the assembling slit between corrugated plating and the base plate and molten bath enter into sighting device I visual field, the sighting device I is obtained the image of both sides, slit line in molten bath, the secondary light source hot spot, and sending to image data processor, image data processor obtains center, molten bath and coupled weld seam center offset and welds the seam of working as the proparea wide according to image; And center, molten bath and coupled weld seam center offset sent to controller, will work as the wide welding condition adjuster that sends to of seam in proparea;
(7) controller is according to the adjustment amount of step (6), and control welding gun drive unit realizes that welding gun, sighting device I Y-direction move, and realizes fine setting, and the welding condition adjuster is adjusted current welding condition according to wide when weld zone, proparea seam simultaneously.
8. monitoring method according to claim 7 is characterized in that, welding condition comprises electric current, voltage, wire feed rate and speed of welding in the described step (7).
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