CN103341685B - A kind of automatic weld tracking control method based on magnetic control arc and laser-vision sensing and system - Google Patents

A kind of automatic weld tracking control method based on magnetic control arc and laser-vision sensing and system Download PDF

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Publication number
CN103341685B
CN103341685B CN201310297612.7A CN201310297612A CN103341685B CN 103341685 B CN103341685 B CN 103341685B CN 201310297612 A CN201310297612 A CN 201310297612A CN 103341685 B CN103341685 B CN 103341685B
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laser
deviation
seam
welding
magnetic control
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CN201310297612.7A
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Chinese (zh)
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CN103341685A (en
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洪宇翔
洪波
李湘文
柳健
汤希
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湘潭大学
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Abstract

A kind of automatic weld tracking control method based on magnetic control arc and laser-vision sensing and system, the automatic real-time track precision that it mainly solves existing space weld seam is low, the technical problems such as System Error-tolerance Property is the best.Its drip irrigation device is: by the deviation information at welding gun (1) the butt welded seam center that magnetic control arc sensor (10) and laser vision sensor (11) obtain, input is to following the tracks of CS central controller (8) in the lump, the fusion method using double-sensing to estimate inspection calibration carries out information processing, deviation information after merging is as the weld seam deviation regulated quantity of actuator, weld seam deviation regulation is performed by actuator, realize soldering joint automatic tracking, complete automatic welding.It is mainly used for soldering joint automatic tracking.

Description

A kind of soldering joint automatic tracking based on magnetic control arc Yu laser-vision sensing Control method and system

Technical field

The present invention relates to a kind of welding control method and system, a kind of controlling party for automatic welding Method and system.

Background technology

During automatic welding, for real-Time Compensation because of the processing of workpiece and rigging error, and because sweating heat deforms institute The position while welding caused and the change of size, it is necessary to use suitable welding seam tracking method.

In conventional weld seam tracking sensor, arc sensor real-time is best, and wherein magnetic control arc passes Because mechanical vibrations are little with abrasion and volume, performance highlights sensor;Laser vision sensor obtains and contains much information, Weld joint tracking is effective.But single sensor is difficult to overcome various uncertain factor butt welded seams in welding process inclined The impact of difference information retrieval, the failed probability of weld joint tracking is bigger.Multiple different sensor is organically combined, It is to solve the effective way of weld joint tracking under complex environment, is also the inexorable trend of Automation of Welding development.

At present, many senses information mix together technology achieves bigger development in terms of Military application, but certainly The weld joint tracking of dynamicization welding system is studied less.Melt for data based on magnetic control arc with vision sensor Conjunction is studied, and sets up based on magnetic control arc sensor, and laser vision sensor carries out the prediction of deviation Fusion criterion, realizes soldering joint automatic tracking on the basis of using double-sensing to estimate the fusion method of inspection calibration, Theoretical reference is provided for many senses information mix together technology application in welding robot weld joint tracking.

Summary of the invention

It is an object of the invention to provide a kind of fast response time, good stability, fault-tolerance height, tracking accuracy High, practical automatic weld tracking control method based on magnetic control arc and laser-vision sensing and system. Propose a kind of weld seam deviation recognition methods based on magnetic control arc Yu laser-vision sensing, for based on magnetic control electricity The data fusion of arc and vision sensor is studied, and sets up based on magnetic control arc sensor, laser vision Sensor carries out the fusion criterion of the prediction of deviation, is using piecewise interpolation data prediction, discreet value effectiveness On the basis of the methods such as inspection, seam track prediction, adaptive weighted fusion, form effective data fusion side Case, it is achieved that spatial complex track weld seam from motion tracking.The method can be prevented effectively from the limitation of single-sensor Property, improving weld joint tracking precision and System Error-tolerance Property, algorithm simply and easily realizes, for multi-sensor data fusion skill Art realizes complicated seam track at welding robot and applies offer theoretical foundation in motion tracking.

The technical solution adopted for the present invention to solve the technical problems is: the invention provides a kind of based on magnetic Control electric arc and the automatic weld tracking control method of laser-vision sensing, in welding process, magnetic control arc senses Device 10 controls welding arc scanning groove, and Hall element 7 is by the welding current signal that detects after filtering Circuit signal processes, and carries out software processes and fortune by interference target signal filter and after useful signal extraction and amplification Calculate, try to achieve welding gun 1 and deviate the deviation information of Weld pipe mill position;Laser is tilted by laser vision sensor 11 It is incident upon on seam groove, image collecting device 6 gathers the laser stripe image comprising characteristics of weld seam, through certainly Adapt to the step such as Threshold segmentation and medium filtering, refinement and slope calculations, obtain the inclined of welding gun 1 butt welded seam center Residual quantity.These two kinds of weld seam deviation information input in the lump to controller 8, use double-sensing to estimate melting of inspection calibration Conjunction method carries out information processing, the deviation information after merging as the weld seam deviation regulated quantity of actuator, by Actuator performs weld seam deviation regulation, it is achieved soldering joint automatic tracking, completes automatic welding.

The present invention uses double-sensing to estimate the fusion method of inspection calibration to Fusion.

The present invention combines magnetic control arc sensor and realizes soldering joint automatic tracking with laser vision sensor.

The present invention uses weld seam deviation real-time detection method based on seam track prediction, can improve weld seam Tracking accuracy.

Present invention also offers a kind of soldering joint automatic tracking based on magnetic control arc with laser-vision sensing to control System, it includes welding gun 1, the source of welding current 2, wire-feed motor 3, actuator, image collecting device 6, Hall Sensor 7, controller 8, driver 9, magnetic control arc sensor 10 and laser vision sensor 11, welding Power supply 2 the two poles of the earth connect wire-feed motor 3 and Hall element 7 respectively, and Hall element 7 is connected with controller 8, Wire-feed motor 3 is connected with the welding gun 1 being arranged in actuator, arranges magnetic control arc sensor on welding gun 1 10, magnetic control arc sensor 10 arranges laser vision sensor 11, laser vision sensor 11 passes through Image collecting device 6 is connected with controller 8, and controller 8 connects actuator by driver 9.

Described actuator includes the motor on welding tractor 4, cross balladeur train 5 and cross balladeur train 5; Cross balladeur train 5 includes high high adjustment balladeur train 13 and the left and right adjusting balladeur train being arranged on high high adjustment balladeur train 13 12, welding gun 1 is arranged on left and right adjusting balladeur train 12.

Described actuator includes each motor on welding robot 14 and welding robot 14, welding gun 1 It is arranged on welding robot 14, is specifically arranged on the end of welding robot 14 arm.

Described actuator includes each motor on special welding machine 15 and special welding machine 15;Special welding machine 15 include X-axis horizontal adjustment balladeur train 16 and Y-axis height adjusting slider 17, and Y-axis height adjusting slider 17 is pacified It is contained on X-axis horizontal adjustment balladeur train 16;Welding gun 1 is arranged on special welding machine 15, is specifically arranged on Y-axis Just on adjusting slider 17.

The invention has the beneficial effects as follows: be difficult to meet real-time space weld joint tracking essence for single sensor The problem of the requirement that degree controls with accurate mass, it is proposed that a kind of magnetic control arc sensor is combined with vision sensor Welding seam tracking method.The method makes system give full play to vision sensor and the dual amount of magnetic control arc sensor The comprehensive advantage survey, being mutually authenticated.Adaptive by these two kinds of different measuring accurate sensor observed quantity weights Should dynamically adjust, select optimum deviation to extract strategy, the effect can followed the tracks of system produces the biggest with precision Impact, the weld seam deviation making system be extracted is closer to the welding gun real displacement relative to Weld pipe mill, it is achieved High-precision weld seam deviation information retrieval;Substantially increase the seam track bigger to degree of crook and broken line weldering Weld joint tracking precision at seam knuckle and stability, actual welding engineer testing demonstrates the effective of this algorithm Property, tracking effect is better than single-sensor welding seam tracking method, and stability is higher, practical, has important Actual application value, can be widely applied to welding robot or in motion tracking special plane system.

Accompanying drawing explanation

Fig. 1 is the operation principle schematic diagram of the present invention;

Fig. 2 is the structural representation of the present invention;

Fig. 3 is the work process schematic diagram that double-sensing estimates the fusion method of inspection calibration;

Fig. 4 is the structural representation of the embodiment of the present invention 7;

Fig. 5 is the structural representation of the embodiment of the present invention 8.

In figure: 1-welding gun, the 2-source of welding current, 3-wire-feed motor, 4-welding tractor, 5-cross balladeur train, 6-schemes As harvester, 7-Hall element, 8-controller, 9-driver, 10-magnetic control arc sensor, 11-swashs Light vision sensor, 12-left and right adjusting balladeur train, 13-height high adjustment balladeur train, 14-welding robot, 15-welds Special plane, 16-X axle horizontal adjustment balladeur train, 17-Y axle height adjusting slider.

Detailed description of the invention

With embodiment, the present invention is described in further details below in conjunction with the accompanying drawings.

Embodiment 1, the present invention uses soldering joint automatic tracking based on magnetic control arc with laser-vision sensing to control Method, in welding process, magnetic control arc sensor 10 controls welding arc scanning groove, Hall element The welding current signal circuit signal after filtering that detects is processed by 7, by interference target signal filter and will effectively believe Number extract and amplify after carry out software processes and computing, try to achieve welding gun 1 deviate Weld pipe mill position deviation letter Breath;Laser is tilted to be incident upon on seam groove by laser vision sensor 11, image collecting device 6 gather Comprise the laser stripe image of characteristics of weld seam, through adaptive threshold fuzziness and medium filtering, refinement and slope calculations Etc. step, obtain the departure at welding gun 1 butt welded seam center.These two kinds of weld seam deviation information input in the lump to control Device 8, the fusion method using double-sensing to estimate inspection calibration carries out information processing, the deviation information after merging As the weld seam deviation regulated quantity of actuator, actuator perform weld seam deviation regulation, it is achieved weld seam is automatic Follow the tracks of, complete automatic welding.Automatic with the weld seam of laser-vision sensing in order to realize based on magnetic control arc sensing Follow the tracks of, need the weld seam deviation information first each sensor obtained to carry out effective integration, after system will merge Weld seam deviation information conveyance is to CS central controller, then is issued instructions to driver drives execution machine by controller Structure carries out real-time online correction, complete weld seam from motion tracking.Refering to Fig. 1 to Fig. 3.

Embodiment 2, multi-sensor data is melted by the fusion method that the present invention uses double-sensing to estimate inspection calibration Close.In the research of hybrid multisensor data fusion algorithm, owing to sensor confidence interval is different with precision, Typically requiring and be rule of thumb weighted each sensor, its weights directly affect measurement, are easily welded by reality The impact of Nonlinear perturbations in T-Ring border, performance is the most unstable.For this problem, it is proposed that a kind of double-sensing is pre- Estimating the fusion method of inspection calibration, double-sensing is estimated the fusion method of inspection calibration and is characterized by: in welding process In, preposition laser vision sensor butt welded seam center carry out early stage and estimate, obtain weld seam lateral deviation Discreet value;Magnetic control arc sensor extracts welding gun relative to Weld pipe mill lateral displacement deviation as measured value, warp After data prediction, by setting threshold value, discreet value carrying out validity check, effective discreet value is by pre- Surveying degree of crook and the whether broken line flex point of seam track, according to predicting the outcome, point two kinds of situations carry out data Merge, when seam track curvature is less than threshold value set by system, use based on the minimum self adaptation of total mean square deviation Laser vision sensor discreet value is processed by excellent Weighted Fusion criterion with magnetic control arc sensor measured value, melts Carry out EKF after conjunction, filtered weld seam deviation fusion value effective discreet value be corrected, Obtain weld seam deviation information more accurately;When threshold value set by seam track curvature is more than system, with magnetic control arc The weld seam deviation measured value of sensor output is as system weld seam deviation fusion value;Invalid discreet value abandons, system Export the warm value of weld seam deviation of a upper periodic sampling.Refering to Fig. 1 to Fig. 5, remaining is with embodiment 1.

Embodiment 3, the present invention combine magnetic control arc sensor and laser vision sensor realize weld seam automatically with Track.Refering to Fig. 1 to Fig. 5, remaining same above-described embodiment.

Embodiment 4, the present invention uses weld seam deviation real-time detection method based on seam track prediction, permissible Improve weld joint tracking precision.In order to solve, seam track is complicated, degree of crook is big, weld seam at the biggest broken line angle Follow the tracks of difficult problem, it is proposed that weld seam deviation real-time detection method based on seam track prediction.Refering to Fig. 1 To Fig. 5, remaining same above-described embodiment.

Weld seam deviation based on seam track prediction detects in real time and is characterized by: passed by preposition laser vision Sensor extracts seam track feature, it is judged that the situation of change of seam track, the relatively big and folding in seam track curvature At line flex point, real-time performance preferable magnetic control arc sensor obtain more accurate weld seam deviation and hold as system The correction amount of row mechanism;And in the case of and non-flex point, extreme point less in seam track curvature, use and swash Light vision sensor obtains weld seam deviation with the method for magnetic control arc sensing data Weighted Fusion.

By the position coordinates of all sampled points in laser vision sensor acquisition future range X sa(xa, ya), seam track F can be obtained through curve matchingrX () is at XrThe approximate function F ' of sectionrX (), by F 'r(x) Function expression calculates XrAll flex points and extreme point in section, and calculate the weld seam predicted at all sampled points Curvature ε of tracki

Predicting the outcome according to this seam track, point two kinds of situations carry out data fusion, and fusion criterion can be concluded As follows:

1, combine welding procedure, if fusion criterion boundary value γ, work as εiDuring > γ, or welding torch position is positioned at flex point, pole At value point, because using laser vision tracking weld seam precision relatively low, even cannot realize following the tracks of, therefore use magnetic control electricity The weld seam deviation measured value of arc sensor output is as system weld seam deviation fusion value;

2, ε is worked asiDuring < γ, and at the non-flex point of welding torch position, extreme point, use Weighted Fusion criterion to dual sensor Observation processes, and exports weld seam deviation fusion value after the valuation of double-sensing data filters.

Embodiment 5, present invention also offers a kind of automatic with the weld seam of laser-vision sensing based on magnetic control arc Tracking control system, it includes welding gun 1, the source of welding current 2, wire-feed motor 3, actuator, image collector Put 6, Hall element 7, controller 8, driver 9, magnetic control arc sensor 10 and laser-vision sensing Device 11, the source of welding current 2 the two poles of the earth connect wire-feed motor 3 and Hall element 7, Hall element 7 and control respectively Device 8 connects, and wire-feed motor 3 is connected with the welding gun 1 being arranged in actuator, arranges magnetic control electricity on welding gun 1 Arc sensor 10, arranges laser vision sensor 11, laser vision sensor on magnetic control arc sensor 10 11 are connected with controller 8 by image collecting device 6, and controller 8 connects actuator by driver 9. Refering to Fig. 1 to Fig. 5, remaining same above-described embodiment.

Embodiment 6, described actuator includes on welding tractor 4, cross balladeur train 5 and cross balladeur train 5 Motor;Cross balladeur train 5 includes high high adjustment balladeur train 13 and the left side being arranged on high high adjustment balladeur train 13 Right regulation balladeur train 12, welding gun 1 is arranged on left and right adjusting balladeur train 12.Deviation information after merging is as holding The weld seam deviation regulated quantity of row mechanism, is performed weld seam deviation regulation by cross balladeur train 5, it is achieved soldering joint automatic tracking, Complete automatic welding.Wherein, for the weld seam deviation on left and right adjusting balladeur train 12 direction, by controller 8 The data fusion method control driver 9 estimating inspection calibration according to double-sensing drives left and right adjusting balladeur train 12 On motor carry out correction regulation;For the weld seam deviation of welding gun 1 central axis direction, by controller 8 Height displacement deviation according to magnetic control arc sensor 10 output controls driver 9 and drives high high adjustment balladeur train Motor on 13 carries out correction regulation.Left and right adjusting balladeur train 12 and high high adjustment balladeur train 13 are to each Being all orthogonal during the welding tracking of road weld seam, the most therefore have another name called it " cross balladeur train ".Whole system is held The regulation of row mechanism is to be sent by controller 8 to instruct to control driver 9, thus drive stepping motor and control The motor of welding tractor 4 processed walking has been worked in coordination with, and its collaborative work mode is by compiling the software of controller 8 Cheng Shixian.Refering to Fig. 1 to Fig. 5, remaining same above-described embodiment.

Embodiment 7, described actuator includes each electricity on welding robot 14 and welding robot 14 Machine, welding gun 1 is arranged on welding robot 14, is specifically arranged on the end of welding robot 14 arm.Will Deviation information after fusion is as the weld seam deviation regulated quantity of actuator, and it is inclined that welding robot 14 performs weld seam Difference regulation, it is achieved soldering joint automatic tracking, completes automatic welding.Wherein, the regulation of whole system actuator It is to be sent by controller 8 to instruct to control driver 9, thus drive stepping motor and control welding robot Each motor of 14 has been worked in coordination with, and its collaborative work mode is by realizing the software programming of controller 8.Ginseng Read Fig. 1 to Fig. 5, remaining same above-described embodiment.

Embodiment 8, described actuator includes each motor on special welding machine 15 and special welding machine 15; Special welding machine 15 includes X-axis horizontal adjustment balladeur train 16 and Y-axis height adjusting slider 17, Y-axis height high adjustment Slide block 17 is arranged on X-axis horizontal adjustment balladeur train 16;Welding gun 1 is arranged on special welding machine 15, specifically pacifies It is contained on Y-axis height adjusting slider 17.Deviation information after merging is adjusted as the weld seam deviation of actuator Joint amount, it is inclined that the X-axis horizontal adjustment balladeur train 16 of special welding machine 15 and Y-axis height adjusting slider 17 perform weld seam Difference regulation, it is achieved soldering joint automatic tracking, completes automatic welding.Wherein, for X-axis horizontal adjustment balladeur train Weld seam deviation on 16 directions, is estimated the data fusion method control of inspection calibration by controller 8 according to double-sensing Driver 9 processed drives the motor on X-axis horizontal adjustment balladeur train 16 to carry out correction regulation;For Y-axis The just weld seam deviation of adjusting slider 17 central axis direction, is exported according to magnetic control arc sensor by controller 8 Height displacement deviation control driver 9 drive Y-axis height adjusting slider 17 on motor entangle Regulation partially.The regulation of whole system actuator is to send instruction by controller 8 to control driver 9, thus The motor of drive stepping motor and control special welding machine 15 walking has been worked in coordination with, and its collaborative work mode is led to Cross the software programming to controller 8 to realize.Refering to Fig. 1 to Fig. 5, remaining same above-described embodiment.

Embodiment 9, the controller of the present invention can be by single-chip microcomputer, DSP, PLC, ARM, FPGA, work Control machine or computer etc. replace, and laser vision sensor can be by laser structure optical sensor, scanning laser sensor Or active light vision sensor replaces, it is intended to by magnetic control arc superior to real-time performance, anti-arc light jamming performance Sensor with and highly sensitive with obtain the laser vision sensor that contains much information and organically combine, by using double biography Sense is estimated and is checked the fusion method of calibration to merge magnetic control arc sensor with laser vision sensor data, Obtain accurate weld seam deviation information, for soldering joint automatic tracking, and be widely used in welding robot or automatic Follow the tracks of in special plane system, overcome the impact that in welding process, various uncertain factor butt welded seam deviation informations extract, Reduce and follow the tracks of failed probability, fundamentally improve overall system performance.Refering to Fig. 1 to Fig. 5, remaining is same Above-described embodiment.

Claims (3)

1. an automatic weld tracking control method based on magnetic control arc Yu laser-vision sensing, is characterized in that: In welding process, magnetic control arc sensor (10) controls welding arc scanning groove, and Hall element (7) will detection The welding current signal arrived circuit signal after filtering process, will interference target signal filter and by useful signal extract and Carry out software processes and computing after amplification, try to achieve the deviation information of welding gun (1) deviation Weld pipe mill position;Swash Laser is tilted to be incident upon on seam groove by light vision sensor (11), image collecting device (6) gather and comprise weldering The laser stripe image of seam feature, through adaptive threshold fuzziness and medium filtering, refinement and slope calculations step, Obtain the departure at welding gun (1) butt welded seam center;These two kinds of weld seam deviation information input in the lump to controller (8), The fusion method using double-sensing to estimate inspection calibration carries out information processing, and the deviation information after merging is as holding The weld seam deviation regulated quantity of row mechanism, is performed weld seam deviation regulation by actuator, it is achieved soldering joint automatic tracking, Complete automatic welding, use weld seam deviation real-time detection method based on seam track prediction, improve weld seam with Track precision, it is characterized by: extracted seam track feature by preposition laser vision sensor, it is judged that seam track Situation of change, at and broken line flex point relatively big in seam track curvature, by the preferable magnetic control arc of real-time performance Sensor obtains the more accurate weld seam deviation correction amount as system actuator;And in seam track curvature relatively In the case of little and non-flex point, extreme point, laser vision sensor is used to add with magnetic control arc sensing data The method that power merges obtains weld seam deviation.
Soldering joint automatic tracking controlling party based on magnetic control arc Yu laser-vision sensing the most according to claim 1 Method, is characterized in that: use double-sensing to estimate the fusion method of inspection calibration to Fusion.
Soldering joint automatic tracking controlling party based on magnetic control arc Yu laser-vision sensing the most according to claim 1 Method, is characterized in that: combines magnetic control arc sensor and realizes soldering joint automatic tracking with laser vision sensor.
CN201310297612.7A 2013-07-17 2013-07-17 A kind of automatic weld tracking control method based on magnetic control arc and laser-vision sensing and system CN103341685B (en)

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