CN103350268A - System and method for detecting virtual arc length in monocular-video-camera-based simulated welding training - Google Patents

System and method for detecting virtual arc length in monocular-video-camera-based simulated welding training Download PDF

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CN103350268A
CN103350268A CN2013101864976A CN201310186497A CN103350268A CN 103350268 A CN103350268 A CN 103350268A CN 2013101864976 A CN2013101864976 A CN 2013101864976A CN 201310186497 A CN201310186497 A CN 201310186497A CN 103350268 A CN103350268 A CN 103350268A
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light source
monocular
simulation
camera
arc length
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CN103350268B (en
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薛金保
张建勋
张卫之
王启宇
张晓亮
詹恒顺
牛靖
李清君
李军
周海燕
窦世涛
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Xian Jiaotong University
China Petroleum First Construction Corp
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China Petroleum First Construction Corp
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Abstract

The invention discloses a system and a method for detecting virtual arc length in a monocular-video-camera-based simulated welding training. The system comprises a simulated welding rod, simulated welding tongs, a simulated test board, a monocular video camera, and a computer; the simulated welding rod is mounted on the simulated welding tongs, a double-tilt sensor used for measuring the angle of rotation and the value of tilt angle of the simulated welding rod is mounted in the simulated welding tongs; a main light source and an auxiliary light source, between which a sharp angle is formed, are mounted at the front end of the simulated welding rod; the emergent light of the main light source transmits in the length direction of the simulated welding rod; the monocular video camera is arranged below the simulated test board; the computer is connected with the monocular video camera and the double-tilt sensor.

Description

Based on the virtual arc length detection system of the simulation welding training of monocular-camera and method
Technical field
The invention belongs to the machine vision sensory field, particularly a kind of locus detection method.
Background technology
Solder technology is to support an important subject of development of modern industry, and it is widely used in shipbuilding, the fields such as automobile making and Aero-Space.Although various automatic weldings and semiautomatic welding development are rapidly, for China's national situation, manual electric arc welding still has more widely uses.Because with respect to automatic welding and semiautomatic welding, manual electric arc welding is more flexible, convenient and cost is lower.But along with the fast development of economy, it is waste that recruitment has appearred in some developed regions of China, and skilled welder's ratio is reducing when welding field then is presented as the decline of welder's overall quantity.This phenomenon has brought challenge for traditional welding training, how to shorten the welders training cycle, and fast culture goes out skilled welder and becomes an important topic.
New thinking-simulation training has been brought in the welding training field of developing into of virtual reality technology and digital simulation technique.Traditional welding training cycle is long, pollution is large, loss is high, directly causes training cost higher.Simultaneously, because manual arc is welded with certain risk, bring pressure at heart easily for elementary welding student, so that they can not enter learning state fast.Simulation training can well address the above problem in the application in welding training field.At first, simulation welding training low-loss, pollution-free not only meets the requirement of government's energy-saving and emission-reduction, can also reduce greatly training cost.Secondly, adopt the simulation welding equipment to assist teacher's pattern that the student is imparted knowledge to students and to improve greatly qualified teachers' utilization rate, man-to-man poor efficiency training pattern in the welding training that thoroughly breaks traditions.At last, simulation welding training equipment is multimedia technology comprehensively, so that the welding teaching is more lively, interesting, and can allow the student learn targetedly, has improved learning efficiency and effect.
At home, Harbin Institute of Technology successfully develops First simulation welding equipment model machine based on the concept of the virtual welding of proposition in 1987.2008, " the real-time location technology in welding rod space in the emulation of arc welding plate welding " that Shanghai Normal University proposes directly served welding training.2009, the people such as Liu Shengchang of armored forces technology institute delivered paper " research of manual electric arc welding operation simulation training system ", for bringing new approaches in simulation welding training field.Abroad, the research work of Germany, U.S. beginning this respect early, the state such as French, Australian, Japanese also begins correlative study in last century Mo, and in succession obtains certain achievement.
Xi'an Communications University's institute of welding has been developed " welding operation simulator " model machine HTS-08, and obtains national inventing patent in 2008.The developer carries out progressively improvement and perfection to model machine HTS-08 on this basis, and in succession develops HTS-09 experiment type and HTS-10 improvement type.
HTS-10 is mainly by detection module, the 3D scene module, and evaluation module and theory examination module form.Detection module hardware mainly is comprised of high-resolution CCD industrial camera and simulation soldering turret and test plate (panel), integrated high-precision tilt angle sensor, and in conjunction with advanced image processing techniques, can be accurately, the real-time positional information that detects welder's operation, realize accuracy of detection ± 0.5mm.The 3D scene module based on virtual reality technology and finite element simulation simulation carry out the three-dimensional scenic modeling, realize the scaling loss of welding rod, send arc light and generation and splash and wait vivid effect, to the user with good experience.Evaluation module utilizes Implementation of Expert System to comprise Real-Time Evaluation, and the welding inclination angle is estimated, and the functions such as arc manipulation trajectory analysis and failure prediction can provide more believable evaluation result.
The variation of arc length (abbreviation arc length) can cause the variation of arc voltage, affects the molten wide and fusion penetration of weld seam, thereby affects appearance of weld and welding quality; Therefore arc length is a parameter that needs in the virtual welding operation by Measurement accuracy.In virtual welding training, arc length can be considered to a upper tolerance of Z coordinate direction in the three dimensions, also is the height of welding position.Yet in the prior art, assay device structures complexity and the accuracy of detection of virtual arc length are not high during the simulation welding, the training quality of impact simulation welding.
Summary of the invention
The object of the invention is to, the virtual arc length detection system of a kind of simulation welding training based on monocular-camera and method are provided, easy, detect when welding simulation simulation arc length fast, accurately.
To achieve these goals, the present invention adopts following technical scheme:
The virtual arc length detection system of a kind of simulation welding training based on monocular-camera comprises simulated electrode, simulation soldering turret, simulation test plate (panel), monocular-camera and computer; Simulated electrode is installed on the simulation soldering turret, and the two obliquity sensors for detection of simulated electrode corner and inclination angle value are housed in the simulation soldering turret; The front end of simulated electrode is equipped with main light source and secondary light source, and the angle between the emergent light of main light source and secondary light source is acute angle; The emergent light of main light source is propagated along the length direction of simulated electrode; Monocular-camera is arranged at simulation test plate (panel) below; Described computer connects monocular-camera and two obliquity sensor.
The present invention further improves and is: described simulation test plate (panel) is plate glass.
The present invention further improves and is: the coplanar and angle of the emergent light of main light source and secondary light source is 45 °.
The present invention further improves and is: main light source and secondary light source are identical laser diode.
The present invention further improves and is: main light source is the different laser diode of emergent light gray value from secondary light source.
The present invention further improves and is: secondary light source is installed on the simulated electrode on the direction of simulation soldering turret handle.
The present invention further improves and is: during the simulation welding, the emergent light of main light source and secondary light source forms main spot and auxiliary hot spot at the simulation test plate (panel); Described computer is used for going out according to the data identification of monocular-camera collection the coordinate of main spot and auxiliary hot spot, and computer calculates virtual arc length in real time according to corner and the inclination angle value of the simulated electrode of the coordinate of main spot and auxiliary hot spot and two obliquity sensor collections.
Carry out the method that virtual arc length detects based on the virtual arc length detection system of the simulation welding training of monocular-camera, may further comprise the steps:
1) operator uses the simulation soldering turret to simulate welding above the simulation test plate (panel), and the illumination that the main light source of simulated electrode front end and secondary light source send is mapped on the simulation test plate (panel) and forms main spot and auxiliary hot spot; Be fixed on the monocular-camera real-time image acquisition of simulation test plate (panel) below;
2) computer real-time calling monocular-camera, a two field picture of acquisition monocular-camera Real-time Collection;
3) computer identifies the coordinate of main spot and auxiliary hot spot in the two field picture that gathers;
4) main spot that obtains according to step 3) of computer and the coordinate of auxiliary hot spot, and two obliquity sensor real-time Transmission is to corner and the inclination angle data of the simulated electrode of computer, calculates according to formula 7 and obtains real-time virtual arc length H:
Figure BDA00003214456000031
Wherein, D is the distance between main spot and the auxiliary hot spot, h 0Be the distance of virtual focus O to the main light source front end, θ is the angle between main light source and the secondary light source,
Figure BDA00003214456000032
Be the simulated electrode corner, μ is the simulated electrode angle of inclination.
The present invention further improves and is: main light source is the different light source of gray value with secondary light source; From the realtime graphic that monocular-camera gathers, two the brightest points are carried out gray scale relatively in the step 3), distinguish main spot and auxiliary hot spot.
The present invention further improves and is: secondary light source is installed on the simulated electrode on the direction of simulation soldering turret handle.
With respect to prior art, the present invention has following beneficial effect:
1) native system adopts a video camera to carry out IMAQ, and its processing speed is faster for biocular systems need to be processed two width of cloth images simultaneously;
2) monocular-camera is fixed in the environment of sealing, only accepts to see through the light that the test plate (panel) upper surface enters video camera, and it is little that it is disturbed by external environment, and stability is high;
3) obtain height value with respect to a special video camera in the binocular camera by horizontal direction collection image calculation and get method, the acquisition precision of monocular system is higher, and by linear fit, monocular-camera can reach 1mm in the accuracy of detection of short transverse;
4) equipment only adopts a video camera and two obliquity sensor as sensor-based system, and equipment volume reduces, cost.
Description of drawings
Fig. 1 is the schematic diagram of simulated electrode end;
Fig. 2 is the geometrical relationship schematic diagram of simulated electrode inclination angle and corner light when being zero;
Fig. 3 is that the simulated electrode inclination angle is zero, the geometrical relationship schematic diagram of light when corner is non-vanishing;
Fig. 4 is angle of inclination exploded view schematic diagram;
Fig. 5 is the geometrical relationship schematic diagram of simulated electrode inclination angle and corner light when all non-vanishing;
Fig. 6 is the virtual arc length detection system of the present invention schematic diagram.
The specific embodiment
See also shown in Figure 1ly, the present invention is based on the virtual arc length detection system of simulation welding training of monocular-camera, comprise simulated electrode 10, simulation soldering turret 12, simulation test plate (panel) 20, monocular-camera and computer.The present invention is at the mutual two luminous point generating device of laser at 45 ° of simulated electrode 10 head design, make it at simulation test plate (panel) 20(plate glass) get two hot spots, the coordinate of two hot spots gathers by the monocular-camera that is arranged at simulation test plate (panel) 20 bottoms, and the coordinate data of collection is transferred to computer; Simulated electrode 10 is installed on the simulation soldering turret 12, two obliquity sensors 11 is housed, for detection of simulated electrode 10 roll angles and angle of pitch value in the simulation soldering turret 12; Simulated electrode 10 roll angles and angle of pitch value that two obliquity sensors 11 on the simulation soldering turret 12 gather are real-time transmitted to computer.Computer calculates simulated electrode 10 ends apart from the height of simulation test plate (panel) 20, i.e. virtual arc length in conjunction with position, light angle, the welding rod dip angle parameter of two light sources.
Main light source 1 and secondary light source 2 adopt identical laser diode, and the environment that moves and use is also identical, and it is relatively more difficult therefore relying on merely monocular-camera to come identification main spot and auxiliary hot spot.Use habit when operating by observing the welder can find, no matter the operator uses left hand or the right hand, and the handle of simulation soldering turret 12 is all towards this side of operator.Always be positioned at the one-sided of weld seam if secondary light source 2 is installed on the simulated electrode 11 towards this directions of simulation soldering turret 12 handles then can protects the auxiliary hot spot 200 of basic guarantee.Such as Fig. 6, the x direction is welding direction, and the y direction is the vertical welding direction; Pass main spot 100(x1, y1) dotted line be weld seam, auxiliary hot spot 200 can be in the one-sided 180 ° of scopes of weld seam during normal operating, namely dash area among the figure.Coordinate system according to simulation test plate (panel) plane then has auxiliary hot spot 200(x2, y2) coordinate y2 greater than the coordinate y1 of main spot.Therefore, install on the basis in certain hardware design, utilize welder's operating habit, just can realize the identification of main spot 100 and auxiliary hot spot 200 by comparing two hot spot coordinate y values.
Main light source 1 can also adopt the different light source of gray value with secondary light source 2, from the realtime graphic that monocular-camera gathers, two the brightest points is carried out gray scale relatively, just can distinguish main spot 100 and auxiliary hot spot 200.
In order to simplify Mathematical Modeling, to save installing space, main light source 1 is installed in the same plane with secondary light source 2, that is to say that the light that light that main light source 1 sends and secondary light source 2 send is coplanar.And main light source 1 is installed along simulated electrode 10 directions, the light that it sends and simulated electrode 10 conllinear, and the angle of main light source 1 and secondary light source 2 is 45 °, as shown in Figure 1.
1, virtual arc length detection formula is derived
1) inclination angle and corner are zero situation
When inclination angle and corner were zero, simulated electrode 10 was perpendicular to horizontal plane, also was that main light source 1 is perpendicular to horizontal plane, then just like the situation of Fig. 2.Two light have virtual focus O, and it is fixed to the distance h 0 of main light source 1 front end, and the angle theta between two light is determined by the light source installation site, is known; According to image detecting method, the main spot 100 that main light source 1 and secondary light source 2 are got and the coordinate of auxiliary hot spot 200 can calculate, and therefore the distance D between two hot spots can be calculated.Then just can obtain arc length H according to formula.
H = h - h 0 = D tan θ - h 0
Wherein, D is that main light source 1 and secondary light source 2 shine the distance between two hot spots of simulating on the test plate (panel) 20; θ is the angle between main light source 1 and the secondary light source 2; h 0Be the distance of virtual focus O to main light source 1 front end; The distance of the h main spot that to be virtual focus O get to main light source 1.
2) inclination angle is the zero non-vanishing situation of corner
In the case, because the inclination angle still is zero, therefore plane, two light places is still perpendicular to horizontal plane, then just like the situation of Fig. 3.Wherein
Figure BDA00003214456000052
Be corner, can be read by obliquity sensor 11.Can draw formula and (3) by geometrical relationship among the figure.
Figure BDA00003214456000061
Figure BDA00003214456000062
Figure BDA00003214456000063
Combination type, (3) and (4), cancellation P and h obtain:
Figure BDA00003214456000064
Formula (5) is arc length computing formula in the zero non-vanishing situation of corner for the inclination angle.
3) the equal non-vanishing situation of inclination angle and corner
This situation has represented the frequent state that arc length is measured, and the formula of deriving will be of universal significance.In the space angle of any one inclination of simulated electrode can projection and be decomposed into the inclination angle and corner on corresponding angle (such as Fig. 4).Therefore, at first carry out the inclination of corner direction by decomposing, then can draw formula (5).On this basis, carry out the inclination of inclination direction such as Fig. 5, the angle of inclination is μ, then can draw relational expression (6), and abbreviation draws final formula (7).
Figure BDA00003214456000065
Abbreviation:
Figure BDA00003214456000066
The parameters on formula (7) equal sign the right all is known maybe can surveying, and just can obtain arc length H accordingly.
See also Fig. 1 to shown in Figure 6, the present invention is based on the virtual arc length detection method of simulation welding training of monocular-camera, may further comprise the steps:
1) operator uses simulation soldering turret 12 to simulate welding above simulation test plate (panel) 20, and the illumination that the main light source 1 of simulated electrode 10 front ends and secondary light source 2 send is mapped on the simulation test plate (panel) 20 and forms main spot 100 and auxiliary hot spot 200; Be fixed on the monocular-camera real-time image acquisition of simulation test plate (panel) 20 belows;
2) computer real-time calling monocular-camera, a two field picture of acquisition monocular-camera Real-time Collection;
3) computer identifies the coordinate of main spot 100 and auxiliary hot spot 200 in the two field picture that gathers;
4) main spot 100 that obtains according to step 3 of computer and the coordinate of auxiliary hot spot 200, and two obliquity sensor 11 real-time Transmission are to corner and the inclination angle data of the simulated electrode 10 of computer, calculate according to formula 7 and obtain real-time virtual arc length H:
Figure BDA00003214456000071
Wherein, D is the distance between main spot 100 and the auxiliary hot spot 200, h 0Be the distance of virtual focus O to main light source 1 front end, θ is the angle between main light source 1 and the secondary light source 2,
Figure BDA00003214456000072
Be simulated electrode 10 corners, μ is simulated electrode 10 angles of inclination;
5) repeating step 2)-4), real-time circulation obtains real-time virtual arc length and the simulated electrode elevation information of welding process.
Main light source 1 can also adopt the different light source of gray value with secondary light source 2, from the realtime graphic that monocular-camera gathers, two the brightest points is carried out gray scale relatively in the step 3), just can distinguish main spot 100 and auxiliary hot spot 200.Can certainly be according to the method for machinery; secondary light source 2 is installed on the simulated electrode 11 towards this direction of simulating soldering turret 12 handles; then can protect the auxiliary hot spot 200 of basic guarantee and always be positioned at the one-sided of weld seam, also can distinguish main spot 100 and auxiliary hot spot 200 with this.

Claims (10)

1. the virtual arc length detection system of the simulation welding training based on monocular-camera is characterized in that, comprises simulated electrode (10), simulation soldering turret (12), simulation test plate (panel) (20), monocular-camera and computer;
Simulated electrode (10) is installed on the simulation soldering turret (12), and the two obliquity sensors (11) for detection of simulated electrode (10) corner and inclination angle value are housed in the simulation soldering turret (12); The front end of simulated electrode (10) is equipped with main light source (1) and secondary light source (2), and the angle between the emergent light of main light source (1) and secondary light source (2) is acute angle; The emergent light of main light source (1) is propagated along the length direction of simulated electrode (10);
Monocular-camera is arranged at simulation test plate (panel) (20) below;
Described computer connects monocular-camera and two obliquity sensor (11).
2. the virtual arc length detection system of the simulation welding training based on monocular-camera according to claim 1 is characterized in that, described simulation test plate (panel) (20) is plate glass.
3. the virtual arc length detection system of the simulation welding training based on monocular-camera according to claim 1 is characterized in that, the coplanar and angle of the emergent light of main light source (1) and secondary light source (2) is 45 °.
4. the virtual arc length detection system of the simulation welding training based on monocular-camera according to claim 1 is characterized in that, main light source (1) is identical laser diode with secondary light source (2).
5. the virtual arc length detection system of the simulation welding training based on monocular-camera according to claim 1 is characterized in that, main light source (1) is the different laser diode of emergent light gray value from secondary light source (2).
6. the virtual arc length detection system of the simulation welding training based on monocular-camera according to claim 1 is characterized in that, it is upper on the direction of simulation soldering turret (12) handle that secondary light source (2) is installed in simulated electrode (11).
7. the virtual arc length detection system of the simulation welding training based on monocular-camera according to claim 1, it is characterized in that, during the simulation welding, main light source (1) forms main spot (100) and auxiliary hot spot (200) with the emergent light of secondary light source (2) at simulation test plate (panel) (20); Described computer is used for going out according to the data identification of monocular-camera collection the coordinate of main spot (100) and auxiliary hot spot (200), and computer calculates virtual arc length in real time according to corner and the inclination angle value of the simulated electrode (10) of the coordinate of main spot (100) and auxiliary hot spot (200) and pair obliquity sensors (11) collection.
8. adopt the virtual arc length detection system of the simulation welding training based on monocular-camera claimed in claim 1 to carry out the method that virtual arc length detects, it is characterized in that, may further comprise the steps:
1) operator uses simulation soldering turret (12) to simulate welding in simulation test plate (panel) (20) top, and the illumination that the main light source (1) of simulated electrode (10) front end and secondary light source (2) send is mapped to upper main spot (100) and the auxiliary hot spot (200) of forming of simulation test plate (panel) (20); Be fixed on the monocular-camera real-time image acquisition of simulation test plate (panel) (20) below;
2) computer real-time calling monocular-camera, a two field picture of acquisition monocular-camera Real-time Collection;
3) computer identifies the coordinate of main spot (100) and auxiliary hot spot (200) in the two field picture that gathers;
4) computer is according to the main spot (100) of step 3) acquisition and the coordinate of auxiliary hot spot (200), and two obliquity sensors (11) real-time Transmission is calculated acquisition real-time virtual arc length H to corner and the inclination angle data of the simulated electrode (10) of computer according to formula 7:
Figure FDA00003214455900021
Wherein, D is the distance between main spot (100) and the auxiliary hot spot (200), h 0Be the distance of virtual focus O to main light source (1) front end, θ is the angle between main light source (1) and the secondary light source (2),
Figure FDA00003214455900022
Be simulated electrode (10) corner, μ is simulated electrode (10) angle of inclination.
9. the method for virtual arc length detection according to claim 8 is characterized in that, main light source (1) is the different light source of gray value with secondary light source (2); From the realtime graphic that monocular-camera gathers, two the brightest points are carried out gray scale relatively in the step 3), distinguish main spot (100) and auxiliary hot spot (200).
10. the method for virtual arc length detection according to claim 8 is characterized in that, it is upper on the direction of simulation soldering turret (12) handle that secondary light source (2) is installed in simulated electrode (11).
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CN111627013A (en) * 2020-05-28 2020-09-04 西南交通大学 Method for detecting arc length in additive manufacturing of non-consumable electrode gas protection arc fuse
CN111627013B (en) * 2020-05-28 2022-04-22 西南交通大学 Method for detecting arc length in additive manufacturing of non-consumable electrode gas protection arc fuse

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