CN103350268B - 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 PDFInfo
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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
Technical field
The invention belongs to machine vision sensory field, particularly a kind of locus detection method.
Background technology
Solder technology supports an important subject of development of modern industry, and it is widely used in shipbuilding, the field such as automobile making and Aero-Space.Although various automatic welding and semiautomatic welding develop rapidly, for China's national situation, covered arc welding still has applies more widely.Because relative to automatic welding and semiautomatic welding, covered arc welding is more flexible, convenient and cost is lower.But along with the fast development of economy, some developed regions of China have occurred that recruitment is waste, and while welding field is then presented as the decline of welder's overall quantity, skilled welder's ratio is in minimizing.This phenomenon brings challenge to traditional welding training, how to shorten the welders training cycle, and fast culture goes out skilled welder becomes an important topic.
The welding training field of developing into of virtual reality technology and digital simulation technique brings new thinking-simulation training.Traditional welding training cycle is long, pollution is large, loss is high, directly causes training cost higher.Meanwhile, because manual arc is welded with certain risk, bring pressure at heart easily to elementary welding student, make them can not enter learning state fast.The application of simulation training in welding training field can well solve the problem.First, simulation welding training low-loss, pollution-free, not only meet the requirement of government's energy-saving and emission-reduction, training cost can also be reduced greatly.Secondly, the pattern of simulation welding gear assisted teacher is adopted to carry out to student the utilization factor that teaching can improve qualified teachers greatly, man-to-man poor efficiency training pattern in the welding training that thoroughly breaks traditions.Finally, simulation welding training equipment can comprehensive multimedia technology, makes welding teaching more lively, interesting, and student can be allowed to learn targetedly, improve learning efficiency and effect.
At home, Harbin Institute of Technology successfully develops First simulation welding gear model machine based on the concept of the virtual welding of proposition in 1987.2008, " in the emulation of arc welding plate welding welding rod space real time positioning technology " that Shanghai Normal University proposes directly served welding training.2009, the people such as the Liu Shengchang of armored forces technology institute published thesis " research of manual arc-welding operations simulated training system ", for new approaches are brought in simulation welding training field.Abroad, the research work of Germany, U.S. beginning this respect comparatively early, the state such as French, Australian, Japanese also in last century Mo beginning correlative study, and obtains certain achievement in succession.
Xi'an Communications University's institute of welding have developed " welding operation simulator " model machine HTS-08, and obtains national inventing patent in 2008.On this basis, developer carries out progressively improvement and perfection to model machine HTS-08, and in succession develops HTS-09 experiment type and HTS-10 improvement type.
HTS-10 is primarily of detection module, and 3D scene module, evaluation module and theory examination module form.Detection module hardware is primarily of high-resolution CCD industrial camera and simulate soldering turret and test plate (panel) composition, integrated high-precision tilt angle sensor, and combine advanced image processing techniques, can accurately, real-time the positional information that welder operates detected, realize accuracy of detection ± 0.5mm.3D scene module carries out three-dimensional scenic modeling based on virtual reality technology and finite element simulation simulation, realizes the scaling loss of welding rod, sends arc light and produces the vivid effects such as splashing, to user with good experience.Evaluation module utilizes Implementation of Expert System to comprise Real-Time Evaluation, and welding inclination angle is evaluated, and the functions such as arc manipulation trajectory analysis and failure prediction, can provide more believable evaluation result.
The change of arc length (abbreviation arc length) can cause the change of arc voltage, affects the molten wide and fusion penetration of weld seam, thus affects appearance of weld and welding quality; Therefore arc length is the parameter needing in virtual welding operation to be accurately.In virtual welding training, arc length can be considered to a upper tolerance of Z coordinate direction in three dimensions, is also the height of welding position.But in prior art, during simulation welding, the assay device structures of virtual arc length is complicated and accuracy of detection is not high, 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, fast, accurately detect simulation welding time simulation arc length.
To achieve these goals, the present invention adopts following technical scheme:
The virtual arc length detection system of simulation welding training based on monocular-camera, comprises simulated electrode, simulation soldering turret, Simulated Plate, monocular-camera and computing machine; Simulated electrode is arranged on simulation soldering turret, and the two obliquity sensors for detecting simulated electrode corner and tilt values are housed in simulation soldering turret; The front end of simulated electrode is provided with main light source and secondary light source, and the angle between main light source and the emergent light of 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 below Simulated Plate; Described computing machine connects monocular-camera and two obliquity sensor.
The present invention further improves and is: described Simulated Plate is sheet glass.
The present invention further improves and is: the emergent light of main light source and secondary light source is coplanar and angle 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 and secondary light source are the different laser diode of emergent light gray-scale value.
The present invention further improves and is: secondary light source is arranged on simulated electrode towards on the direction of simulation soldering turret handle.
The present invention further improves and is: during simulation welding, the emergent light of main light source and secondary light source forms main spot and auxiliary hot spot on Simulated Plate; Described computing machine is used for the coordinate going out main spot and auxiliary hot spot according to the data identification of monocular-camera collection, and computing machine calculates virtual arc length in real time according to the corner of main spot and the coordinate of auxiliary hot spot and the simulated electrode of two obliquity sensor collection and tilt values.
Simulation welding training virtual arc length detection system based on monocular-camera carries out the method for virtual arc length detection, comprises the following steps:
1) operator uses simulation soldering turret above Simulated Plate, carry out simulation welding, and the illumination that the main light source of simulated electrode front end and secondary light source send is mapped on Simulated Plate and forms main spot and auxiliary hot spot; Be fixed on the monocular-camera real-time image acquisition below Simulated Plate;
2) computing machine real-time calling monocular-camera, obtains a two field picture of monocular-camera Real-time Collection;
3) computer recognizing goes out the coordinate of main spot and auxiliary hot spot in a gathered two field picture;
4) coordinate of the main spot that obtains according to step 3) of computing machine and auxiliary hot spot, and two obliquity sensor real-time Transmission is to the corner of the simulated electrode of computing machine and pitch angle data, calculates obtain real-time virtual arc length H according to formula 7:
Wherein, D is the distance between main spot and auxiliary hot spot, h
0for virtual focus O is to the distance of main light source front end, θ is the angle between main light source and secondary light source,
for simulated electrode corner, μ is simulated electrode angle of inclination.
The present invention further improves and is: main light source and secondary light source are the different light source of gray-scale value; From the realtime graphic that monocular-camera gathers in step 3), gray scale is carried out to the brightest two points and compares, distinguish main spot and auxiliary hot spot.
The present invention further improves and is: secondary light source is arranged on simulated electrode towards on the direction of simulation soldering turret handle.
Relative to prior art, the present invention has following beneficial effect:
1) native system adopts a video camera to carry out image acquisition, needs to process its processing speed for two width images faster relative to biocular systems simultaneously;
2) monocular-camera is fixed in closed environment, only accepts the light entering video camera through test plate (panel) upper surface, and it is little by external environment interference, and stability is high;
3) calculate height value relative to a video camera special in binocular camera by horizontal direction collection image and obtain 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, and cost reduces.
Accompanying drawing explanation
Fig. 1 is the schematic diagram of simulated electrode end;
The geometric relationship schematic diagram of Fig. 2 is simulated electrode inclination angle and corner when being zero light;
Fig. 3 is simulated electrode inclination angle is zero, the geometric relationship schematic diagram of light when corner is non-vanishing;
Fig. 4 is angle of inclination exploded view schematic diagram;
Fig. 5 be simulated electrode inclination angle and corner all non-vanishing time light geometric relationship schematic diagram;
Fig. 6 is the present invention's virtual arc length detection system schematic diagram.
Embodiment
Refer to shown in Fig. 1, 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, Simulated Plate 20, monocular-camera and computing machine.The present invention is at simulated electrode 10 head design two spot laser generating meanss at 45 ° mutually, make it at Simulated Plate 20(sheet glass) on get two hot spots, the coordinate of two hot spots is gathered by the monocular-camera be arranged at bottom Simulated Plate 20, and the coordinate data of collection is transferred to computing machine; Simulated electrode 10 is arranged on simulation soldering turret 12, in simulation soldering turret 12, two obliquity sensor 11 is housed, for detecting simulated electrode 10 roll angle and pitching angle value; Simulated electrode 10 roll angle that two obliquity sensors 11 on simulation soldering turret 12 gather and pitching angle value are real-time transmitted to computing machine.Computing machine in conjunction with the position of two light sources, light angle, welding rod dip angle parameter calculating simulation welding rod 10 end apart from the height of Simulated Plate 20, i.e. virtual arc length.
Main light source 1 and secondary light source 2 adopt identical laser diode, run also identical with the environment used, therefore rely on monocular-camera to carry out identification main spot merely more difficult with auxiliary hot spot.Use habit when operating by observing welder can find, no matter operator uses left hand or the right hand, and the handle of simulation soldering turret 12 is all towards this side of operator.If secondary light source 2 to be arranged on this direction towards simulation soldering turret 12 handle on simulated electrode 11, the auxiliary hot spot of basic guarantee 200 can be protected and be always positioned at the one-sided of weld seam.If Fig. 6, x direction is direction of welding, y direction is vertical welding direction; Through main spot 100(x1, y1) dotted line be weld seam, during normal running, auxiliary hot spot 200 can within the scope of one-sided 180 ° of weld seam, namely dash area in figure.According to the coordinate system of Simulated Plate plane, then have auxiliary hot spot 200(x2, y2) coordinate y2 be greater than the coordinate y1 of main spot.Therefore, on certain hardware design installation foundation, utilizing the operating habit of welder, just can realize the identification of main spot 100 and auxiliary hot spot 200 by comparing two hot spot coordinate y values.
The light source that main light source 1 and secondary light source 2 can also adopt gray-scale value different, from the realtime graphic that monocular-camera gathers, carries out gray scale to the brightest two points and compares, just can distinguish main spot 100 and auxiliary hot spot 200.
In order to simplify mathematical model, save installing space, main light source 1 and secondary light source 2 are arranged in same plane, and that is the light that sends of the light that sends of main light source 1 and secondary light source 2 is coplanar.And main light source 1 is installed along simulated electrode 10 direction, its light sent and simulated electrode 10 conllinear, and main light source 1 is 45 ° with the angle of secondary light source 2, as shown in Figure 1.
1, virtual arc length detection formula is derived
1) inclination angle and corner are the situation of zero
When inclination angle and corner are zero, simulated electrode 10 perpendicular to surface level, also namely main light source 1 perpendicular to surface level, then just like the situation of Fig. 2.Two light have virtual focus O, and it is to the distance h of main light source 1 front end
0be fixing, the angle theta between two light is determined by light source installation site, is known; According to image detecting method, the coordinate of the main spot 100 that main light source 1 and secondary light source 2 are got and auxiliary hot spot 200 can calculate, and the distance D therefore between two hot spots can calculate.Then just arc length H can be obtained according to formula.
Wherein, D is the distance that main light source 1 and secondary light source 2 are irradiated on Simulated Plate 20 between two hot spots; θ is the angle between main light source 1 and secondary light source 2; h
0for virtual focus O is to the distance of main light source 1 front end; H is the distance of the main spot that virtual focus O gets to main light source 1.
2) inclination angle is the non-vanishing situation of zero corner
In the case, because inclination angle is still zero, therefore two light place planes are still perpendicular to surface level, then just like the situation of Fig. 3.Wherein
for corner, can be read by obliquity sensor 11.Formula and (3) can be drawn by geometric relationship in figure.
Combination type, (3) and (4), cancellation P and h obtains:
Formula (5) for inclination angle be the arc length computing formula in the non-vanishing situation of zero corner.
3) situation that inclination angle and corner are all non-vanishing
This situation represents the frequent state that arc length is measured, and the formula derived will be of universal significance.In space, any one angle tilted of simulated electrode can project and be decomposed into the corresponding angle (as Fig. 4) on inclination angle and corner.Therefore, by decomposing the inclination first carrying out corner direction, then formula (5) can be drawn.On this basis, as Fig. 5 carries out the inclination of inclination direction, angle of inclination is μ, then can draw relational expression (6), and abbreviation draws final formula (7).
Abbreviation:
Parameters on the right of formula (7) equal sign is all known maybe can surveying, and just can obtain arc length H accordingly.
Refer to shown in Fig. 1 to Fig. 6, the present invention is based on the virtual arc length detection method of simulation welding training of monocular-camera, comprise the following steps:
1) operator uses simulation soldering turret 12 above Simulated Plate 20, carry out simulation welding, and the illumination that the main light source 1 of simulated electrode 10 front end and secondary light source 2 send is mapped on Simulated Plate 20 and forms main spot 100 and auxiliary hot spot 200; Be fixed on the monocular-camera real-time image acquisition below Simulated Plate 20;
2) computing machine real-time calling monocular-camera, obtains a two field picture of monocular-camera Real-time Collection;
3) computer recognizing goes out the coordinate of main spot 100 and auxiliary hot spot 200 in a gathered two field picture;
4) coordinate of the main spot 100 that obtains according to step 3 of computing machine and auxiliary hot spot 200, and two obliquity sensor 11 real-time Transmission is to the corner of the simulated electrode 10 of computing machine and pitch angle data, calculates obtain real-time virtual arc length H according to formula 7:
Wherein, D is the distance between main spot 100 and auxiliary hot spot 200, h
0for virtual focus O is to the distance of main light source 1 front end, θ is the angle between main light source 1 and secondary light source 2,
for simulated electrode 10 corner, μ is simulated electrode 10 angle of inclination;
5) step 2 is repeated)-4), real-time circulation obtains real-time virtual arc length and the simulated electrode elevation information of welding process.
The light source that main light source 1 and secondary light source 2 can also adopt gray-scale value different, from the realtime graphic that monocular-camera gathers in step 3), carries out gray scale to the brightest two points and compares, just can distinguish main spot 100 and auxiliary hot spot 200.Can certainly according to the method for machinery; secondary light source 2 is arranged on this direction towards simulation soldering turret 12 handle on simulated electrode 11; then can protect the auxiliary hot spot of basic guarantee 200 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 (9)
1. adopt the simulation welding training virtual arc length detection system based on monocular-camera to carry out the method for virtual arc length detection, it is characterized in that, the virtual arc length detection system of the described simulation welding training based on monocular-camera, comprises simulated electrode (10), simulation soldering turret (12), Simulated Plate (20), monocular-camera and computing machine; Simulated electrode (10) is arranged in simulation soldering turret (12), and the two obliquity sensors (11) for detecting simulated electrode (10) corner and tilt values are housed in simulation soldering turret (12); The front end of simulated electrode (10) is provided 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 Simulated Plate (20) below; Described computing machine connects monocular-camera and two obliquity sensor (11);
Described method of carrying out virtual arc length detection comprises the following steps:
1) operator uses simulation soldering turret (12) to carry out simulation welding in Simulated Plate (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 on Simulated Plate (20) and forms main spot (100) and auxiliary hot spot (200); Be fixed on the monocular-camera real-time image acquisition of Simulated Plate (20) below;
2) computing machine real-time calling monocular-camera, obtains a two field picture of monocular-camera Real-time Collection;
3) computer recognizing goes out the coordinate of main spot (100) and auxiliary hot spot (200) in a gathered two field picture;
4) computing machine is according to step 3) coordinate of the main spot (100) that obtains and auxiliary hot spot (200), and two obliquity sensor (11) real-time Transmission is to the corner of the simulated electrode of computing machine (10) and pitch angle data, calculates according to formula 7 and obtain real-time virtual arc length H:
Wherein, D is the distance between main spot (100) and auxiliary hot spot (200), h
0for virtual focus O is to the distance of main light source (1) front end, θ is the angle between main light source (1) and secondary light source (2),
for simulated electrode (10) corner, μ is simulated electrode (10) angle of inclination.
2. the method that detects of virtual arc length according to claim 1, is characterized in that, main light source (1) and secondary light source (2) are the different light source of gray-scale value; Step 3) in from the realtime graphic that monocular-camera gathers, gray scale is carried out to the brightest two points and compares, distinguish main spot (100) and auxiliary hot spot (200).
3. the method for virtual arc length detection according to claim 1, is characterized in that, secondary light source (2) is arranged on simulated electrode (10) towards on the direction of simulation soldering turret (12) handle.
4. the method for virtual arc length detection according to claim 1, it is characterized in that, described Simulated Plate (20) is sheet glass.
5. the method for virtual arc length detection according to claim 1, it is characterized in that, the emergent light of main light source (1) and secondary light source (2) is coplanar and angle is 45 °.
6. the method for virtual arc length detection according to claim 1, it is characterized in that, main light source (1) and secondary light source (2) are identical laser diode.
7. the method that detects of virtual arc length according to claim 1, is characterized in that, main light source (1) and secondary light source (2) are the different laser diode of emergent light gray-scale value.
8. the method for virtual arc length detection according to claim 1, is characterized in that, secondary light source (2) is arranged on simulated electrode (10) towards on the direction of simulation soldering turret (12) handle.
9. the method for virtual arc length detection according to claim 1, it is characterized in that, during simulation welding, main light source (1) forms main spot (100) and auxiliary hot spot (200) with the emergent light of secondary light source (2) on Simulated Plate (20); Described computing machine is used for the coordinate going out main spot (100) and auxiliary hot spot (200) according to the data identification of monocular-camera collection, and the corner of the simulated electrode (10) that computing machine gathers according to the coordinate of main spot (100) and auxiliary hot spot (200) and two obliquity sensor (11) and tilt values calculate virtual arc length in real time.
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| US10056010B2 (en) * | 2013-12-03 | 2018-08-21 | Illinois Tool Works Inc. | Systems and methods for a weld training system |
| US10105782B2 (en) | 2014-01-07 | 2018-10-23 | Illinois Tool Works Inc. | Feedback from a welding torch of a welding system |
| US10170019B2 (en) | 2014-01-07 | 2019-01-01 | Illinois Tool Works Inc. | Feedback from a welding torch of a welding system |
| US10417934B2 (en) | 2014-11-05 | 2019-09-17 | Illinois Tool Works Inc. | System and method of reviewing weld data |
| US10402959B2 (en) | 2014-11-05 | 2019-09-03 | Illinois Tool Works Inc. | System and method of active torch marker control |
| US10204406B2 (en) | 2014-11-05 | 2019-02-12 | Illinois Tool Works Inc. | System and method of controlling welding system camera exposure and marker illumination |
| 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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| CN101539422B (en) * | 2009-04-22 | 2011-04-13 | 北京航空航天大学 | Monocular vision real time distance measuring method |
| CN101587659B (en) * | 2009-06-29 | 2011-02-09 | 西安交通大学 | Simulation training device for manual arc welding rod-moving operation, and arc welding rod-moving detection method |
| CN102394018A (en) * | 2011-07-18 | 2012-03-28 | 中国石油天然气第一建设公司 | Method for modelling and simulating one-sided welding two-sided forming process by grids |
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Address after: 471023 Luolong District, Henan, Luoyang Patentee after: China Petroleum & Natural Gas Construction Co., Ltd. Patentee after: Xi'an Jiaotong University Address before: 471023 No. 87 Longmen Avenue, Guan Lin Town, Luoyang City, Henan Province Patentee before: China Petroleum Natural Gas No.1 Construction Co. Patentee before: Xi'an Jiaotong University |