CN103753015B - A kind of laser-beam welding machine seam tracking system and welding seam tracking method - Google Patents

A kind of laser-beam welding machine seam tracking system and welding seam tracking method Download PDF

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Publication number
CN103753015B
CN103753015B CN201310733478.0A CN201310733478A CN103753015B CN 103753015 B CN103753015 B CN 103753015B CN 201310733478 A CN201310733478 A CN 201310733478A CN 103753015 B CN103753015 B CN 103753015B
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welding
laser
module
main control
processing module
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CN201310733478.0A
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CN103753015A (en
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黄品桦
安业勋
岳民栋
张伟
何林
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深圳市光大激光科技股份有限公司
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    • BPERFORMING OPERATIONS; TRANSPORTING
    • B23MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23KSOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K26/00Working by laser beam, e.g. welding, cutting or boring
    • B23K26/02Positioning or observing the workpiece, e.g. with respect to the point of impact; Aligning, aiming or focusing the laser beam
    • B23K26/04Automatically aligning, aiming or focusing the laser beam, e.g. using the back-scattered light
    • B23K26/044Seam tracking

Abstract

The invention discloses a kind of laser-beam welding machine seam tracking system, wherein, the optical signal that CCD vision sensor is gathered converts the view data of Serial output chronologically to, to obtain weld seam path profile picture, this image processing module is used for butt welded seam path profile picture and carries out pretreatment, calculate actual weld seam path width and tracking direction, in conjunction with detecting the workpiece height obtained, export actual welding track data, main control module is used for processing actual welding track data, and send control instruction according to result, numerical control driver module drives a laser welding head for the control instruction performing main control module, and regulate the position of this laser welding head and control the welding action of this laser welding head.The present invention not only achieves automatic laser welding, also has the advantages such as deviation is little, precision is high, welding quality is good.

Description

A kind of laser-beam welding machine seam tracking system and welding seam tracking method

Technical field

The present invention relates to laser weld, tracking technique, particularly relate to a kind of laser-beam welding machine seam tracking system and welding seam tracking method.

Background technology

In existing laser beam welding, laser facula mobile route be by operator with the mode of described point programme setting a laser facula mobile route.This method requires very high to the processing of groove, the assembly precision of workpiece, and the shape of some weld seam is difficult to mathematically show, deviation is there is due to subjective during operator's described point, welded part processing, on there is dimensional discrepancy in clip process, and by the impact of the multiple factors such as thermogenetic distortion in welding process, make to produce certain deviation between actual welds track and the track of solder joint, welding process stable to be completed and welding quality creates direct impact, particularly to the welding of some complex curve weld seams.At present, though laser weld seam track has adopted programming mode to realize automatically running, but still do not realize auto modification and compensation, actual very nearly the same with Process Control System.Present stage, domestic THE WELD SEAM TRACKING TECHNOLOGY can be described as of a great variety, such as mechanical type tracking, photo-electric tracking, infrared ray tracking etc., but most of technology maturity is inadequate, there is more problem and shortage.

Summary of the invention

The technical problem to be solved in the present invention is, for the deficiencies in the prior art, a kind of laser-beam welding machine seam tracking system and welding seam tracking method are provided, wherein, the position for the treatment of welding line is detected by the CCD vision sensor be synchronized with the movement with laser welding head, then by main control module, the physical location of surveyed laser welding head and its theoretical path are compared, according to the position of the modified result laser welding head compared, thus reach the object of seam track from motion tracking, not only achieve automatic laser welding, also there is deviation little, precision is high, the advantages such as welding quality is good.

For solving the problems of the technologies described above, the present invention adopts following technical scheme.

A kind of laser-beam welding machine seam tracking system, it includes: a CCD vision sensor, and the optical signal for being gathered converts the view data of Serial output chronologically to, to obtain weld seam path profile picture; One image processing module, it is connected to CCD vision sensor, and this image processing module is used for butt welded seam path profile picture and carries out pretreatment, calculates actual weld seam path width and tracking direction, in conjunction with detecting the workpiece height obtained, export actual welding track data; One main control module, it is connected to image processing module, and this main control module is used for processing actual welding track data, and sends control instruction according to result; One numerical control driver module, it is connected to main control module, and this numerical control driver module drives a laser welding head for the control instruction performing main control module, and regulates the position of this laser welding head and control the welding action of this laser welding head.

Preferably, also include: a ultrasonic sensor, it is for detecting welding position, output detections data; One welding quality message processing module, it is connected between ultrasonic sensor and main control module, the detection data that this welding quality message processing module is used for ultrasonic sensor to export contrast with the normal data preset, by undesirable welding position information transmission to main control module, by main control module sending controling instruction to numerical control driver module, and by numerical control driver module control laser welding head, repair welding is carried out to this welding position.

A kind of laser-beam welding machine welding seam tracking method, the method comprises the steps: step S1, the optical signal that CCD vision sensor is gathered converts the view data of Serial output chronologically to, to obtain weld seam path profile picture, and this weld seam path profile picture is transferred to image processing module; Step S2, image processing module butt welded seam path profile picture carries out pretreatment, calculates actual weld seam path width and tracking direction, in conjunction with detecting the workpiece height obtained, exports actual welding track data to main control module; Step S3, main control module processes actual welding track data, and sends control instruction to numerical control driver module according to result; Step S4, numerical control driver module performs the control instruction that main control module sends, and driving laser soldering tip, to regulate the position of this laser welding head and to control the welding action of this laser welding head.

Preferably, the method also comprises the steps: step S5, detect, and output detections data is to welding quality message processing module with ultrasonic sensor to welding position; Step S6, welding quality message processing module contrasts detecting data with the normal data preset, by undesirable welding position information transmission to main control module, by main control module sending controling instruction to numerical control driver module, and by numerical control driver module control laser welding head, repair welding is carried out to this welding position.

Preferably, step S1 comprises to step S3 and synchronously patrols crack approach, and synchronously patrolling limit is welding while, obtain weld seam center and weld contour, size.

Preferably, step S1 to step S3 comprises and asynchronously patrols crack approach, and asynchronous limit of patrolling utilizes CCD vision sensor to obtain weld seam path in advance, afterwards according to this weld seam path continuous welding.

Preferably, in step S2, image processing module butt welded seam path profile picture carries out preprocessing process and comprises filtering process and Edge contrast.

Preferably, in step S2, image processing module carries out angle point grid coupling by SIFT algorithm, splices the view data that CCD vision sensor exports.

Preferably, in step S2, the interfering picture in image processing module filtering weld seam path profile picture, obtains useful image information, and reinforcement of weld characteristic signal, extract weld bead feature points, protrude image outline, carry out image mosaic afterwards.

Preferably, in step S6, undesirable welding position is there is trachoma, position that weld penetration is inadequate.

In laser-beam welding machine seam tracking system disclosed by the invention, the optical signal that CCD vision sensor is gathered converts the view data of Serial output chronologically to, to obtain weld seam path profile picture, this image processing module is used for butt welded seam path profile picture and carries out pretreatment, calculate actual weld seam path width and tracking direction, in conjunction with detecting the workpiece height obtained, export actual welding track data, main control module is used for processing actual welding track data, and send control instruction according to result, numerical control driver module drives a laser welding head for the control instruction performing main control module, and regulate the position of this laser welding head and control the welding action of this laser welding head.The present invention's beneficial effect is compared to existing technologies, automatically welding process is completed by weld joint tracking, laser beam welding is made to achieve intellectually and automatically, greatly improve the efficiency of laser weld processing, improving laser solder technology level, be particularly suitable for the welding of docking style, corner connection type, undaform weld seam and other irregular weld seam, meanwhile, reduce production cost.By real-time automatic tracking and the adjustment of butt welded seam, can effectively avoid causing the quality problems such as welding skew by multiple objective factor affects, effective raising welding quality, because welding process completes automatically, the workload that artificial described point is programmed can reduce even to be ignored, thus reduction production cost, improve working conditions.

Accompanying drawing explanation

Fig. 1 is the structured flowchart of laser-beam welding machine seam tracking system.

Detailed description of the invention

Below in conjunction with drawings and Examples, the present invention is described in more detail.

The invention discloses a kind of laser-beam welding machine seam tracking system, as shown in Figure 1, it includes:

One CCD vision sensor 10, optical signal for being gathered converts the view data of Serial output chronologically to, to obtain weld seam path profile picture, by this CCD vision sensor 10 can realize butt welded seam position high speed, high-precisionly to take pictures continuously, to obtain center and the characteristic parameter such as weld contour and size of weld seam.

One image processing module 20, it is connected to CCD vision sensor 10, this image processing module 20 carries out pretreatment for butt welded seam path profile picture, calculate actual weld seam path width and tracking direction, in conjunction with detecting the workpiece height obtained, export actual welding track data, this workpiece height is for adjusting the vertical position of soldering tip.Further, there are asynchronous timesharing and synchronous real-time two kinds of application models in this image processing module 20, and the image procossing link of synchronous application is in real time based on embedded system, and therefore, the design direction of image processing system is high speed, high accuracy, transplantable.In addition, the image captured by CCD vision sensor 10 be local, interrupted, so need to splice image.The main research of this image processing module 20 is, by the design of embedded system and the exploitation of image processing software, be aided with computer function, filter and obtain information useful in weld image, reinforcement of weld characteristic signal, extract weld bead feature points, outstanding image outline, retain about the useful structural information in object limit, carry out the splicing of useful image, calculate and export weld width, highly, the information such as tracking direction position.

One main control module 30, it is connected to image processing module 20, this main control module 30 is for processing actual welding track data, and send control instruction according to result, this main control module 30 adopts PLC intelligent control technology, computer technology, automatic control technology and mechanics of communication and the serial Electromechanical Design such as industrial computer, servomotor, realizes the conversion of instruction, for operational order is assigned by executing agency, as required, hand control and automation two kinds of operator schemes can be designed to.

One numerical control driver module 40, it is connected to main control module 30, this numerical control driver module 40 drives a laser welding head 70 for the control instruction performing main control module 30, and regulate the position of this laser welding head 70 and control the welding action of this laser welding head 70, wherein, this laser welding head 70 is located at the top of weldment 100, and the weld seam 101 aimed on weldment 100, before laser welding head 70 is preferably located at by CCD vision sensor 10, track up weld image to be welded also transmits in real time, automatically according to weld seam to provide initial data.In this numerical control driver module 40, by the two-dimensional slipway designed in advance, the bond pad locations of adjustment laser welding head 70 and laser focal, make laser welding head 70 be in the middle of weld seam 101 all the time.

As a kind of preferred embodiment, this laser-beam welding machine seam tracking system also includes ultrasonic sensor 50 and a welding quality message processing module 60, the echo that this ultrasonic sensor 50 utilizes ultrasonic wave to reflect to form through weld seam detects welding position, and output detections data.This welding quality message processing module 60 is connected between ultrasonic sensor 50 and main control module 30, this welding quality message processing module 60 contrasts with the normal data preset for the detection data exported by ultrasonic sensor 50, by undesirable welding position information transmission to main control module 30, by main control module 30 sending controling instruction to numerical control driver module 40, and control laser welding head 70 by numerical control driver module 40 repair welding is carried out to this welding position.

In the present embodiment, the particular content about this image processing module 20 is as follows:

1, application system:

1) comprise and be not limited to the read-write capability of current conventional image file, at least comprising bmp, jpg, tif, avi etc.; 2) comprise and be not limited to current conventional ccd image fetch interface, at least comprising avt, basler etc.; 3) the Morphological scale-space function of view data, comprises convergent-divergent, rotation, gray processing, binaryzation, contrast strengthen, brightness regulation, gain conversions etc.; 4) algorithm process that conventional location is relevant, comprises the functions such as Corner Detection, sift/surf, edge extracting, chain code following, gray scale identification, geometric match.Its systematic function is: 1) the gray level image access time of single width 1280 × 960 is no more than 100ms; 2) the template matches time is no more than 300ms; 3) the Corner Detection time is no more than 500ms.Positioning precision and main flow positioning software (halcon, mil etc.) difference are less than 2 pixel, and the repetitive positioning accuracy amplitude of beating is less than 1.5pixel.The image procossing storehouse of this image processing module mainly operates in the windows system of WinXP and above version.The computer configuration of this image processing module needs more than CPU1.8G, recommendation double-core CPU, minimum internal memory 512Mb.System supports standard image format, as forms such as bmp, jpg; CCD interface is commonly used in system support, as basler(GigE network interface), avt(1394 capture card) etc.

2, above-mentioned application system comprises following level:

1) application layer is called, calling corresponding to other programs, there is provided dynamic base, static library and header file interface, upper procedure is carried out instantiation mainly for image library and is called and necessary interface function registered callbacks, as the image capture interface, the error handle notification interface that do not comprise in storehouse.2) image processing function, image processing function calls realization for functions such as image adjustment, geometric transformation, fixation and recognitions, completes the process based on view data, and accept and realize downlink and uplink interfaces.3) matrix computations, matrix computations realizes for the conversion of view data and the main body of function algorithm, as the algorithm packaging that image processing function calls, the algorithm of main flow general-purpose algorithm and our company's research and development all performs for matrix data, to realize the treatment effect of efficient stable.4) normal pictures read-write interface, reads and writes for standard picture formats such as bmp, jpg, tif.5) ccd image fetch interface, realizes the standard fetch interface companies such as Basler, Avi being commonly used to CCD product, and can realize other CCD fetch interfaces by user, and the call back function that registration is corresponding, to adapt to the particularization application of different product.

3, operational mode:

The image procossing storehouse of this image processing module can be run as two kinds of reference patterns, 1) graphical display images display mode only directly calls as the encapsulation of image source (file or CCD), do not check rights of using, externally do not present data-interface, processing procedure is without daily record; 2) image display+process, display+tupe can realize all functions interface interchange (meet rights of using---check usb softdog), and data handling procedure can be looked into and can survey, and produces log database in order to checking.

4, control is run:

The image procossing storehouse of this image processing module supports that multi-core CPU performs, and when data processing, splits thread, meet the real-time for the treatment of effect according to core cpu number.

Based on the laser-beam welding machine seam tracking system of said structure, the present embodiment also proposes a kind of laser-beam welding machine welding seam tracking method, and the method comprises the steps:

The optical signal that step S1, CCD vision sensor 10 is gathered converts the view data of Serial output chronologically to, to obtain weld seam path profile picture, and this weld seam path profile picture is transferred to image processing module 20.

Step S2, image processing module 20 butt welded seam path profile picture carries out pretreatment, calculates actual weld seam path width and tracking direction, in conjunction with detecting the workpiece height obtained, exports actual welding track data to main control module 30.In this step, image processing module 20 butt welded seam path profile picture carries out preprocessing process and comprises filtering process and Edge contrast, to remove interference and noise, carries out edge extracting afterwards.For the extraction of the discrete solder joint of large format, information due to single image collection be local, interrupted, need to carry out splicing synthesis to general image, so, this image processing module 20 carries out angle point grid coupling by SIFT algorithm, the view data that CCD vision sensor 10 exports is spliced, to realize harmless splicing, forms vision signal.Further, the interfering picture in image processing module 20 filtering weld seam path profile picture, obtains useful image information, and reinforcement of weld characteristic signal, extract weld bead feature points, protrude image outline, carry out image mosaic afterwards.

Step S3, main control module 30 pairs of actual welding track datas process, and send control instruction to numerical control driver module 40 according to result.Above-mentioned steps S1 is in step S3, become with the process of the center and the characteristic parameter such as weld contour and size that obtain weld seam and patrol limit, patrol limit and have synchronous and asynchronous two kinds of patterns, synchronously patrolling limit is welding while, obtain weld seam center and weld contour, size, under the prerequisite that weld seam theoretical path is known, with the synchronous operating process completed in real time of welding, also can be applied to welding direction change not quite, the not too fast weld seam of speed of welding welds in real time; Asynchronous limit of patrolling utilizes CCD vision sensor 10 to obtain weld seam path in advance, afterwards according to this weld seam path continuous welding, this process need find weld seam path in advance, and afterwards again by this path continuous welding, this pattern is applicable to that speed of welding is fast, welding breadth is comparatively large or the model of discrete welds point.

Step S4, numerical control driver module 40 performs the control instruction that main control module 30 sends, and driving laser soldering tip 70, to regulate the position of this laser welding head 70 and to control the welding action of this laser welding head 70.

Step S5, detect, and output detections data is to welding quality message processing module 60 with ultrasonic sensor 50 to welding position.

Step S6, welding quality message processing module 60 contrasts detecting data with the normal data preset, by undesirable welding position information transmission to main control module 30, by main control module 30 sending controling instruction to numerical control driver module 40, and control laser welding head 70 by numerical control driver module 40 and repair welding is carried out to this welding position, in this step, undesirable welding position is there is trachoma, position that weld penetration is inadequate.

In laser-beam welding machine seam tracking system disclosed by the invention, have employed CCD visual sensing digital image processing techniques and ultrasound, and in conjunction with certain control technology, by CCD vision sensor 10, image processing module 20, main control module 30, numerical control driver module 40, ultrasonic sensor 50 and welding quality message processing module 60 form, its main operational principle is that the CCD vision sensor 10 by being synchronized with the movement with laser welding head 70 detects the position for the treatment of welding line, then by main control module 30, the theoretical path that surveyed physical location and laser welding head 70 are moved is compared, revised the position of laser welding head 70 in real time by numerical control driver module 40 according to the result compared, reach the object of seam track from motion tracking, it detects the side-play amount of weld seam and the precision of the degree of depth can reach 0.05mm.In addition, system also adopts ultrasonic sensor detection technique, detect welding position, by the exploitation and design of embedded system, the data realized sonac 50 obtains process, the qualitative data detected and the standard preset are contrasted, undesirable weld information is conducted to middle main control module 30, control numerical control driver module 40 by main control module 30 and complete the repair welding of defective in quality part is operated.This shows, not only achieve automatic laser welding by above-mentioned laser-beam welding machine seam tracking system, also there is the advantages such as deviation is little, precision is high, welding quality is good.

More than just preferred embodiment of the present invention, is not limited to the present invention, all make in technical scope of the present invention amendment, equivalently to replace or improvement etc., all should be included in scope that the present invention protects.

Claims (8)

1. a laser-beam welding machine seam tracking system, is characterized in that, includes:
One CCD vision sensor, the optical signal for being gathered converts the view data of Serial output chronologically to, to obtain weld seam path profile picture;
One image processing module, it is connected to CCD vision sensor, and this image processing module is used for butt welded seam path profile picture and carries out pretreatment, calculates actual weld seam path width and tracking direction, in conjunction with detecting the workpiece height obtained, export actual welding track data;
One main control module, it is connected to image processing module, and this main control module is used for processing described actual welding track data, and sends control instruction according to result;
One numerical control driver module, it is connected to main control module, and this numerical control driver module drives a laser welding head for the control instruction performing main control module, and regulates the position of this laser welding head and control the welding action of this laser welding head;
One ultrasonic sensor, it is for detecting welding position, output detections data;
One welding quality message processing module, it is connected between ultrasonic sensor and main control module, the detection data that this welding quality message processing module is used for ultrasonic sensor to export contrast with the normal data preset, by undesirable welding position information transmission to main control module, by main control module sending controling instruction to numerical control driver module, and by numerical control driver module control laser welding head, repair welding is carried out to this welding position.
2. a laser-beam welding machine welding seam tracking method, is characterized in that, the method comprises the steps:
The optical signal that step S1, CCD vision sensor is gathered converts the view data of Serial output chronologically to, to obtain weld seam path profile picture, and this weld seam path profile picture is transferred to image processing module;
Step S2, described image processing module butt welded seam path profile picture carries out pretreatment, calculates actual weld seam path width and tracking direction, in conjunction with detecting the workpiece height obtained, exports actual welding track data to main control module;
Step S3, described main control module processes actual welding track data, and sends control instruction to numerical control driver module according to result;
Step S4, described numerical control driver module performs the control instruction that main control module sends, and driving laser soldering tip, to regulate the position of this laser welding head and to control the welding action of this laser welding head;
Step S5, detect, and output detections data is to welding quality message processing module with ultrasonic sensor to welding position;
Step S6, described detection data and the normal data preset contrast by described welding quality message processing module, by undesirable welding position information transmission to main control module, by main control module sending controling instruction to numerical control driver module, and by numerical control driver module control laser welding head, repair welding is carried out to this welding position.
3. laser-beam welding machine welding seam tracking method as claimed in claim 2, is characterized in that, described step S1 comprises to step S3 and synchronously patrols crack approach, and described limit of synchronously patrolling is welding while, obtain weld seam center and weld contour, size.
4. laser-beam welding machine welding seam tracking method as claimed in claim 2, it is characterized in that, described step S1 to step S3 comprises and asynchronously patrols crack approach, and described asynchronous limit of patrolling utilizes CCD vision sensor to obtain weld seam path in advance, afterwards according to this weld seam path continuous welding.
5. laser-beam welding machine welding seam tracking method as claimed in claim 2, it is characterized in that, in described step S2, described image processing module butt welded seam path profile picture carries out preprocessing process and comprises filtering process and Edge contrast.
6. laser-beam welding machine welding seam tracking method as claimed in claim 5, it is characterized in that, in described step S2, described image processing module carries out angle point grid coupling by SIFT algorithm, splices the view data that CCD vision sensor exports.
7. laser-beam welding machine welding seam tracking method as claimed in claim 6, it is characterized in that, in described step S2, interfering picture in described image processing module filtering weld seam path profile picture, obtain useful image information, and reinforcement of weld characteristic signal, extract weld bead feature points, protrude image outline, carry out image mosaic afterwards.
8. laser-beam welding machine welding seam tracking method as claimed in claim 2, is characterized in that, in described step S6, described undesirable welding position is there is trachoma, position that weld penetration is inadequate.
CN201310733478.0A 2013-12-27 2013-12-27 A kind of laser-beam welding machine seam tracking system and welding seam tracking method CN103753015B (en)

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