CN104162752B - Sheet metal lap weld little characteristic point four head serial vision-based detection tracking means - Google Patents
Sheet metal lap weld little characteristic point four head serial vision-based detection tracking means Download PDFInfo
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- 239000002184 metals Substances 0.000 title claims abstract description 10
- 238000003466 welding Methods 0.000 claims abstract description 189
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- 229910000831 Steel Inorganic materials 0.000 claims abstract description 5
- 239000010959 steel Substances 0.000 claims abstract description 5
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- 238000004519 manufacturing process Methods 0.000 description 6
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- 238000004021 metal welding Methods 0.000 description 1
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Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K37/00—Auxiliary devices or processes, not specially adapted to a procedure covered by only one of the preceding main groups
Abstract
Description
Technical field
Technical scheme of the present invention relates to vision welding field, specifically replaces human eye in welding process, identify weld signature point and control the device that welding gun has moved welding for camera.
Background technology
In order to meet the demand of day by day complicated welding production, it is an important application that vision is incorporated in welding field, in welding process, vision can replace eye recognition weld signature, and characteristic information is passed to programmable logic controller (PLC) (ProgrammableLogicController, be called for short PLC), and then carry out moving welding according to deviation information control welding gun.But its application is still subject to the restriction of several factors, the harmony of work, real-time and robustness be also far from reaching as people trick as one degree.How accurately to obtain weld signature point is stubborn problem always, is also the key determining vision welder quality.
Visible detection method has the advantages such as noncontact, Large visual angle and system flexibility are good, is in recent years widely used in industrial environment especially welding field.Vision-based detection realizes by means of yi word pattern laser line generator; yi word pattern laser line generator and camera are encapsulated in vision and protect in box; collected by camera to image be sent to industrial computer; industrial computer application vision extraction procedure realizes Visual Feature Retrieval Process and communicates to PLC with by characteristic point position; PLC controls welding gun centering weld seam, completes real-time welding process.
At welding technology field, traditional welding method relies on manpower to realize, undertaken welding by human eye determination weld signature point control welding gun or by teaching process control welding gun motion track, but this method efficiency is lower, not there is flexibility, need according to different sheet metal feature respectively teaching weld.Vision is introduced welding, can detect in real time by realization character point, thus control welding gun real-time tracking, save the teaching time, improve production efficiency, decrease human input, there is social benefit and economic benefit.
CN102139487A discloses " welding robot long-distance demonstration visual sensor ", and sensor can realize accurate field teaching, and vectoring aircraft mechanical arm realizes accurate tracking.This method is suitable only for small lot, modularized production, is not suitable for producing in enormous quantities, can not monitor in real time deformation skews such as welding plates in welding.
CN103480991A discloses " the online vision-based detection of a kind of sheet metal bead weld and control device ", sheet metal welding is carried out by parallel eight, four tunnel vision sensor, this system is parallel mechanism structure, be applicable to multiple production line go into operation simultaneously, for such as longer welding plate welding efficiency is relatively not high, and be not suitable for overlap joint welding procedure.
CN101973032A reports " a kind of welding robot line structured light vision sensor off-line programing system and method ", need to write a large amount of information off-line storehouse to weld, path planning and movement programming are carried out to welding track, welding process just performs precalculated track, can not process in real time in time for the site error occurred in welding process, higher to on-the-spot stability requirement.
The present invention is directed to above deficiency, propose and weld visual monitor system in real time, can adapt to the overlap joint welding plate of differing heights, can replace completely manually welding, flexibility ratio is high, and adapt to the on-the-spot error occurred, real-time is good, and reliability is high.System is provided with four cover sensing welders, can weld simultaneously, improve welding efficiency.
Summary of the invention
For above problem, technical problem to be solved by this invention is: adopt serial No. four vision sensor and welding machine, and four cover vision sensors independently carry out feature detection, and every cover system is equipped with limit switch, has worked in coordination with welding process.Crucial device is vision sensor, and enclosed inside has separated laser and USB industrial camera.Can weld comparatively long overlap welding plate, four tunnel serials welding collaborative works, complete long overlap welding plate weld task, save time than Method for Single Sensor System simultaneously.Realize extract real-time weld signature point in welding process, deviation data is sent to PLC and then control welding gun further and move realization welding in real time, do not change by site environment and welding work pieces deformation etc. affects, the intelligent welding of realization.
Technical scheme of the present invention is:
A kind of sheet metal lap weld little characteristic point four head serial vision-based detection tracking means, the composition of this device comprises gantry framework, industrial computer, PLC regulator cubicle,
Wherein, the crossbeam of gantry framework carries four welding guns, the side of each welding gun respectively rigid connecting is connected to a vision sensor, welding gun opposite side respectively rigid connecting is connected to a welding controller, in four welding guns, respectively there is a welding gun at the two ends, left and right of gantry truck transom, 1/4 and 1/2 position is played in the left side that two other welding gun lays respectively at gantry framework crossbeam, vision sensor is fixed on the front end of welding gun direct of travel, together to advance movement with welding gun, in welding process, three welding gun direct of travels in left side are consistent, for advancing from left to right, the welding direction of right side welding gun is contrary with three, left side welding gun welding direction, advance from right to left, industrial computer is positioned at one end of crossbeam, PLC regulator cubicle is positioned at gantry framework sidepiece,
Described vision sensor enclosed inside has industrial camera and laser instrument, industrial camera is arranged on the top of vision sensor inwall, laser instrument is arranged on the sidewall of vision sensor inside, angularly install with industrial camera, angle of regulation range 20 ° ~ 70 °, at grade, there is U-lag at vision sensor back for filters center and industrial camera optical axis center;
The camera signal line of each vision sensor inside is also connected with industrial computer through respective hinge inner by Base top contact respectively with laser power supply line, and four hinges are positioned on the boss of framework side, gantry, below crossbeam; Overlap joint steel plate to be welded is positioned on the framework platform surface of gantry, is pressed with presser feet above;
Described welding gun top rigid is connected with vertical direction bias adjustment servomotor, vertical direction manual rocker is rigidly connected in the vertical direction on bias adjustment servomotor, welding gun is also rigidly connected with the first contiguous block, cylinder is arranged on the first contiguous block, cylinder and lateral deviation regulate servomotor to be rigidly connected, lateral deviation regulates servomotor top rigid to be connected with longitudinal bias and regulates servomotor, horizontal manual rocker is rigidly attached to lateral deviation and regulates on servomotor, and longitudinal manual rocker is rigidly attached to longitudinal bias and regulates on servomotor; Vertical direction manual rocker is rigidly connected in the vertical direction on bias adjustment servomotor; Cylinder is rigidly connected by the second contiguous block vision sensor,
Visual sensing apparatus is connected with the slideway of gantry framework contiguous block with gantry framework beam sides, regulates servomotor to drive the 3rd slide block to slide along welding direction together with welding gun by longitudinal bias,
Described industrial computer is connected with the PLC in PLC regulator cubicle by industrial bus, and PLC regulates servomotor and longitudinal bias to regulate servomotor to be connected with vertical direction bias adjustment servomotor, lateral deviation respectively.
Described PLC regulator cubicle comprises PLC, gauge tap and indicator lamp, and gauge tap is connected with PLC and indicator lamp by wiring.
The invention has the beneficial effects as follows:
This invention exploits sheet metal lap weld little characteristic point four head serial vision-based detection tracking means, this device can replace manpower to carry out work, every platform machine four welding guns weld simultaneously, substantially reduce the weld interval of each long overlap steel plate, save human resources, effectively save weld interval, system four welding machine can or work independently simultaneously, whole day twenty four hours continuous firing can be realized, avoid workman due to the welding error caused such as tired out, improve welding quality; System architecture simple and flexible, can carry out angle adjustment according to setting height(from bottom), adopts separated laser, reduces the volume of sensor; Be applicable to the impact of on-the-spot changeable factor, intelligent vision welding can according to welding plate in welding process because the skew that the factors such as machine vibration cause detects current signature point position in real time, as can be seen from implementation result data, between consecutive frame, maximum deviation is within 5 pixels, welding gun position deviation, within 0.5mm, improves precision and the degree of accuracy; Workman is freed from work situation rugged environment, realizes the effect that a workman monitors multiple stage welding simultaneously, can effectively save factory production system space and cost.
Accompanying drawing explanation
Below in conjunction with drawings and Examples, the present invention is further described.
Fig. 1 is system framework schematic diagram.
11 is gantry framework 12 be welding plate presser feet 131,132,133,134 for welding gun 141,142,143,144 be vision sensor
151,152,153,154 is protection wiring hinge, and interior cloth cabling 16 is industrial computer 17 is welding controller for overlap joint welding plate 18 is PLC regulator cubicle 191
Fig. 2 is encapsulation vision sensor schematic internal view.
144 is vision sensor 111 for industrial camera 110 is yi word pattern laser instrument
Fig. 3 is present system structure chart.
Fig. 4 is the invention process handling process.
Fig. 5 is industrial computer monitoring interface.
50 is original image viewing area, and 51 is reconstruction of three-dimensional images viewing area, and 52 is welded condition monitoring, 53 is speed of welding display box, and 54 is lateral coordinates display box, and 55 is longitudinal coordinate display box, 56 is vertical missing display box, 57 is program exit button, and 58 for arranging button, can arrange the information such as pid control parameter, 59 for starting welding button, 510 is starting point search button, and 511 is presser feet lifting button, and 512 is switching push button between four sensor display interfaces.
Fig. 6 is welding controller interface
61 is that the manual/auto switching push button 62 of welding process is for welding start button 63 is for welding gun left lateral right lateral button under manual mode 64 is for welding stop button
Fig. 7 is vision sensor installation drawing.
71 is baffle plate, 72 is vertical missing adjustment servomotor, 73 is vertical direction manual rocker, and 74 is cylinder, and 75 is lateral deviation adjustment servomotor, 76 is longitudinal manual rocker, 77 is longitudinal bias adjustment servomotor, and 78 is horizontal manual rocker, and 79 is the contiguous block between cylinder and vision sensor, 710 is the contiguous block between welding gun and cylinder, and 711 is visual sensing apparatus and gantry framework contiguous block.
Fig. 8 is that curve map is extracted in vision sensor 141 butt welded seam position; Wherein, Fig. 8 a is weld seam weld signature point lateral coordinates curve map, and Fig. 8 b is weld seam weld signature point longitudinal coordinate curve map, and Fig. 8 c is weld seam weld signature point vertical missing curve map;
Fig. 9 is that curve map is extracted in vision sensor 142 butt welded seam position; Wherein, Fig. 9 a is weld seam weld signature point lateral coordinates curve map, and Fig. 9 b is weld seam weld signature point longitudinal coordinate curve map, and Fig. 9 c is weld seam weld signature point vertical missing curve map;
Figure 10 is that curve map is extracted in vision sensor 143 butt welded seam position; Wherein, Figure 10 a is weld seam weld signature point lateral coordinates curve map, and Figure 10 b is weld seam weld signature point longitudinal coordinate curve map, and Figure 10 c is weld seam weld signature point vertical missing curve map;
Figure 11 is that curve map is extracted in vision sensor 144 butt welded seam position; Wherein, Figure 11 a is weld seam weld signature point lateral coordinates curve map, and Figure 11 b is weld seam weld signature point longitudinal coordinate curve map, and Figure 11 c is weld seam weld signature point vertical missing curve map.
Detailed description of the invention
Below embodiments of the invention are elaborated, but scope of the present invention can not be limited with this.Any the replacement of parts well know in the art, combination, discrete is done to mechanism of the present invention, and do equivalent change well know in the art or replace all not exceed exposure of the present invention and protection domain to the invention process step.
Fig. 1 is whole system structure chart.
A kind of sheet metal lap weld little characteristic point four head serial vision-based detection tracking means, the composition of this device comprises gantry framework 11, industrial computer 16, PLC regulator cubicle 18,
Wherein, the crossbeam of gantry framework 11 carries four welding guns 131,132,133,134, the side of welding gun 131,132,133,134 respectively rigid connecting is connected to vision sensor 141,142,143,144, welding gun 131,132,133,134 opposite side respectively rigid connecting is connected to a welding controller, welding controller and vision sensor are followed together with welding gun and are moved, welding controller 191 can realize controlling welding gun 134 and weld and manually, automatically switch, and is convenient to debugging.Wherein, welding gun 131, 134 two ends, left and right laying respectively at gantry framework 11 crossbeam, welding gun 132, 1/4 and 1/2 position is played in 133 left sides laying respectively at gantry framework crossbeam, vision sensor 141, 142, 143, 144 are fixed on welding gun 131 by contiguous block, 132, 133, the front end of 134 direct of travels, respectively with welding gun 131, 132, 133, 134 together advance movement, play vision-based detection characteristic point and guide the effect of welding, in welding process, welding gun 131, 132, 133 direct of travels are consistent, for advancing from left to right, welding gun 134 welding direction and welding gun 131, 132, 133 welding directions are contrary, advance from right to left, industrial computer 16 is positioned at one end of crossbeam, PLC regulator cubicle 18 is positioned at gantry framework sidepiece, the beam sides of gantry framework 11 has slideway, moves along welding direction for welding gun 131,132,133,134 and contiguous block,
Wherein, for vision sensor 144, its enclosed inside has industrial camera 111 and yi word pattern laser instrument 110, industrial camera 111 is the DH-HV1351UM camera of company of Daheng, be arranged on the top of vision sensor 144 inwall, yi word pattern laser instrument 110 (is well-known device, yi word pattern structural light stripes can be sent) install on vision sensor 144 sidewall, angularly install with industrial camera 111, the structured light launched with yi word pattern laser instrument 110 of angle at industrial camera 111 imaging plane in middle part for proper angle, and its angle can regulate, adjustable range 20 ° ~ 70 °, yi word pattern laser instrument 110 center and industrial camera 111 optical axis center are at grade, there is U-lag at vision sensor 144 back, water-cooled can be carried out.Four vision sensors 141, 142, 143, the industrial camera holding wire of 144 inside and laser power supply line are by Base top contact and through protecting wiring hinge 151, 152, 153, 154 inside are connected with industrial computer 16, protection wiring hinge 151, 152, 153, 154 are positioned on the boss of framework side, gantry, below crossbeam, inside has vertical missing to regulate servomotor 72, lateral deviation regulates servomotor 75, longitudinal bias regulates servomotor 77 and PLC connecting line, vision sensor 141, 142, 143, 144 with industrial computer 16 connecting line, be not wound around for the protection of circuit is stable.17 is overlap joint welding plate, on the framework platform surface of gantry, and be fixed by the presser feet 12 of welding plate and prevent from welding process, causing the mobile dislocation of steel plate due to various external factor and then causing problems of welded quality, the presser feet 12 of welding plate is positioned at side, framework surface, gantry, motive force can be provided to control the lifting of the presser feet 12 of welding plate by external air pump by industrial computer 16, and then compress overlap joint welding plate 17.
Welding gun 134 top rigid is connected with vertical missing and regulates servomotor 72, band dynamic air cylinder 74, welding gun 134 can vertically move up and down, and the extreme position moved up and down is determined by cylinder 74, and cylinder 74 is arranged on the contiguous block 710 between welding gun and cylinder and is rigidly connected with welding gun 134, cylinder 74 and lateral deviation regulate servomotor 75 to be rigidly connected, vertical direction manual rocker 73 is rigidly attached to vertical missing and regulates on servomotor 72, horizontal manual rocker 78 is rigidly attached to lateral deviation and regulates on servomotor 75, longitudinal manual rocker 76 is rigidly attached to longitudinal bias and regulates on servomotor 77, longitudinal bias regulates servomotor 77 to be arranged on lateral deviation and regulates servomotor 75 top, under manual mode, by vertical direction manual rocker 73, horizontal manual rocker 78, longitudinal manual rocker 76, can realize manually in the vertical direction, laterally, longitudinal welding gun 134 position adjustments.Cylinder 74 is rigidly connected with vision sensor 144 by the contiguous block 79 between cylinder and vision sensor, and vision sensor 144 enclosed inside has industrial camera 111 and yi word pattern laser instrument 110.Wherein, relate in system connection be and be rigidly connected.Visual sensing apparatus is connected with the slideway of gantry framework contiguous block 711 with gantry framework beam sides, servomotor 77 is regulated to drive visual sensing apparatus to slide along welding direction together with welding gun 134 with gantry framework contiguous block 711 by longitudinal bias, support vision sensor 144 and welding gun 134 structure, vision sensor 144 and welding gun 134 are all installed vertically on and overlap above welding plate 17, welded seam area is aimed at center, and the plane orthogonal that welding gun 134 center and industrial camera 111 optical axis form is in overlapping weldment 17; Vision sensor 144 is positioned at the dead ahead of welding gun 134 direct of travel.
Be packaged with industrial camera 111 and yi word pattern laser instrument 110 in vision sensor 144, between industrial camera 111 with industrial computer 16, carry out being connected the transmission with data with USB line.Industrial computer 16 obtains the image information sent, through image filtering, skeletal extraction, a series of process such as feature extraction, the position deviation information of the characteristic point extracted is sent to the PLC in PLC regulator cubicle 18 via serial communication, PLC will be laterally, longitudinally, vertical missing amount passes to lateral deviation respectively and regulates servomotor 75, longitudinal bias regulates servomotor 77, vertical missing regulates servomotor 72, lateral deviation regulates servomotor 75, longitudinal bias regulates servomotor 77, vertical missing regulates servomotor 72 according to deviation information and then controls welding gun 134 and carry out moving thus centering weld seam welds in real time.
By starting point search button 510, industrial computer 16 obtains welding initial point, industrial computer 16 will weld initial point positional information, the PLC in PLC regulator cubicle 18 is sent to via serial communication, welding initial point positional information is passed to lateral deviation and regulates servomotor 75, longitudinal bias to regulate servomotor 77, vertical missing to regulate servomotor 72 by PLC respectively, and lateral deviation regulates servomotor 75, longitudinal bias to regulate servomotor 77, vertical missing to regulate servomotor 72 to control welding gun 134 according to welding initial point information and moves to welding initial point position.Wherein, serial communication is both-way communication pattern.Meanwhile, industrial computer 16 display screen not only can show view synthesis information, also can show weld signature point position and deviation information; Operating personnel can carry out speed by display screen to process, the pid parameter of control is arranged, and realize the real-time monitoring to welding process.
The main composition of described PLC regulator cubicle 18 is PLC, gauge tap, indicator lamp and wiring etc., and gauge tap is connected with PLC and indicator lamp by wiring, to complete and to show PLC electrifying condition;
Fig. 4 is the invention process handling process, first the presser feet 12 of welding plate is compressed, carry out starting point search, welding gun 131,132,133,134 is made to move to welding initial point, and then beginning welding process, the image that industrial camera collects is through image filtering, main lines detection, feature point extraction and then obtain transverse direction, longitudinal direction, vertical missing, and deviation information passes to PLC, and PLC respectively control deviation regulates driven by motor welding gun to carry out the welding that bias adjustment realizes centering weld seam.
Fig. 5 is industrial computer monitoring interface, for one of them vision sensor 144 processing procedure, original image viewing area 50 can show image processing data in real time, reconstruction of three-dimensional images viewing area 51 can be carried out three-dimensional reconstruction according to the data message extracted and shows, 52 is welded condition monitoring, between industrial camera 111 and industrial computer 16, PLC regulator cubicle 18 can normal communication time, state box be green display, otherwise be grey display, at this time just need to carry out trouble shooting.53 is speed of welding display box, welding gun speed can be set by screen and communication to PLC.By clicking " set " button 58, the setting of the transmission of pid parameter and presser feet width etc. can be realized to controller.Click " presser feet lifting " button 511, just can complete and the presser feet 12 of welding plate is closely pressed on above overlap joint welding plate 17, prevent the disturbance occurred in welding process from causing welding plate position to offset.And then continue to click " starting point search " button 510, now, welding gun can Automatic-searching welding starting point.Press " starting welding " button 59, now, welding starts, 54,55,56 show lateral coordinates display box, longitudinal coordinate display box, the vertical missing display box that special overlap welding in industrial computer connects the characteristic point that process software identifies respectively, and successively send these three deviations to PLC, control welding gun and carry out mobile centering weld seam in transverse direction, longitudinal direction, vertical direction according to the amount of deflection, complete continuous welding.Between four sensor display interfaces, switching push button 512 can switch between four sensors, monitors respectively to four sensors.Namely program exit button 57 can ensure that program safety exits.
For one of them vision sensor 144 processing procedure, if need manually to weld, need, by the manual/auto switching push button 61 of welding process pressing welding controller 191, to be switched to manual mode and to weld.Press welding start button 62, namely can manually weld, press welding gun left lateral right lateral button 63 under manual mode, namely can control welding gun 134 and move left and right and weld, press welding stop button 64, namely can stop welding.
The methods such as the storage related in industrial computer in the present invention, manipulation and signal transacting are known technology, and this area ordinary person technical staff can write relative program to realize according to the popular software VC that is described through of above-mentioned steps completely.
The application attestation of this enforcement, the invention process is convenient, the monitoring that can realize overlapping welding with from motion tracking, the needs of production line can be met.
The weld signature of the present embodiment detects data result as shown in Fig. 8, Fig. 9, Figure 10, Figure 11.Overlap joint welding plate for 2 mm of thickness of length 12 meters carries out test welding, speed of welding is 1m/s, at Fig. 8, Fig. 9, Figure 10, Tu11Zhong, we can see that between consecutive frame, maximum metrical error is less than 5 pixels, and namely corresponding welding gun adjusting deviation coverage error is within 0.5mm.
Unaccomplished matter of the present invention is known technology.
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