CN104400279A - CCD-based method and system for automatic identification and track planning of pipeline space weld seams - Google Patents
CCD-based method and system for automatic identification and track planning of pipeline space weld seams Download PDFInfo
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- CN104400279A CN104400279A CN201410536548.8A CN201410536548A CN104400279A CN 104400279 A CN104400279 A CN 104400279A CN 201410536548 A CN201410536548 A CN 201410536548A CN 104400279 A CN104400279 A CN 104400279A
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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
- B23K37/02—Carriages for supporting the welding or cutting element
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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
The invention discloses a CCD-based method and system for automatic identification and track planning of pipeline space weld seams and meets common welding robots' requirements on welding of the pipeline space weld seams. Before welding, a CCD collects weld seam images in a one-eye and two-position way, and transmits the weld seam images to a main control computer through a USB cable; the main control computer conducts three-dimensional reconstruction on the weld seam of a workpiece in three parts according to a general stereoscopic vision principle to obtain the three-dimensional coordinate information of the three parts of the weld seam, combines the three-dimensional coordinate information to obtain the complete three-dimensional coordinates of the weld seam to determine the starting point of welding and determine the pose change of a robot tool coordinate system in the welding process, and transmits the pose change to a robot control cabinet via the Ethernet to control a welding robot to perform welding. Through a vision sensing system, the method and the system provided by the invention can be adapted to welding of butting and intersection of pipelines of different diameters to conduct all-position automatic welding, and avoids the limitation that only single-path weld seams can be welded according manual teaching.
Description
Technical field:
The present invention relates to a kind of solder technology of pipeline space weld seam of view-based access control model sensing, particularly a kind of pipeline space weld seam based on CCD identifies the method and system with trajectory planning automatically, and it belongs to intelligent Technology of Welding Robot field.
Background technology:
Pipe pipe docks, and pipe pipe intersecting welding is more common in fields such as oil, boiler and metallurgical constructions, and Guan Guanxiang passes through the space curve that generation is relatively assisted, and can produce the shape of a saddle space curve of standard time orthogonal, then can produce more complicated space curve during oblique.The saddle-shaped seam welding procedure that Guan Guanxiang passes through in the market is commonly used in automatic welding special plane, and machine tool type is generally used for the welding of the pipe pipe intersection that batch is large, workpiece is single, and lathe volume is large, weight large, and the workpiece type be suitable for is limited; Suspension type saddle-shaped welding robot, then can adapt to the welding of the saddle-shaped seam in certain limit, and pipe pipe oblique weld seam is subject to the impact of oblique angles, but the weld joint tracking of this type of welding robot generally uses off-line programing and teaching memory technique.
In the above-mentioned special welding machine for pipeline space weld seam, a critical problem all can be faced in actual production, pass through teaching exactly, constantly can only repeat the action of teaching in advance, namely the weld seam of particular path can only be welded, when pipe diameter change, change in location, Guan Guanxiang pass through the angle change of oblique, must teaching again, and can not make a response to welding surroundings change, the mismachining tolerance, rigging error etc. of such as workpiece.And the change of these factors can cause the original teaching track of welding seam bias, reduce welding quality and even form waste product.Therefore, when pipe welding seam welds, automatically can adapt to pipe diameter and position is the key issue realizing robot welding application.
At present, although research visual sensing being applied to welding robot is many, have also been obtained certain application, and the comparative maturity wherein applied is active vision, i.e. additional laser or structured light, but rare about investigation and application visual sensing is applied in pipeline welding.At present, in visible report, in document " Li Kai; view-based access control model sensor conduit welding robot tracking system research [Ph.D. Dissertation], Harbin Institute of Technology ", for long distance pipeline, have developed pipe welding robot tracking system, propose the pipe welding robot annular solder weld joint tracking algorithm based on circular cylindrical coordinate, but pipe ring seam welding can only be followed the tracks of, welding when Guan Guanxiang passes through can not be applied to.Number of patent application is 201110224808.4, name is called that " robot initial welding position recognition system and method based on monocular vision sensing " provides a kind of robot initial welding position recognition methods of thanking to device based on monocular vision sensing, but the weld seam of the workpiece that working needle is right is level, towards fixing and be changeless relative to the height of vision sensor, and be not suitable for space weld when Guan Guanxiang passes through.
Therefore, necessary the deficiency solving prior art is improved to prior art.
Summary of the invention:
For above-mentioned deficiency of the prior art and need of production, provide a kind of pipeline space weld seam based on CCD automatically to identify the method and system with trajectory planning, welding needs when common six axle welding robots pass through for the docking of pipe pipe and Guan Guanxiang can be met.
The present invention adopts following technical scheme: a kind of pipeline space weld seam based on CCD identifies the method with trajectory planning automatically, and it comprises the steps:
(1) welding module is selected: on main control computer, select pipe pipe to dock welding or pipe pipe related subgroup;
(2) workpiece picture to be welded is gathered: main control computer sends shooting signal to welding robot, welding robot adopts the mode of " an order dibit ", successively move to the 3 picture group sheets that 6 different camera sites gather workpiece to be welded, the weld seam picture gathered is transferred to main control computer by USB line;
(3) image procossing: main control computer carries out image procossing to received picture, extract weld profile, according to general binocular stereo vision, respectively three-dimensional reconstruction is carried out to 3 picture group sheets, obtain the three-dimensional coordinate information of weld seam under camera coordinates system in every picture group sheet, and store;
(4) path of welding is determined: the three-dimensional coordinate that the three-dimensional coordinate of weld seam under camera coordinates system in every picture group sheet is converted under robot base mark system, then the final three-dimensional coordinate obtaining complete solder path is merged, and determine to weld starting point according to final coordinate, and determine the change of robot tool coordinate system anglec of rotation in welding process, and store;
(5) weld: main control computer sends to robot control cabinet the path of welding data obtained, thus control welding robot moves in welding starting point, starts welding, completes whole welding process.
Further, three-dimensional reconstruction step concrete in described step (3) is: for each assembly welding seam picture, extract the pixel coordinate of figure weld profile in the left side in each group, calculate polar curve, determine the pixel coordinate of the point on corresponding right figure in corresponding left figure, calculate weld seam in each group camera site, the left side time, the three-dimensional coordinate of weld seam under camera coordinates system.
Further, described step (4) specifically comprises:
Step 1: determine weld seam three-dimensional coordinate: according to the transition matrix between tool coordinates system and robot base mark system and the transition matrix between tool coordinates system and camera coordinates system, the three-dimensional coordinate that the three-dimensional coordinate of weld seam under camera coordinates system in every picture group sheet is converted under robot base mark system, and merge the final three-dimensional coordinate obtaining complete weld seam, transformation matrix between described tool coordinates system and robot base mark system can be obtained by the pose of main control computer read machine people, transformation matrix between described tool coordinates system and camera coordinates system can be tested by hand and eye calibrating and be obtained,
Step 2: determine to weld starting point: according to the three-dimensional coordinate of the complete weld seam obtained under robot base mark system, determines that the maximum point of X-coordinate value is as welding starting point;
Step 3: determine anglec of rotation when robot tool coordinate system welds: be defined in welding process, only has the anglec of rotation of tool coordinates system Z axis in conversion, the anglec of rotation of X-axis and Y-axis is all constant, according to the distance on weld seam between adjacent 2, calculate the differential seat angle that between adjacent 2, Z axis rotates, and in weld seam starting point, the anglec of rotation of each axle of tool coordinates system is pre-set by main control computer, and then obtain the anglec of rotation of tool coordinates system on each coordinate position.
The present invention also adopts following technical scheme: a kind of pipeline space weld seam based on CCD identifies the system with trajectory planning automatically, it comprises welding robot, visual sensing system, robot control cabinet and main control computer, described welding robot is connected with robot control cabinet, main control computer is communicated by Ethernet with robot control cabinet, main control computer is connected by USB line with visual sensing system, visual sensing system is fixedly mounted on welding robot robot end welding gun, described visual sensing system comprises CCD industrial digital video camera and optical filter, described main control computer body comprises:
Image collection module, adopts the mode control CCD industrial digital video camera of " an order dibit " to gather workpiece picture to be welded;
Image processing module, be divided into weld seam picture processing two submodules that pipe pipe docks and Guan Guanxiang passes through, utilize image procossing, extract the weld profile on picture, according to general binocular stereo vision, respectively three-dimensional reconstruction is carried out to 3 assembly welding seam pictures, obtain the three-dimensional coordinate of weld seam under camera coordinates system in every picture group sheet respectively;
Path calculation module, the three-dimensional coordinate that the three-dimensional coordinate of weld seam under camera coordinates system in every picture group sheet is converted under robot base mark system, and merge the final three-dimensional coordinate obtaining complete weld seam, determine to weld starting point according to final three-dimensional coordinate again, and determine that tool coordinates ties up to the anglec of rotation under each coordinate;
Communication/control module, obtains the real-time pose information of robot, the path of welding data obtained is sent to robot control cabinet by Ethernet, thus control welding robot moves to welding starting point, welds.
The present invention has following beneficial effect:
(1) the present invention identifies based on the pipeline space weld seam of CCD to provide system platform with trajectory planning automatically, pass through visual sensing system, meet six common axle welding robots to the docking of pipe pipe and the welding needs that pass through of Guan Guanxiang, automatically can adapt to different angles oblique when different-diameter, diverse location and Guan Guanxiang pass through and the weld seam that produces;
(2) visual sensing system is utilized, automatic identification seam track, obtain the three-dimensional coordinate information of complete weld seam, carry out all-position automatic welding technology, eliminate the impact of the welding qualities such as the mismachining tolerance of workpiece, rigging error, avoid the limitation that artificial teaching can only weld particular path weld seam, decrease labour, reduce manufacturing cost and time cost.
Accompanying drawing illustrates:
Fig. 1 is the position view of robot when gathering image.
Fig. 2 is weld seam measurement of coordinates principle and each ordinate transform figure.
Fig. 3 is the workflow diagram of a specific embodiment of the present invention.
Fig. 4 is the pose schematic diagram of robot tool coordinate system in welding process.
Fig. 5 is the welding robot jig schematic diagram based on CCD of the present invention.
Fig. 6 is the control principle block diagram of the welding robot of view-based access control model sensing.
Detailed description of the invention:
For making object of the present invention, technical scheme and beneficial effect clearly, below in conjunction with specific embodiment, and with reference to accompanying drawing, the present invention is described in further detail, but embodiments of the present invention are not limited thereto.
The pipeline space weld seam that the present invention is based on CCD identifies and method for planning track automatically, comprises the following steps:
(1) welding module is selected: on main control computer, select pipe pipe to dock or pipe pipe related subgroup;
(2) workpiece picture to be welded is gathered: adopt the mode of " an order dibit " to gather workpiece picture to be welded, main control computer sends a signal to welding robot, welding robot successively moves to 6 different camera sites, concrete camera site as shown in Figure 1, the picture gathered in position 1 and 2 is one group, the picture that position 3 and 4 gathers is one group, the picture that position 5 and 6 gathers is one group, main control computer is sent a signal to behind each camera site of arrival, receive the main control computer after signal, send shooting signal to CCD, 3 picture group sheets of shooting workpiece, and be transferred to main control computer by USB line,
(3) image procossing: main control computer carries out corresponding image procossing to received picture, extract weld profile, as shown in Figure 2, the matrix relationship H of camera site, left and right can calculate at the pose of camera site, every picture group sheet left and right according to the robot read, general binocular stereo vision is utilized to carry out three-dimensional reconstruction, for each picture group sheet, extract the pixel coordinate of left figure weld profile in every group, calculate polar curve, determine the pixel coordinate of corresponding left side point on corresponding right figure, calculate camera when often organizing camera site, the left side, in every picture group sheet, weld seam is at camera coordinates system O
lx
ly
lz
lunder three-dimensional coordinate information, and to store,
(4) path of welding is determined: the three-dimensional coordinate of weld seam under camera coordinates system that every picture group sheet obtains is converted into the three-dimensional coordinate under robot base mark, then the final three-dimensional coordinate namely obtaining complete path of welding is merged, and determine to weld starting point according to final coordinate, and determine the change of robot tool coordinate system anglec of rotation in welding process, and store;
(5) after above job step completes, main control computer sends path data to robot control cabinet by Ethernet, the center controlling welding robot tool coordinates system moves in welding starting point, robot carries out welding job according to the path of welding calculated to workpiece, until welding job completes or continues the welding job of next workpiece.The course of work of whole embodiment, as shown in Figure 3.
Described step (4), is specifically divided into:
Step 1: determine weld seam three-dimensional coordinate: utilize camera coordinates system O
lx
ly
lz
lwith TCP (Tool Center Point) tool coordinates system O
tx
ty
tz
tbetween transition matrix T, tool coordinates system O
tx
ty
tz
tand the transition matrix D between robot base mark system OXYZ, by every part weld seam of obtaining at camera coordinates system O
lx
ly
lz
lunder three-dimensional coordinate be converted to the three-dimensional coordinate under robot base mark system OXYZ, and merge the final three-dimensional coordinate namely obtaining complete weld seam, described transition matrix T is tested by hand and eye calibrating and obtains, and described transition matrix D can be calculated by the pose of read machine people.
Step 2: determine to weld starting point: according to the three-dimensional coordinate of the complete weld seam obtained under robot base mark system, determines that the maximum point of X-coordinate value is as welding starting point.
Step 3: determine anglec of rotation when tool coordinates system welds: if Fig. 4 is the relative position that tool coordinates ties up to workpiece in welding process, in the position that weld seam is different, the anglec of rotation of tool coordinates system Z axis is only had to convert, the anglec of rotation of X-axis and Y-axis is all constant, according to the distance on weld seam between adjacent 2, the anglec of rotation calculating Z axis between adjacent 2 is poor, and in weld seam starting point, the anglec of rotation of each axle of tool coordinates system is pre-set by main control computer, therefore, the anglec of rotation of tool coordinates system on each coordinate position of weld seam can be obtained.Workpiece weld seam to be welded described in this specific embodiment be the pipe welding seam that Guan Guanxiang passes through.
Simultaneously, the present invention also provides a kind of pipeline space weld seam based on CCD automatically to identify the system with trajectory planning, as shown in Figure 5, the pipeline space weld seam based on CCD of the present embodiment identifies the system with trajectory planning automatically, comprise: six axle welding robots, visual sensing system, robot control cabinet, main control computer.Wherein:
Six axle welding robots, are connected with robot control cabinet, and for welding duct work, robot drives visual sensing system, after moving to corresponding camera site, send shooting signal to main control computer;
Visual sensing system, is fixedly mounted on the end of welding robot welding gun, moves with welding gun, and wherein visual sensing system comprises CCD industrial digital video camera, optical filter.Visual sensing system and welding robot relation between the two, determined by hand and eye calibrating experiment, the weld seam picture collected sends main control computer to by USB line;
Robot control cabinet, with main control computer by ethernet communication, thus the motion of control;
Main control computer, ethernet communication is passed through with robot control cabinet, can read machine people pose data and send the motion of order control, and image procossing is carried out to the weld seam picture received, obtain the Complete three-dimensional coordinate information of weld seam, and the angle change of calculating robot's tool coordinates when tying up to welding, according to the motion of the result obtained by Ethernet control;
As shown in Figure 6, main control computer body comprises:
Image collection module, the mode control CCD of " an order dibit " is adopted to gather workpiece picture to be welded, be specially: by controlling the motion of welding robot, respectively at 3 picture group sheets of 6 diverse location shooting workpiece weld seams, the weld seam picture taken sends main control computer to by USB line;
Image processing module, be divided into weld seam picture processing two submodules that pipe pipe docks and Guan Guanxiang passes through, utilize image procossing, extract the weld profile on picture, according to general binocular stereo vision, respectively three-dimensional reconstruction is carried out to 3 assembly welding seam pictures, obtain the three-dimensional coordinate of weld seam under camera coordinates system in every picture group sheet respectively;
Path calculation module, the three-dimensional coordinate that the three-dimensional coordinate of weld seam under camera coordinates system in every picture group sheet is converted under robot base mark system, and merge the final three-dimensional coordinate obtaining complete weld seam, determine to weld starting point according to final three-dimensional coordinate again, and determine that tool coordinates ties up to the anglec of rotation under each coordinate;
Communication/control module, obtains the real-time pose information of robot, the path of welding result obtained is sent to robot controller by Ethernet, thus control moves to welding starting point, welds.
The present invention identifies based on the pipeline space weld seam of CCD to provide system platform with trajectory planning automatically, pass through visual sensing system, meet six common axle welding robots to the docking of pipe pipe and the welding needs that pass through of Guan Guanxiang, automatically can adapt to different angles oblique when different-diameter, diverse location and Guan Guanxiang pass through and the weld seam that produces; Utilize visual sensing system, automatic identification seam track, obtain the three-dimensional coordinate information of complete weld seam, carry out all-position automatic welding technology, eliminate the impact of the welding qualities such as the mismachining tolerance of workpiece, rigging error, avoid the limitation that artificial teaching can only weld particular path weld seam, decrease labour, reduce manufacturing cost and time cost.
The above is only the preferred embodiment of the present invention, it should be pointed out that for those skilled in the art, can also make some improvement under the premise without departing from the principles of the invention, and these improvement also should be considered as protection scope of the present invention.
Claims (4)
1. automatically identify based on the pipeline space weld seam of CCD and it is characterized in that the method with trajectory planning: comprise the steps
(1) welding module is selected: on main control computer, select pipe pipe to dock welding or pipe pipe related subgroup;
(2) workpiece picture to be welded is gathered: main control computer sends shooting signal to welding robot, welding robot adopts the mode of " an order dibit ", successively move to the 3 picture group sheets that 6 different camera sites gather workpiece to be welded, the weld seam picture gathered is transferred to main control computer by USB line;
(3) image procossing: main control computer carries out image procossing to received picture, extract weld profile, according to general binocular stereo vision, respectively three-dimensional reconstruction is carried out to 3 picture group sheets, obtain the three-dimensional coordinate information of weld seam under camera coordinates system in every picture group sheet, and store;
(4) path of welding is determined: the three-dimensional coordinate that the three-dimensional coordinate of weld seam under camera coordinates system in every picture group sheet is converted under robot base mark system, then the final three-dimensional coordinate obtaining complete solder path is merged, and determine to weld starting point according to final coordinate, and determine the change of robot tool coordinate system anglec of rotation in welding process, and store;
(5) weld: main control computer sends to robot control cabinet the path of welding data obtained, thus control welding robot moves in welding starting point, starts welding, completes whole welding process.
2. the pipeline space weld seam based on CCD according to claim 1 identifies the method with trajectory planning automatically, it is characterized in that: three-dimensional reconstruction step concrete in described step (3) is: for each assembly welding seam picture, extract the pixel coordinate of figure weld profile in the left side in each group, calculate polar curve, determine the pixel coordinate of the point on corresponding right figure in corresponding left figure, calculate weld seam in each group camera site, the left side time, the three-dimensional coordinate of weld seam under camera coordinates system.
3. the pipeline space weld seam based on CCD according to claim 1 automatically identifies and it is characterized in that the method with trajectory planning: described step (4) specifically comprises:
Step 1: determine weld seam three-dimensional coordinate: according to the transition matrix between tool coordinates system and robot base mark system and the transition matrix between tool coordinates system and camera coordinates system, the three-dimensional coordinate that the three-dimensional coordinate of weld seam under camera coordinates system in every picture group sheet is converted under robot base mark system, and merge the final three-dimensional coordinate obtaining complete weld seam, transformation matrix between described tool coordinates system and robot base mark system can be obtained by the pose of main control computer read machine people, transformation matrix between described tool coordinates system and camera coordinates system can be tested by hand and eye calibrating and be obtained,
Step 2: determine to weld starting point: according to the three-dimensional coordinate of the complete weld seam obtained under robot base mark system, determines that the maximum point of X-coordinate value is as welding starting point;
Step 3: determine anglec of rotation when robot tool coordinate system welds: be defined in welding process, only has the anglec of rotation of tool coordinates system Z axis in conversion, the anglec of rotation of X-axis and Y-axis is all constant, according to the distance on weld seam between adjacent 2, calculate the differential seat angle that between adjacent 2, Z axis rotates, and in weld seam starting point, the anglec of rotation of each axle of tool coordinates system is pre-set by main control computer, and then obtain the anglec of rotation of tool coordinates system on each coordinate position.
4. the pipeline space weld seam based on CCD identifies the system with trajectory planning automatically, it is characterized in that: comprise welding robot, visual sensing system, robot control cabinet and main control computer, described welding robot is connected with robot control cabinet, main control computer is communicated by Ethernet with robot control cabinet, main control computer is connected by USB line with visual sensing system, visual sensing system is fixedly mounted on welding robot robot end welding gun, described visual sensing system comprises CCD industrial digital video camera and optical filter, described main control computer body comprises:
Image collection module, adopts the mode control CCD industrial digital video camera of " an order dibit " to gather workpiece picture to be welded;
Image processing module, be divided into weld seam picture processing two submodules that pipe pipe docks and Guan Guanxiang passes through, utilize image procossing, extract the weld profile on picture, according to general binocular stereo vision, respectively three-dimensional reconstruction is carried out to 3 assembly welding seam pictures, obtain the three-dimensional coordinate of weld seam under camera coordinates system in every picture group sheet respectively;
Path calculation module, the three-dimensional coordinate that the three-dimensional coordinate of weld seam under camera coordinates system in every picture group sheet is converted under robot base mark system, and merge the final three-dimensional coordinate obtaining complete weld seam, determine to weld starting point according to final three-dimensional coordinate again, and determine that tool coordinates ties up to the anglec of rotation under each coordinate;
Communication/control module, obtains the real-time pose information of robot, the path of welding data obtained is sent to robot control cabinet by Ethernet, thus control welding robot moves to welding starting point, welds.
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