Summary of the invention
In order to solve the problem, the invention provides a kind of welding torch displacement control system following the tracks of position while welding, introducing welding torch navigation system and image identification system are accurately determined the position of welding torch and the position of weld seam, based on the content of the difference determination welding torch drive singal between the position of welding torch and the position of weld seam, thus mobile welding torch arrives correct welding position performs welding, improve the automatization level that welding controls.
According to an aspect of the present invention, provide a kind of welding torch displacement control system following the tracks of position while welding, described control system comprises CCD camera, image pick-up card, image processor, flush bonding processor and welding torch driver, described CCD camera is for taking the weldment image of equipment to be welded, described image pick-up card is connected with described CCD camera, for performing image pretreatment operation to described weldment image, export pretreatment image, described image processor performs recognition of welding seam position operation to described pretreatment image, export Weld pipe mill line position, described flush bonding processor is connected respectively with described image processor and described welding torch driver, welding torch drive singal is sent to described welding torch driver based on described Weld pipe mill line position, described welding torch drive singal moves for driving welding torch.
More specifically, in the welding torch displacement control system of described tracking position while welding, also comprise: welding torch, adopt oxygen and mesolow acetylene as welding heat source, treat welding equipment and weld, weld is the Weld pipe mill line position in equipment to be welded, welding torch position sensor, comprises electromagnetic type proximity switch, for determining the current location of welding torch in real time, pickup-light source, is arranged on described CCD camera, and for the shooting of described CCD camera provides illumination, the intensity of light source of described pickup-light source and the brightness of described CCD camera surrounding environment are inversely proportional to, memory, for prestoring binary-state threshold and stain amount threshold, also for prestoring calibration line upper limit gray threshold and calibration line lower limit gray threshold, described binary-state threshold is between 0-255, described binary-state threshold is used for gray level image to be treated to binary image, described calibration line upper limit gray threshold and described calibration line lower limit gray threshold are used for the calibration line in image and background separation, and calibration line is given data in the position in target that is taken, display, is connected with flush bonding processor, for showing combination picture, described image pick-up card comprises contrast strengthen device, medium filtering device and gray processing processing apparatus, described contrast strengthen device is connected with described CCD camera, for described weldment image is performed contrast enhancement processing, export and strengthen weldment image, described medium filtering device is connected with described contrast strengthen device, medium filtering window based on 3 × 3 picture element matrixs performs medium filtering to described enhancing weldment image, output filtering weldment image, described gray processing processing apparatus is connected with described medium filtering device, gray processing process is performed to described filtering weldment image, export described pretreatment image, described contrast strengthen device, described medium filtering device and described gray processing processing apparatus are integrated on one piece of fpga chip, described image processor is connected respectively with described memory and described image pick-up card, described image processor comprises weld seam detection device, calibration line recognition means and position while welding determining device, described weld seam detection device is connected with described gray processing processing apparatus and described memory, based on described binary-state threshold, described pretreatment image is treated to binaryzation weldment image, described weld seam detection device each row pixel to described binaryzation weldment image detects, if the quantity of stain pixel is more than or equal to described stain amount threshold in a row pixel, then this row pixel is weld seam pixel column, for every bar weld seam pixel column, described weld seam detection device detects every one-row pixels vertical with this weld seam pixel column in described binaryzation weldment image, detect the one-row pixels that wherein stain pixel is maximum, using the intersection point of the pixel column that detects and this weld seam pixel column as Weld pipe mill point, by the Weld pipe mill point of all weld seam pixel columns composition axis of a weld, described calibration line recognition means is connected with described gray processing processing apparatus and described memory, the pixel identification of gray value in described pretreatment image between described calibration line upper limit gray threshold and described calibration line lower limit gray threshold is formed calibration line pattern, described position while welding determining device is connected respectively with described weld seam detection device and described calibration line recognition means, measure the relative position of described axis of a weld and described calibration line pattern, the known location determination Weld pipe mill line position on described equipment to be welded based on described relative position and described calibration line, described weld seam detection device, described calibration line recognition means and described position while welding determining device adopt different fpga chips to realize respectively, described flush bonding processor and described welding torch position sensor, described position while welding determining device is connected respectively with described welding torch driver, welding torch displacement is determined in current location based on described Weld pipe mill line position and described welding torch, and welding torch displacement is included in described welding torch drive singal to send to described welding torch driver, described welding torch driver drives described welding torch to move according to described welding torch displacement based on described welding torch drive singal, described flush bonding processor also with described CCD camera, described weld seam detection device is connected respectively with described calibration line recognition means, by described calibration line pattern, described axis of a weld is compound on described weldment image to form combination picture, wherein, described binary-state threshold is used for that gray level image is treated to binary image and comprises, the gray value of described binary-state threshold with each pixel in gray level image is compared, gray value is less than the pixel of described binary-state threshold, represent the pixel value of this pixel with 0, this pixel is stain, and gray value is more than or equal to the pixel of described binary-state threshold, represent the pixel value of this pixel with 1, this pixel is white point.
More specifically, in the welding torch displacement control system of described tracking position while welding, also comprising: wireless receiving and dispatching interface, being connected for setting up bidirectional communication link with the welding monitor supervision platform of far-end, to receive the control instruction that described welding monitor supervision platform sends.
More specifically, in the welding torch displacement control system of described tracking position while welding, described wireless receiving and dispatching interface is also connected with described flush bonding processor, so that described combination picture is wirelessly sent to described welding monitor supervision platform.
More specifically, in the welding torch displacement control system of described tracking position while welding, described wireless receiving and dispatching interface also comprises encoder, with before described combination picture is wirelessly sent to described welding monitor supervision platform, performs compressed encoding to described combination picture.
More specifically, in the welding torch displacement control system of described tracking position while welding, the coding standard that described compressed encoding adopts is MPEG-2 or MPEG-4.
Detailed description of the invention
Below with reference to accompanying drawings the embodiment of the welding torch displacement control system of tracking position while welding of the present invention is described in detail.
According to concrete welding procedure, welding can be subdivided into other special welding such as gas welding, electric resistance welding, arc welding, induction welding and laser weld.The energy source of welding has a variety of, comprises gas flame, electric arc, laser, electron beam, friction and ultrasonic wave etc.Except using in the factory, welding can also be carried out in a variety of contexts, as field, under water and space.
But no matter take which kind of welding manner, no matter wherein, welding all may bring danger to operator, so must take suitable safeguard procedures when welding.Welding the injury that may cause to human body, to comprise burn, electric shock, inpairment of vision, suction toxic gas, Ultraviolet radiation excessive etc.Simultaneously due to manually-operated particularity, and manual operation is easily by the impact of extraneous factor, and the efficiency of human weld is lower, and the welding training dynamics of each welder and welding torch experience is irregular differs, causes their welding quality also disunity.
As can be seen here, there is many drawbacks in human weld's pattern of the prior art, in order to ensure the reliability of welding quality, the mode taking machine to weld is needed to substitute human weld, this requires that welding robot can detect the position of weld seam and the position of welding torch voluntarily in real time, determine the deviation of the two, with deviation for controlling basis, control welding torch moves to position while welding and welds.That is, the automatic tracking system for weld seam has become one of emphasis of current welding field research.
The present invention has built a kind of welding torch displacement control system following the tracks of position while welding, the current location of welding torch is determined in real time by welding torch alignment sensor, by IMAQ and treatment technology complete the detection of butt welded seam position of center line targetedly, and adopt welding torch driver with the deviation based on welding position and position while welding further, drive welding torch to move to position while welding to weld, whole process does not need manual operation, improves efficiency and the quality of welding.
Fig. 1 is the block diagram of the welding torch displacement control system of the tracking position while welding illustrated according to an embodiment of the present invention, described control system comprises: CCD camera 1, image pick-up card 2, image processor 3, flush bonding processor 4, welding torch driver 5 and power supply unit 6, described flush bonding processor 4 is connected respectively with described CCD camera 1, described image pick-up card 2, described image processor 3, described welding torch driver 5 and described power supply unit 6, and described image pick-up card 2 is connected respectively with described CCD camera 1 and described image processor 3.
Wherein, described CCD camera 1 is for taking the weldment image of equipment to be welded, described image pick-up card 2 is for performing image pretreatment operation to described weldment image, export pretreatment image, described image processor 3 performs recognition of welding seam position operation to described pretreatment image, export Weld pipe mill line position, described flush bonding processor 4 sends welding torch drive singal based on described Weld pipe mill line position to described welding torch driver 5, described welding torch drive singal moves for driving welding torch, and described power supply unit 6 is for providing supply of electric power for described control system.
Then, continue to be further detailed the concrete structure of the welding torch displacement control system of tracking position while welding of the present invention.
Described control system also comprises: welding torch, and adopt oxygen and mesolow acetylene as welding heat source, treat welding equipment and weld, weld is the Weld pipe mill line position in equipment to be welded.
Described control system also comprises: welding torch position sensor, comprises electromagnetic type proximity switch, for determining the current location of welding torch in real time.
Described control system also comprises: pickup-light source, is arranged on described CCD camera 1, and for the shooting of described CCD camera 1 provides illumination, the intensity of light source of described pickup-light source and the brightness of described CCD camera 1 surrounding environment are inversely proportional to.
Described control system also comprises: memory, for prestoring binary-state threshold and stain amount threshold, also for prestoring calibration line upper limit gray threshold and calibration line lower limit gray threshold, described binary-state threshold is between 0-255, described binary-state threshold is used for gray level image to be treated to binary image, described calibration line upper limit gray threshold and described calibration line lower limit gray threshold are used for the calibration line in image and background separation, and calibration line is given data in the position in target that is taken.
Described control system also comprises: display, is connected with flush bonding processor 4, for showing combination picture.
Described image pick-up card 2 comprises contrast strengthen device, medium filtering device and gray processing processing apparatus, described contrast strengthen device is connected with described CCD camera 1, for described weldment image is performed contrast enhancement processing, export and strengthen weldment image, described medium filtering device is connected with described contrast strengthen device, medium filtering window based on 3 × 3 picture element matrixs performs medium filtering to described enhancing weldment image, output filtering weldment image, described gray processing processing apparatus is connected with described medium filtering device, gray processing process is performed to described filtering weldment image, export described pretreatment image, described contrast strengthen device, described medium filtering device and described gray processing processing apparatus are integrated on one piece of fpga chip.
Described image processor 3 is connected respectively with described memory and described image pick-up card 2, described image processor 3 comprises weld seam detection device, calibration line recognition means and position while welding determining device, described weld seam detection device is connected with described gray processing processing apparatus and described memory, based on described binary-state threshold, described pretreatment image is treated to binaryzation weldment image, described weld seam detection device each row pixel to described binaryzation weldment image detects, if the quantity of stain pixel is more than or equal to described stain amount threshold in a row pixel, then this row pixel is weld seam pixel column, for every bar weld seam pixel column, described weld seam detection device detects every one-row pixels vertical with this weld seam pixel column in described binaryzation weldment image, detect the one-row pixels that wherein stain pixel is maximum, using the intersection point of the pixel column that detects and this weld seam pixel column as Weld pipe mill point, by the Weld pipe mill point of all weld seam pixel columns composition axis of a weld.
Described calibration line recognition means is connected with described gray processing processing apparatus and described memory, the pixel identification of gray value in described pretreatment image between described calibration line upper limit gray threshold and described calibration line lower limit gray threshold is formed calibration line pattern, described position while welding determining device is connected respectively with described weld seam detection device and described calibration line recognition means, measure the relative position of described axis of a weld and described calibration line pattern, the known location determination Weld pipe mill line position on described equipment to be welded based on described relative position and described calibration line, described weld seam detection device, described calibration line recognition means and described position while welding determining device adopt different fpga chips to realize respectively.
Described flush bonding processor 4 is connected respectively with described welding torch position sensor, described position while welding determining device and described welding torch driver 5, welding torch displacement is determined in current location based on described Weld pipe mill line position and described welding torch, and welding torch displacement being included in described welding torch drive singal to send to described welding torch driver 5, described welding torch driver 5 drives described welding torch to move according to described welding torch displacement based on described welding torch drive singal.
Described flush bonding processor 4 is also connected respectively with described CCD camera 1, described weld seam detection device and described calibration line recognition means, is compound on described weldment image described calibration line pattern, described axis of a weld to form combination picture.
Wherein, described binary-state threshold is used for that gray level image is treated to binary image and comprises, the gray value of described binary-state threshold with each pixel in gray level image is compared, gray value is less than the pixel of described binary-state threshold, represent the pixel value of this pixel with 0, this pixel is stain, and gray value is more than or equal to the pixel of described binary-state threshold, represent the pixel value of this pixel with 1, this pixel is white point.
Wherein, can also comprise in described control system: wireless receiving and dispatching interface, be connected for setting up bidirectional communication link with the welding monitor supervision platform of far-end, to receive the control instruction that described welding monitor supervision platform sends, described wireless receiving and dispatching interface can also be connected with described flush bonding processor 4, so that described combination picture is wirelessly sent to described welding monitor supervision platform, described wireless receiving and dispatching interface can also comprise encoder, with before described combination picture is wirelessly sent to described welding monitor supervision platform, compressed encoding is performed to described combination picture, selectively, the coding standard that described compressed encoding adopts is MPEG-2 or MPEG-4.
In addition, Image Coding refers under the requirement meeting certain fidelity, converts the carrying out of view data, encode and compresses, and removes the data volume needed when redundant data reduces representative digit image, so that the storage of image and transmission.Namely damage or nondestructively represent the technology of original picture element matrix with less data volume.Image compression encoding can be divided into two classes: a class compression is reversible, and namely can recover original image completely from the data after compression, information is not lost, and is called lossless compression-encoding; Another kind of compression is irreversible, and namely cannot recover original image completely from the data after compression, information has certain loss, is called that lossy compression method is encoded.
In addition, mpeg standard mainly contains following five, MPEG-1, MPEG-2, MPEG-4, MPEG-7 and MPEG-21 etc.MPEG expert group is built in 1988, be responsible for specially as CD sets up Audio and Video standard, and member is the technical specialist for video, audio frequency and system regions.And after, the record of sound and image has successfully been departed from traditional analog form by them, establishes ISO/IEC11172 compression and coding standard, and makes MPEG-form, makes audio-visual communication aspect enter the biometrics epoch.Therefore, the MPEG-X version of everybody current general reference, be exactly by ISO (InternationalOrganizationforStandardization) formulate and issue video, audio frequency, data compression standard.
The technology of video compressing encoding of mpeg standard mainly make use of there is motion compensation interframe compression coding techniques to reduce temporal redundancy, utilize DCT technology to reduce the spatial redundancies of image, utilize entropy code then in information expression, to reduce statistical redundancy degree.The integrated use of this several technology, greatly strengthen compression performance.
Adopt the welding torch displacement control system of tracking position while welding of the present invention, too rely on artificial for existing welding torch control mode and cause that welding precision is not high, the easy technical problem that injures of the personnel that cause, introduce machine bond pattern and carry out alternative human weld's pattern, this machine bond pattern can be accurately identified the centrode of weld seam, and can according to the current location of the centrode adjustment welding torch of weld seam, thus while raising welding control system automatization level, ensured the reliability of welding.
Be understandable that, although the present invention with preferred embodiment disclose as above, but above-described embodiment and be not used to limit the present invention.For any those of ordinary skill in the art, do not departing under technical solution of the present invention ambit, the technology contents of above-mentioned announcement all can be utilized to make many possible variations and modification to technical solution of the present invention, or be revised as the Equivalent embodiments of equivalent variations.Therefore, every content not departing from technical solution of the present invention, according to technical spirit of the present invention to any simple modification made for any of the above embodiments, equivalent variations and modification, all still belongs in the scope of technical solution of the present invention protection.