CN104741802B - A kind of welding quality monitoring system and method - Google Patents
A kind of welding quality monitoring system and method Download PDFInfo
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- CN104741802B CN104741802B CN201510145918.XA CN201510145918A CN104741802B CN 104741802 B CN104741802 B CN 104741802B CN 201510145918 A CN201510145918 A CN 201510145918A CN 104741802 B CN104741802 B CN 104741802B
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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
- B23K26/00—Working by laser beam, e.g. welding, cutting or boring
- B23K26/346—Working by laser beam, e.g. welding, cutting or boring in combination with welding or cutting covered by groups B23K5/00 - B23K25/00, e.g. in combination with resistance welding
- B23K26/348—Working by laser beam, e.g. welding, cutting or boring in combination with welding or cutting covered by groups B23K5/00 - B23K25/00, e.g. in combination with resistance welding in combination with arc heating, e.g. TIG [tungsten inert gas], MIG [metal inert gas] or plasma welding
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Abstract
The present invention provides a kind of welding quality monitoring system and method, and the system includes：Welding gun, the welding gun is welded for butt welding point；Thermal infrared imager, the thermal infrared imager is used for the molten bath infrared thermal imaging data for shooting with video-corder the solder joint；Image pick-up card, described image capture card is used to gather the molten bath infrared thermal imaging data, and the molten bath infrared thermal imaging data are sent to pattern process computer；Pattern process computer, described image processing computer is used to analyze the molten bath infrared thermal imaging data acquisition welding parameter, the welding parameter is compared with default welding standard, obtain quality of welding spot assessment result, so, the on-line monitoring of automatic welding quality can be achieved, monitoring efficiency and quality is improved, loss is reduced.
Description
Technical field
The invention belongs to petroleum works technical field, more particularly to a kind of welding quality monitoring system and method.
Background technology
Laser/electric arc combined welding technology has that speed of welding is fast, welding penetration is big, bridging capability good, weld properties
Well, the advantages of layer thickness, a saving wlding.It is complicated but laser/electric arc combined weldering welding equipment system is huge, electricity
All multi-parameters such as arc voltage, wire feed rate, laser energy, laser defocusing amount, laser incident angle, chevilled silk spacing can all influence weldering
Connect molding effect and welding quality.Therefore need to monitor welding process quality on-line.
At present, automatic welding of pipelines equipment is by manually directly observing on-line monitoring welding quality, this monitoring mode one
Aspect does not adapt to laser/higher speed of welding of electric arc combined weldering, it is impossible to the internal fusion situation of observation, and can not record monitoring
Data；Another aspect superlaser can also be damaged to the eyes and skin of human body, although had protective gear, but should be use up
Amount is avoided.
The content of the invention
The problem of existing for prior art, the embodiments of the invention provide a kind of welding quality monitoring system and method,
It is inaccurate for solving manual observation welding quality of the prior art, and superlaser can not be avoided to the technology of human injury
Problem.
The invention provides a kind of welding quality monitoring system, the system includes：
Welding gun, the welding gun is welded for butt welding point；
Thermal infrared imager, the thermal infrared imager is used for the molten bath infrared thermal imaging data for shooting with video-corder the solder joint；
Image pick-up card, described image capture card is used to gather the molten bath infrared thermal imaging data, and the molten bath is red
Outer thermal imaging data are sent to pattern process computer；
Pattern process computer, described image processing computer is used to analyze the molten bath infrared thermal imaging data acquisition weldering
Parameter is connect, the welding parameter is compared with default welding standard, quality of welding spot assessment result is obtained.
In such scheme, described image processing computer includes：
Image processor, described image processor is used to analyze the molten bath infrared thermal imaging data, obtains weldering
Connect parameter；
Mass analyzer, the mass analyzer is used to compare the welding parameter with default welding standard, obtains
Take quality of welding spot assessment result；
Memory, the memory is used to store the molten bath infrared thermal imaging data.
In such scheme, the welding parameter includes：Size, structure and the thermograde in the molten bath.
In such scheme, described image processing computer is additionally operable to：When the welding parameter for detecting the solder joint is unsatisfactory for
During the welding standard, weld interval, the welding position information of the solder joint are extracted, the weld interval and the welding is analyzed
The defect that position is present.
In such scheme, the welding gun includes：Laser welding gun and arc welding gun.
In such scheme, described image processing computer is additionally operable to：
The molten bath infrared thermal imaging data stored in the memory are read, to the molten bath infrared thermal imaging data
Carry out off-line analysis.
The present invention also provides a kind of welding quality monitoring method, and methods described includes：
Welded using welding gun butt welding point；
Shoot with video-corder the molten bath infrared thermal imaging data of the solder joint；
Gather and send the molten bath infrared thermal imaging data；
The molten bath infrared thermal imaging data acquisition welding parameter is analyzed, by the welding parameter and default welding standard
Compare, obtain quality of welding spot assessment result.
In such scheme, methods described also includes：When the welding parameter for detecting the solder joint is unsatisfactory for the welding mark
On time, weld interval, the welding position information of the solder joint are extracted, what the analysis weld interval and the welding position were present
Defect.
In such scheme, the welding parameter includes：Size, structure and the thermograde in the molten bath.
In such scheme, methods described also includes：The molten bath infrared thermal imaging data are read, to the infrared heat in the molten bath
Imaging data carries out off-line analysis.
The invention provides a kind of welding quality monitoring system and method, methods described includes：Clicked through using welding gun butt welding
Row welding；Shoot with video-corder the molten bath infrared thermal imaging data of the solder joint；Gather and send the molten bath infrared thermal imaging data；Analysis
The molten bath infrared thermal imaging data acquisition welding parameter, the welding parameter is compared with default welding standard, is obtained
Quality of welding spot assessment result；In this way, the on-line monitoring of automatic welding quality can be realized, monitoring efficiency and quality are improved, is dropped
Low loss, reference data is provided for welding quality.
Brief description of the drawings
Fig. 1 is the welding quality monitoring system overall structure diagram that the embodiment of the present invention one is provided；
Fig. 2 is the structural representation for the deflector that the embodiment of the present invention one is provided；
Fig. 3 is the structural representation for the protective plate that the embodiment of the present invention one is provided；
Fig. 4 is the welding quality monitoring method schematic flow sheet that the embodiment of the present invention two is provided.
Embodiment
In order to ensure the welding quality of laser/electric arc combined weldering, welding quality monitoring efficiency is improved, the invention provides one
Welding quality monitoring system and method are planted, methods described includes：Welded using welding gun butt welding point；Shoot with video-corder the molten of the solder joint
Pond infrared thermal imaging data；Gather and send the molten bath infrared thermal imaging data；Analyze the molten bath infrared thermal imaging data
Welding parameter is obtained, the welding parameter is compared with default welding standard, quality of welding spot assessment result is obtained.
Technical scheme is described in further detail below by drawings and the specific embodiments.
Embodiment one
The present embodiment provides a kind of welding quality monitoring system, as shown in figure 1, the system includes：Welding gun 1, infrared heat
As instrument 2, image pick-up card 3, pattern process computer 4；Wherein,
The welding gun 1 is welded for butt welding point；The welding gun 1 includes：Laser welding gun 11 and arc welding gun 12.
The thermal infrared imager 2 is used in the welding process of welding gun 1, shoots with video-corder the molten bath infrared thermal imaging data of the solder joint
And appearance of weld process；
After the completion of the infrared thermography 2 shoots with video-corder the molten bath infrared thermal imaging data and appearance of weld process,
Described image capture card 3 specifically for：The molten bath infrared thermal imaging data and appearance of weld process are gathered, the molten bath is red
Outer thermal imaging data appearance of weld process is sent to pattern process computer 4；
After described image processing computer 4 receives the molten bath infrared thermal imaging data, specifically for：Analysis is described
Molten bath infrared thermal imaging data acquisition welding parameter, the welding parameter is compared with default welding standard, obtains solder joint
Quality assessment result.Here, the welding parameter includes：Size, structure and the thermograde in the molten bath.
Specifically, described image processing computer 4 includes：Image processor 41, mass analyzer 42 and memory 43；
Wherein,
After described image processing computer 4 receives the molten bath infrared thermal imaging data, described image processor 41
Specifically for：The molten bath infrared thermal imaging data are analyzed, welding parameter is obtained, the welding parameter is sent to institute
State mass analyzer 42.
When the mass analyzer 42 receives the welding parameter, specifically for：By the welding parameter with presetting
Welding standard compare, it is automatic to obtain quality of welding spot assessment result；And to detecting that the time of abnormal solder joint, coordinate are remembered
Record, the time of the abnormal solder joint, coordinate are sent to memory 43.
The memory 43 is used to store the molten bath infrared thermal imaging data, the view data of the welding fabrication process
And time, the coordinate data of the Abnormal welding point.
Here, when the welding parameter that described image processing computer 4 detects the solder joint is unsatisfactory for the welding standard
When, it is additionally operable to：Weld interval, the welding position information of the solder joint are extracted, the weld interval of the solder joint and the weldering is analyzed
The defect of position presence is connect, reference data is provided for Welding quality test.
When operating personnel need off-line analysis, described image processing computer 4 is additionally operable to：
The molten bath infrared thermal imaging data stored in the memory 43 are read, to the molten bath infrared thermal imaging number
According to off-line analysis is carried out, off-line analysis information is obtained；And the molten bath infrared thermal imaging process and welding fabrication are played by frame
Process, the welding procedure for different materials, different parameters provides data reference.
In addition, in order to solve in high-speed welding, it is ensured that the Combined Welding welding gun and the weld seam keep dynamic to essence
Degree, it is ensured that appearance of weld effect and welding quality.The welding quality monitoring system that the present embodiment is provided also includes：Laser sensor
5th, controller 6, actuator 7, deflector 8 and protective plate 9.Wherein,
The laser sensor 5 is used for the first position image information and second place image information for gathering weld seam, by institute
State first position image information and second place image information is sent to pattern process computer 4.Specifically, the laser sensing
Device 5 projects the laser stripe of the specific frequency on weld seam after optical filter filters other frequency interferences light by Charged Couple
Element (CCD, Charge-coupled Device) imaging unit absorbs the image information for including weld seam parameter.The weld seam ginseng
Number includes：The lateral deviation of the weld seam, longitudinal bias, the unfitness of butt joint of the alignment clearance of the weld seam and the weld seam.
In welding process, when described image processing computer 4 receives the first position image information and second
When putting image information, described image processor 41 is believed according to the first position image information and the second place image first
Breath calculates the lateral deviation of the weld seam, longitudinal bias；The counterpart of weld seam according to the second place image information acquisition
Gap and the unfitness of butt joint of the weld seam, are controlled according to the alignment clearance and the unfitness of butt joint the Fitting Calculation laser output power
Amount.
Specifically, described image processor 41 calculates laser output power control using laser power control Function Fitting
Amount.
Because the Combined Welding has the characteristics of big fusion penetration, bridging capability are good, therefore larger unfitness of butt joint is adapted to, it is described
The value of unfitness of butt joint is specifically as follows：0~2mm.But if the unfitness of butt joint is more than 2mm, it is necessary to increase swashing for the Combined Welding
Optical output power control amount.
In general, two-sided 1mm root faces are welded thoroughly needs 1KW laser output power, therefore, is molded inside weld seam
When, required first laser power output P1It can be drawn according to formula (1).
P1=P0*(1+1/2*C) (1)
Wherein, in formula (1), the P0Based on power, the C be unfitness of butt joint.
Further, because the focal diameter of the laser beam of the Combined Welding is generally 0.33mm, when root face is smaller,
The alignment clearance that the laser beam is adapted to is 0~0.3mm；And root face be 4~10mm thicker root face when, it is described swash
Diameter of the light beam at negative defocus becomes big, and the alignment clearance being adapted to is 0~0.5mm.Wherein, the negative defocus swashs to be described
The focus point of light beam is located at the back side of welding workpiece.
And alignment clearance it is excessive when so that laser transmission potential is excessive, causes weld seam too high behind, therefore can be according to formula
(2) second laser power output P is adjusted according to 0~0.5mm alignment clearance2。
P2=P0*(1-1/2*G) (2)
Wherein, in formula (2), the G is alignment clearance.
It therefore, it can draw the relational expression of the laser power control function, shown in such as formula (3)：
P=P0*(1+1/2*C-1/2*G) (3)
Wherein, the 1mm correspondence 1v voltages of the unfitness of butt joint and the alignment clearance.
Here, the lateral deviation is the second place image information and the second place image information in level side
Upward residual quantity；The longitudinal bias is the second place image information and the first position image information in vertical direction
On residual quantity.Wherein,
The first position image information is specifically included：The initial weld positional information of the Combined Welding welding gun；
The second place image information is specifically included：In predetermined period, the welding position that the Combined Welding welding gun is reached
Confidence ceases.The default cycle is 1~3s.
Specifically, the first position image information and second place image information that 41 pairs of image processor is received are filtered
The image procossings such as ripple, binaryzation, Threshold segmentation and rim detection, using Digital Image Processing algorithm fit with weld seam have than
The weld image of example relation, longitudinal bias and lateral deviation of the welding gun with weld seam centering, plus ratio are determined according to structure light principle
Longitudinal bias described in coefficient amendment and the lateral deviation.
Here, the setting height(from bottom) of the laser sensor 5 obtained by calculating has relation with proportionality coefficient.For example, setting in advance
Fixed setting height(from bottom) is 100mm, then proportionality coefficient is 1.But can have alignment error in installation process, or due to machinery
The limitation of structure can not accurately install vision sensor in 100mm height, now need setting ratio coefficient, such as install high
Spend for 90mm, proportionality coefficient needs to be set to 0.9；Or setting height(from bottom) be 110mm when, proportionality coefficient needs to be set to 1.1, is repaiied with this
Order the accurate weld seam dimensional information of acquisition.In summary, the proportionality coefficient is generally 1 or so.In use, install high
Degree should try one's best close to 100mm, and otherwise the image quality of the laser sensor 5 for focusing can be affected.
Secondly, the lateral deviation is converted to lateral deviation voltage by described image processor 41, and the longitudinal direction is inclined
Difference is converted to longitudinal bias voltage, is entered according to the advanced amount of delay pre-set after line delay calculating, by the lateral deviation
Voltage, the longitudinal bias voltage and the laser output power controlled quentity controlled variable are sent to controller 6.Here, it is described advanced
Amount of delay is determined according to the leading amount of the laser sensor 5 with the speed of welding of the Combined Welding.Such as, when the leading amount
For 1m, when the speed of welding is 1m/s, it may be determined that the advanced amount of delay is 1s.
Specifically, the lateral deviation is converted to corresponding first by described image processor 41 according to the first conversion coefficient
Pixel, the lateral deviation voltage is converted to by first pixel；
The longitudinal bias is converted to by corresponding second pixel according to the second conversion coefficient, by second pixel
Be converted to the longitudinal bias voltage.Wherein,
First conversion coefficient is：The 1mm lateral deviation 100 first pixels of correspondence, described in 100
Lateral deviation voltage described in first pixel correspondence 1V；
Second conversion coefficient is：The 1mm longitudinal bias 100 second pixels of correspondence, described in 100
Longitudinal bias voltage described in second pixel correspondence 1V.
Wherein, first conversion coefficient and second conversion coefficient are determined according to the setting height(from bottom) of laser sensor 5.
The lateral deviation is converted into the lateral deviation voltage when described image processor 41, the longitudinal direction is inclined
When difference is converted to the longitudinal bias voltage, the controller 6 specifically for：Actuator 7 is controlled according to the lateral deviation
Lateral deviation described in voltage amendment, the longitudinal bias according to the longitudinal bias voltage amendment；So that the Combined Welding
Welding gun keeps accurate Shaft alignment state with the weld seam.The laser sensing is adjusted according to the laser output power controlled quentity controlled variable in real time
The output energy of device 5, it is ensured that the alignment clearance of laser output power and the weld seam, unfitness of butt joint are matched, and then ensure welding
Quality.
In welding process, the deflector 8 is used for：Change the airflow direction of compressed air, eliminate the air-flow to electricity
The interference of arc-welding protective gas, it is to avoid weld blowhole occur.As shown in Fig. 2 the deflector 8 is T-shape metallic plate, it is described to lead
First circular hole concentric with Laser Focusing point is provided with stream plate 8, laser optical path is connected.The diameter of first circular hole can lead to
The Gaussian beam energy dissipation for crossing Laser Welding rifle 11 is calculated, and first circular hole is assembled the Gaussian beam laser energy
86%.
Here, the material of the deflector 8 includes：Copper coin, aluminium sheet.
One end of the deflector 8 is linear pattern, and the first width is 55mm, and the first length is 60mm；The deflector 8
The other end is arc, and the second width is 90mm, and the second length is 150mm.The thickness of the deflector 8 is 0.1mm.
Specifically, one end of the deflector 8 is arranged on below the focusing lens of the laser welding gun 11, the other end with
One end connection of the laser sensor 5, in welding process, the high pressure air stream of horizontal air blowing curtain is from laser welding gun 11
After side is blown out, after the other end guiding of the deflector 8, it is discharged to welding gun both sides remotely, eliminates high pressure compressed empty
Interference of the air-flow to Combined Welding protection air-flow, effectively inhibits weld blowhole, improves welding quality.
Further, in welding process, the protective plate 9 specifically for：It is prevented effectively from the focusing lens of laser welding gun 11
Polluted by welding slag, eliminate influence of the laser welding gun 11 protection gas curtain air-flow to protection air-flow, improve welding quality and
Welding efficiency；Wherein,
As shown in figure 3, the protective plate 9 is " L " type metallic plate, the protective plate 9 includes：First metallic plate 91 and second
Metallic plate 92；Wherein,
First metallic plate 91 is rectangle, rectangular a length of 100mm, rectangular a width of 64mm.
Mounting hole is provided with first metallic plate 91, the mounting hole includes three rows, to adjust the peace of first metallic plate 91
Dress height.
Second metallic plate 92 is square, and the square length of side is to be set on 64mm, second metallic plate 92
It is equipped with second circular hole concentric with the focus point of laser welding gun 11.
Specifically, before welding, by the protective plate 9 be arranged on laser welding gun 11 laser head at, and can by formula h=
D/D*H calculates the setting height(from bottom) h of the protective plate 9；Wherein,
The d is the diameter of second circular hole；The H is the focal length of laser welding gun 11.The diameter d of second circular hole
For 7.3~7.5mm.
The welding quality monitoring system that the present embodiment is provided, with advantages below：
(1) can in real time monitor and analyze molten bath and form situation and appearance of weld situation, the bad solder joint of accurate recording when
Between and positional information, obtain welding quality assessment result；Compared with artificial directly observation high-speed welding, quality of welding spot inspection is improved
The efficiency and quality of survey, it is to avoid injury of the laser to human body.
(2) reference data is provided for quality of welding spot detection, reduces loss.
Embodiment two
Corresponding to embodiment one, the present embodiment also provides a kind of welding quality monitoring method, as shown in figure 4, methods described
Including following steps：
Step 410, welded using welding gun butt welding point；
In this step, the welding gun includes laser welding gun and arc welding gun.
Step 411, the molten bath infrared thermal imaging data of the solder joint are shot with video-corder；
In this step, in welding gun welding process, the molten bath infrared thermal imaging of the solder joint is shot with video-corder using infrared thermoviewer
Data and appearance of weld process.
Step 412, gather and send the molten bath infrared thermal imaging data；
After the completion of the infrared thermography shoots with video-corder the molten bath infrared thermal imaging data and appearance of weld process, profit
The molten bath infrared thermal imaging data and appearance of weld process are gathered with described image capture card, by the molten bath infrared thermal imaging
Data appearance of weld process is sent to pattern process computer.
Step 413, analyze the molten bath infrared thermal imaging data acquisition welding parameter, by the welding parameter with it is default
Welding standard compares, and obtains quality of welding spot assessment result；
After described image processing computer receives the molten bath infrared thermal imaging data, the infrared heat in molten bath is analyzed
Imaging data obtains welding parameter, and the welding parameter is compared with default welding standard, obtains quality of welding spot and assesses knot
Really.Here, the welding parameter includes：Size, structure and the thermograde in the molten bath.
Specifically, described image processing computer includes：Image processor, mass analyzer and memory；Wherein,
When described image processing computer receive the molten bath infrared thermal imaging data after, by the molten bath it is infrared heat into
As data are sent to described image processor, described image processor is analyzed the molten bath infrared thermal imaging data, obtained
Welding parameter is taken, the welding parameter is sent to the mass analyzer.
When the mass analyzer receives the welding parameter, by the welding parameter and default welding standard phase
Compare, it is automatic to obtain quality of welding spot assessment result；And to detecting that the time of abnormal solder joint, coordinate record, will be described different
The time of normal solder joint, coordinate are sent to memory.
The memory be used for store the molten bath infrared thermal imaging data, the view data of the welding fabrication process with
And time, the coordinate data of the Abnormal welding point.
Here, it is unsatisfactory for the welding standard to the welding parameter of the solder joint when described image handles COMPUTER DETECTION
When, weld interval, the welding position information of the solder joint are also extracted, the weld interval of the solder joint and the welding position is analyzed
The defect of presence, reference data is provided for Welding quality test.
When operating personnel need off-line analysis, what is stored in the described image processing computer reading memory is described
The molten bath infrared thermal imaging data are carried out off-line analysis by molten bath infrared thermal imaging data, obtain off-line analysis information；And lead to
Cross frame and play the molten bath infrared thermal imaging process and welding fabrication process, be that different materials, the welding procedure of different parameters are carried
For data reference.
In addition, the present embodiment also utilizes laser sensor, controller, actuator, deflector and protective plate, it is ensured that at a high speed
During welding, the Combined Welding welding gun and the weld seam keep dynamic to precision, it is ensured that appearance of weld effect and welding quality.Its
In,
The laser sensor is used for the first position image information and second place image information for gathering weld seam, will be described
First position image information and second place image information are sent to pattern process computer.Specifically, the laser sensor
The laser stripe for projecting the specific frequency on weld seam is first by Charged Couple after optical filter filters other frequency interferences light
Part CCD imaging units absorb the image information for including weld seam parameter.The weld seam parameter includes：The lateral deviation of the weld seam,
The unfitness of butt joint of longitudinal bias, the alignment clearance of the weld seam and the weld seam.
In welding process, when described image processing computer receives the first position image information and the second place
During image information, described image processor is first according to the first position image information and the second place image information meter
Calculate lateral deviation, the longitudinal bias of the weld seam；The alignment clearance of weld seam according to the second place image information acquisition
And the unfitness of butt joint of the weld seam, according to the alignment clearance and the unfitness of butt joint the Fitting Calculation laser output power controlled quentity controlled variable.
Specifically, described image processor calculates laser output power controlled quentity controlled variable using laser power control Function Fitting.
Because the Combined Welding has the characteristics of big fusion penetration, bridging capability are good, therefore larger unfitness of butt joint is adapted to, it is described
The value of unfitness of butt joint is specifically as follows：0~2mm.But if the unfitness of butt joint is more than 2mm, it is necessary to increase swashing for the Combined Welding
Optical output power control amount.
In general, two-sided 1mm root faces are welded thoroughly needs 1KW laser output power, therefore, is molded inside weld seam
When, required first laser power output P1It can be drawn according to formula (1).
P1=P0*(1+1/2*C) (1)
Wherein, in formula (1), the P0Based on power, the C be unfitness of butt joint.
Further, because the focal diameter of the laser beam of the Combined Welding is generally 0.33mm, when root face is smaller,
The alignment clearance that the laser beam is adapted to is 0~0.3mm；And root face be 4~10mm thicker root face when, it is described swash
Diameter of the light beam at negative defocus becomes big, and the alignment clearance being adapted to is 0~0.5mm.Wherein, the negative defocus swashs to be described
The focus point of light beam is located at the back side of welding workpiece.
And alignment clearance it is excessive when so that laser transmission potential is excessive, causes weld seam too high behind, therefore can be according to formula
(2) second laser power output P is adjusted according to 0~0.5mm alignment clearance2。
P2=P0*(1-1/2*G) (2)
Wherein, in formula (2), the G is alignment clearance.
It therefore, it can draw the relational expression of the laser power control function, shown in such as formula (3)：
P=P0*(1+1/2*C-1/2*G) (3)
Wherein, the 1mm correspondence 1v voltages of the unfitness of butt joint and the alignment clearance.
Here, the lateral deviation is the second place image information and the second place image information in level side
Upward residual quantity；The longitudinal bias is the second place image information and the first position image information in vertical direction
On residual quantity.Wherein,
The first position image information is specifically included：The initial weld positional information of the Combined Welding welding gun；
The second place image information is specifically included：In predetermined period, the welding position that the Combined Welding welding gun is reached
Confidence ceases.The default cycle is 1~3s.
Specifically, the first position image information and second place image information that 41 pairs of image processor is received are filtered
The image procossings such as ripple, binaryzation, Threshold segmentation and rim detection, using Digital Image Processing algorithm fit with weld seam have than
The weld image of example relation, longitudinal bias and lateral deviation of the welding gun with weld seam centering, plus ratio are determined according to structure light principle
Longitudinal bias described in coefficient amendment and the lateral deviation.
Here, the setting height(from bottom) of the laser sensor 5 obtained by calculating has relation with proportionality coefficient.For example, setting in advance
Fixed setting height(from bottom) is 100mm, then proportionality coefficient is 1.But can have alignment error in installation process, or due to machinery
The limitation of structure can not accurately install vision sensor in 100mm height, now need setting ratio coefficient, such as install high
Spend for 90mm, proportionality coefficient needs to be set to 0.9；Or setting height(from bottom) be 110mm when, proportionality coefficient needs to be set to 1.1, is repaiied with this
Order the accurate weld seam dimensional information of acquisition.In summary, the proportionality coefficient is generally 1 or so.In use, install high
Degree should try one's best close to 100mm, and otherwise the image quality of the laser sensor 5 for focusing can be affected.
Secondly, the lateral deviation is converted to lateral deviation voltage by described image processor, by the longitudinal bias
Longitudinal bias voltage is converted to, is entered according to the advanced amount of delay pre-set after line delay calculating, by lateral deviation electricity
Pressure amount, the longitudinal bias voltage and the laser output power controlled quentity controlled variable are sent to controller.Here, the advanced delay
Measure and determined according to the leading amount of the laser sensor with the speed of welding of the Combined Welding.Such as, when the leading amount be 1m,
When the speed of welding is 1m/s, it may be determined that the advanced amount of delay is 1s.
Specifically, the lateral deviation is converted to corresponding first picture by described image processor according to the first conversion coefficient
Vegetarian refreshments, the lateral deviation voltage is converted to by first pixel；
The longitudinal bias is converted to by corresponding second pixel according to the second conversion coefficient, by second pixel
Be converted to the longitudinal bias voltage.Wherein,
First conversion coefficient is：The 1mm lateral deviation 100 first pixels of correspondence, described in 100
Lateral deviation voltage described in first pixel correspondence 1V；
Second conversion coefficient is：The 1mm longitudinal bias 100 second pixels of correspondence, described in 100
Longitudinal bias voltage described in second pixel correspondence 1V.
Wherein, first conversion coefficient and second conversion coefficient are determined according to the setting height(from bottom) of laser sensor.
When the lateral deviation is converted to the lateral deviation voltage, by the longitudinal bias by described image processor
When being converted to the longitudinal bias voltage, the controller specifically for：Actuator is controlled according to the lateral deviation voltage
The amount amendment lateral deviation, the longitudinal bias according to the longitudinal bias voltage amendment；So that the Combined Welding welding gun
Accurate Shaft alignment state is kept with the weld seam.The laser sensor is adjusted according to the laser output power controlled quentity controlled variable in real time
Export energy, it is ensured that the alignment clearance of laser output power and the weld seam, unfitness of butt joint are matched, and then guarantee welding quality.
In welding process, change the airflow direction of compressed air using deflector, eliminate the air-flow and arc welding is protected
Protect the interference of gas, it is to avoid weld blowhole occur.As shown in Fig. 2 the deflector is T-shape metallic plate, on the deflector
First circular hole concentric with Laser Focusing point is provided with, laser optical path is connected.The diameter of first circular hole can pass through laser
The Gaussian beam energy dissipation of welding gun is calculated, and first circular hole is assembled the 86% of the Gaussian beam laser energy.
Here, the material of the deflector includes：Copper coin, aluminium sheet.
One end of the deflector is linear pattern, and the first width is 55mm, and the first length is 60mm；The deflector it is another
One end is arc, and the second width is 90mm, and the second length is 150mm.The thickness of the deflector is 0.1mm.
Specifically, one end of the deflector is arranged on below the focusing lens of the laser welding gun, the other end and institute
One end connection of laser sensor is stated, in welding process, the high pressure air stream of horizontal air blowing curtain is from the side of laser welding gun
After blowout, after the other end guiding of the deflector, it is discharged to welding gun both sides remotely, eliminates high pressure air stream pair
The interference of Combined Welding protection air-flow, effectively inhibits weld blowhole, improves welding quality.
Further, in welding process, eliminate the laser welding gun using protective plate and protect gas curtain air-flow to protection gas
The influence of stream, is prevented effectively from laser welding gun focusing lens and is polluted by welding slag, improves welding quality and welding efficiency；Wherein,
As illustrated, the protective plate is " L " type metallic plate, the protective plate includes：First metallic plate and the second metal
Plate；Wherein,
First metallic plate is rectangle, rectangular a length of 100mm, rectangular a width of 64mm.Institute
State and mounting hole is provided with the first metallic plate, the mounting hole includes three rows, to adjust the setting height(from bottom) of first metallic plate.
Second metallic plate is square, and the square length of side is to be provided with 64mm, second metallic plate
The second concentric circular hole with the laser welding gun focus point.
Specifically, before welding, at the laser head that the protective plate is arranged on to laser welding gun, and formula h=d/ can be passed through
D*H calculates the setting height(from bottom) h of the protective plate；Wherein,
The d is the diameter of second circular hole；The H is the focal length of laser welding gun.The diameter d of second circular hole is
7.3~7.5mm.
The foregoing is only a preferred embodiment of the present invention, is not intended to limit the scope of the present invention, it is all
Any modifications, equivalent substitutions and improvements made within the spirit and principles in the present invention etc., should be included in the protection of the present invention
Within the scope of.
Claims (10)
1. a kind of welding quality monitoring system, it is characterised in that the system includes：
Welding gun, the welding gun is welded for butt welding point；
Laser sensor, first position image information and second place image information for gathering weld seam；The first position
Image information is specifically included：The image information of the initial weld position of Combined Welding welding gun；The second place image information is specific
Including：In predetermined period, the Combined Welding welding gun reaches the image information of welding position；
Thermal infrared imager, the thermal infrared imager is used for the molten bath infrared thermal imaging data for shooting with video-corder the solder joint；
Image pick-up card, described image capture card is used to gather the molten bath infrared thermal imaging data, by the infrared heat in the molten bath
Imaging data is sent to pattern process computer；
Pattern process computer, described image processing computer is used to analyze the molten bath infrared thermal imaging data acquisition welding ginseng
Number, the welding parameter is compared with default welding standard, obtains quality of welding spot assessment result；
The first position image information and the second place image information are filtered, binaryzation, Threshold segmentation and side
Edge detection process, the weld image for having proportionate relationship with weld seam is fitted using Digital Image Processing algorithm, according to structure light
Principle determines the lateral deviation of the weld seam and the longitudinal bias of the weld seam；
Controller, the controller is used to control actuator lateral deviation according to lateral deviation voltage amendment, according to vertical
To longitudinal bias described in deviation voltage amount amendment；
Accurate centering is kept with the weld seam according to the revised lateral deviation, longitudinal bias control Combined Welding welding gun
State.
2. the system as claimed in claim 1, it is characterised in that described image processing computer includes：
Image processor, described image processor is used to analyze the molten bath infrared thermal imaging data, obtains welding ginseng
Number；
Mass analyzer, the mass analyzer is used to compare the welding parameter with default welding standard, obtains weldering
Point mass assessment result；
Memory, the memory is used to store the molten bath infrared thermal imaging data.
3. the system as claimed in claim 1, it is characterised in that the welding parameter includes：The size in the molten bath, structure with
And thermograde.
4. the system as claimed in claim 1, it is characterised in that described image processing computer is additionally operable to：It is described when detecting
When the welding parameter of solder joint is unsatisfactory for the welding standard, weld interval, the welding position information of the solder joint are extracted, institute is analyzed
State the defect that weld interval and the welding position are present.
5. the system as claimed in claim 1, it is characterised in that the welding gun includes：Laser welding gun and arc welding gun.
6. the system as claimed in claim 1, it is characterised in that described image processing computer is additionally operable to：
The molten bath infrared thermal imaging data stored in memory are read, the molten bath infrared thermal imaging data are carried out offline
Analysis.
7. a kind of welding quality monitoring method, it is characterised in that methods described includes：
Welded using welding gun butt welding point；
Gather the first position image information and second place image information of weld seam；The first position image information is specifically wrapped
Include：The image information of the initial weld position of Combined Welding welding gun；The second place image information is specifically included：In predetermined period
Interior, the Combined Welding welding gun reaches the image information of welding position；
Shoot with video-corder the molten bath infrared thermal imaging data of the solder joint；
Gather and send the molten bath infrared thermal imaging data；
The molten bath infrared thermal imaging data acquisition welding parameter is analyzed, by the welding parameter compared with default welding standard
Compared with acquisition quality of welding spot assessment result；
The first position image information and the second place image information are filtered, binaryzation, Threshold segmentation and side
Edge detection process, the weld image for having proportionate relationship with weld seam is fitted using Digital Image Processing algorithm, according to structure light
Principle determines the lateral deviation of the weld seam and the longitudinal bias of the weld seam；
Actuator lateral deviation according to lateral deviation voltage amendment is controlled, is indulged according to longitudinal bias voltage amendment
To deviation；
Accurate centering is kept with the weld seam according to the revised lateral deviation, longitudinal bias control Combined Welding welding gun
State.
8. method as claimed in claim 7, it is characterised in that methods described also includes：When the welding for detecting the solder joint
When parameter is unsatisfactory for the welding standard, weld interval, the welding position information of the solder joint are extracted, the weld interval is analyzed
And the defect that the welding position is present.
9. method as claimed in claim 7, it is characterised in that the welding parameter includes：The size in the molten bath, structure with
And thermograde.
10. method as claimed in claim 7, it is characterised in that methods described also includes：Read the molten bath infrared thermal imaging
The molten bath infrared thermal imaging data are carried out off-line analysis by data.
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