CN104942404A - Dual-wavelength binocular vision seam tracking method and tracking system - Google Patents

Dual-wavelength binocular vision seam tracking method and tracking system Download PDF

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CN104942404A
CN104942404A CN201510412801.3A CN201510412801A CN104942404A CN 104942404 A CN104942404 A CN 104942404A CN 201510412801 A CN201510412801 A CN 201510412801A CN 104942404 A CN104942404 A CN 104942404A
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welding
seam
structured light
fixed mount
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CN104942404B (en
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高向东
黄冠雄
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Guangdong University of Technology
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    • BPERFORMING OPERATIONS; TRANSPORTING
    • B23MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23KSOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K9/00Arc welding or cutting
    • B23K9/12Automatic feeding or moving of electrodes or work for spot or seam welding or cutting
    • B23K9/127Means for tracking lines during arc welding or cutting
    • B23K9/1272Geometry oriented, e.g. beam optical trading
    • B23K9/1274Using non-contact, optical means, e.g. laser means

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Abstract

本发明公开了一种双波长双目视觉焊缝跟踪方法,该方法包括图像采集、数据处理和焊缝跟踪等步骤,本发明同时公开了一种实现该方法的跟踪系统,本系统采用近红外和结构光双波长双目视觉传感系统,同时测量熔池和焊缝不同波长的焊缝区域图像并传输到微型工业控制机中,利用多信息融合算法和焊缝图像三维重建算法准确测量焊缝位置;微型工业控制机根据焊缝位置检测结果应用卡尔曼滤波算法对焊缝跟踪偏差状态进行最优估计,通过伺服驱动器驱动伺服电动机运动从而控制三轴运动工作台产生相应的运动,控制焊炬或激光头进行纠偏,实现焊缝的精确跟踪。该系统可以克服焊接现场的强光、飞溅和电磁干扰,提高焊缝跟踪精度及可靠性。

The invention discloses a dual-wavelength binocular vision welding seam tracking method, which includes the steps of image acquisition, data processing, and welding seam tracking. The invention also discloses a tracking system for realizing the method. The system uses near-infrared And structured light dual-wavelength binocular vision sensing system, simultaneously measure the weld area images of different wavelengths of the molten pool and weld and transmit them to the micro-industrial control computer, use the multi-information fusion algorithm and the three-dimensional reconstruction algorithm of the weld image to accurately measure the welding seam The seam position; the micro-industrial control computer applies the Kalman filter algorithm to optimally estimate the seam tracking deviation state according to the seam position detection results, and drives the servo motor to move through the servo drive to control the three-axis motion table to generate corresponding motion and control the welding seam. Torch or laser head can be used to rectify the deviation, so as to realize the precise tracking of the welding seam. The system can overcome strong light, spatter and electromagnetic interference at the welding site, and improve the accuracy and reliability of welding seam tracking.

Description

双波长双目视觉焊缝跟踪方法及跟踪系统Dual-wavelength binocular vision welding seam tracking method and tracking system

技术领域 technical field

本发明属于焊接技术领域,具体涉及一种双波长双目视觉焊缝跟踪方法及跟踪系统。 The invention belongs to the field of welding technology, and in particular relates to a dual-wavelength binocular vision welding seam tracking method and tracking system.

背景技术 Background technique

焊接是制造业领域重要的加工技术,具有工作条件恶劣、工作量大及质量要求高等诸多特点。电弧焊和激光焊是焊接工业中较常用的焊接工艺方法,以电弧和激光束作为被控对象实现焊接自动控制是焊接自动化的一个重要手段。其中,精确的焊缝跟踪是保证焊接质量的前提,即在整个焊接过程中必须控制激光束或电弧使其始终与焊缝对中,否则就会造成废品。为此,需精确地自动检测出焊缝的位置并实现自动跟踪。 Welding is an important processing technology in the manufacturing industry, which has many characteristics such as harsh working conditions, heavy workload and high quality requirements. Arc welding and laser welding are more commonly used welding methods in the welding industry. Using arc and laser beam as the controlled object to realize automatic welding control is an important means of welding automation. Among them, accurate seam tracking is the premise to ensure the welding quality, that is, the laser beam or arc must be controlled throughout the welding process so that it is always aligned with the seam, otherwise it will cause waste. To this end, it is necessary to accurately and automatically detect the position of the weld seam and realize automatic tracking.

由于焊接是一门复杂的热加工工艺技术,工件在焊接过程中要产生热变形,并且在焊接过程中会出现强烈的辐射、弧光、烟尘、飞溅等干扰,使得在焊接过程中实现焊缝位置的精确检测相当困难。同时,焊接装置机构误差、夹具装配误差和焊接过程焊件热变形等因素造成的焊缝路径实际上是三维曲线焊缝,涉及到较为复杂的三维曲线跟踪问题。并且焊缝间隙小且没有坡口、坐标不在同一平面,自动识别和测量难度极大。 Since welding is a complex thermal processing technology, the workpiece will be thermally deformed during the welding process, and there will be strong radiation, arc light, smoke, spatter and other interference during the welding process, so that the weld position can be realized during the welding process. Accurate detection is quite difficult. At the same time, the weld path caused by factors such as welding device mechanism error, fixture assembly error, and weldment thermal deformation during welding is actually a three-dimensional curve weld, which involves a relatively complicated three-dimensional curve tracking problem. In addition, the weld gap is small, there is no groove, and the coordinates are not on the same plane, so automatic identification and measurement are extremely difficult.

目前国内外对于焊缝位置信息的获取主要集中在以下几种方法:(1)结构光视觉传感方法。结构光视觉传感法通过激光源发射结构光对熔池前端的三维曲线焊缝进行扫描,由于焊缝与其两边的钢板一般有高度差,在结构光的照射下会形成焊缝轮廓线,呈现出焊缝的三维信息。目前工业上应用的焊缝跟踪器的工作原理大多数是结构光视觉传感方法。但该方法有其难以克服的缺陷:对于等厚平板对接焊,一般只能有效检测间隙大于0.15mm的焊缝。对于间隙小于0.15mm的焊缝,焊接前通常需要在对接焊缝表面处开微坡口,以使结构光在此处变形。但这无疑增加了加工成本、降低了焊接生产效率。而对于紧密对接、无坡口的焊缝,结构光几乎不产生变形,所以,传统的单波长结构光测量方法难以准确地识别和测量该种焊缝。再加上强烈的弧光和辐射干扰,更容易使得焊缝检测出现误判。(2)红外传感方法。该方法多用于电弧焊或焊件背面传感激光焊的焊缝识别,焊接熔池及周围形成一定的温度场并伴随红外辐射,使用红外摄像机直接拍摄熔池获取红外热像,对采集到的弧焊区红外热像进行定量分析,可以获得电弧偏离焊缝的量化信息。由于剧烈的熔池和温度变化使得很难获得层次分明的红外图像,再加上红外传感器易受环境干扰,所以该方法存在精度不高等问题。(3)直接图像传感方法。该方法利用摄像机直接拍摄熔池,通过图像处理分析灰度分布,推测焊缝中心偏差信息。由于该方法直接获取熔池图像,很大程度上消除了导前误差。但由于熔池变化剧烈且熔池处的焊缝已经熔化,焊缝信息基本湮没,因此难以从根本上获取焊缝偏差的特征和规律。(4)其它方法。如利用差动变压器作为检测垂直和水平方向偏差的传感器;根据焊缝间隙对声发射波传播有影响的现象,利用声发射-微处理器控制的焊缝检测系统;应用电弧传感器实现带有坡口的V形焊缝检测;利用电涡流方法检测焊缝,但不能准确判断焊缝左右偏差位置;超声波传感方法需要超声变换器与被焊板材的紧密接触,极大地限制了超声波传感器在检测焊缝方面的应用。以上方法在检测小间隙焊缝时都有局限性。 At present, the acquisition of weld position information at home and abroad mainly focuses on the following methods: (1) structured light visual sensing method. The structured light visual sensing method scans the three-dimensional curved weld seam at the front end of the molten pool by emitting structured light from a laser source. Since the weld seam generally has a height difference with the steel plates on both sides, the contour line of the weld seam will be formed under the irradiation of structured light, showing 3D information of the weld seam. Most of the seam trackers currently used in industry work on the structured light vision sensing method. However, this method has its insurmountable defects: for the butt welding of flat plates of equal thickness, it can only effectively detect welds with a gap greater than 0.15mm. For welds with a gap less than 0.15mm, it is usually necessary to make a micro-groove on the surface of the butt weld before welding, so that the structured light can be deformed here. But this undoubtedly increases the processing cost and reduces the welding production efficiency. For welds with tight butt joints and no grooves, structured light hardly produces deformation. Therefore, it is difficult for traditional single-wavelength structured light measurement methods to accurately identify and measure such welds. Coupled with strong arc light and radiation interference, it is more likely to cause misjudgment of weld detection. (2) Infrared sensing method. This method is mostly used for weld seam identification of arc welding or laser welding with sensor on the back of the weldment. A certain temperature field is formed in and around the welding molten pool and accompanied by infrared radiation. The infrared camera is used to directly shoot the molten pool to obtain infrared thermal images. Quantitative analysis of the infrared thermal image of the arc welding area can obtain the quantitative information of the arc deviation from the weld seam. Due to the drastic melt pool and temperature changes, it is difficult to obtain a well-defined infrared image, and the infrared sensor is susceptible to environmental interference, so this method has problems such as low accuracy. (3) Direct image sensing method. This method uses the camera to directly shoot the molten pool, analyzes the gray distribution through image processing, and infers the deviation information of the weld center. Since the method directly acquires the melt pool image, the leading error is eliminated to a great extent. However, due to the drastic change of the molten pool and the weld at the molten pool has been melted, the information of the weld is basically obliterated, so it is difficult to fundamentally obtain the characteristics and laws of the weld deviation. (4) Other methods. For example, using a differential transformer as a sensor to detect vertical and horizontal deviations; according to the phenomenon that the weld gap has an impact on the propagation of acoustic emission waves, the acoustic emission-microprocessor-controlled weld detection system is used; The V-shaped weld seam detection at the mouth; the eddy current method is used to detect the weld seam, but the left and right deviation position of the weld seam cannot be accurately judged; the ultrasonic sensing method requires the close contact between the ultrasonic transducer and the welded plate, which greatly limits the ultrasonic sensor in the detection Applications for weld seams. The above methods have limitations in detecting small gap welds.

发明内容 Contents of the invention

本发明的主要目的在于克服上述现有焊缝跟踪方法的不足,提供一种检测精度高、运行可靠、简单易用、具有一定通用性的双波长视觉传感和三轴伺服驱动的焊缝跟踪系统。 The main purpose of the present invention is to overcome the deficiencies of the above-mentioned existing seam tracking methods, and provide a seam tracking with dual-wavelength visual sensing and three-axis servo drive with high detection accuracy, reliable operation, easy to use, and certain versatility system.

为达到上述目的,本发明提供了一种双波长双目视觉焊缝跟踪方法,该方法包括如下步骤: In order to achieve the above object, the present invention provides a dual-wavelength binocular visual seam tracking method, the method comprises the following steps:

a.图像采集:微型工业控制机发出指令使结构光激光器发射出横跨于焊缝的结构光,同时发出指令启动近红外摄像机、结构光摄像机工作,焊接过程中同步协调近红外摄像机与结构光摄像机通过图像采集卡分别采集熔池区域红外图像与熔池前端焊缝的结构光图像,并将获得的双波长图像传输到微型工业控制机中; a. Image acquisition: The micro-industrial control computer issues instructions to make the structured light laser emit structured light across the weld seam, and at the same time issue instructions to start the near-infrared camera and the structured light camera to work, and coordinate the near-infrared camera and the structured light camera through the welding process synchronously The image acquisition card collects the infrared image of the molten pool area and the structured light image of the welding seam at the front of the molten pool, and transmits the obtained dual-wavelength image to the micro industrial control computer;

b.数据处理:应用多信息融合算法对熔池区域红外图像与熔池前端焊缝的结构光图像进行处理,计算出准确的焊缝位置及跟踪纠偏量; b. Data processing: apply the multi-information fusion algorithm to process the infrared image of the molten pool area and the structured light image of the welding seam at the front end of the molten pool, and calculate the accurate welding seam position and tracking correction amount;

c.焊缝跟踪:应用卡尔曼滤波对焊缝跟踪偏差状态进行最优估计,找到滤波估计误差与测量误差之间的关系,通过伺服驱动器驱动伺服电动机运动从而控制三轴运动工作台产生相应的运动,实现焊缝的精确跟踪。 c. Weld seam tracking: apply Kalman filter to optimally estimate the state of seam tracking deviation, find the relationship between filter estimation error and measurement error, and drive the servo motor to move through the servo drive to control the three-axis motion table to produce corresponding motion. Accurate tracking of weld seams is achieved.

在上述方案中,所述近红外摄像机摄取的近红外光波长范围为960-990nm;所述结构光摄像机摄取的可视结构光波长范围为640-660nm。 In the above scheme, the near-infrared light captured by the near-infrared camera has a wavelength range of 960-990 nm; the visible structured light captured by the structured light camera has a wavelength range of 640-660 nm.

为实现该方法,本发明还公开了一种双波长双目视觉焊缝跟踪系统,该系统包括双波长双目视觉检测系统、三轴伺服驱动焊缝跟踪系统和微型工业控制机,该双波长双目视觉检测系统包括近红外摄像机、结构光摄像机、结构光激光器和传感器安装板,所述结构光摄像机安装在传感器安装板左前端,所述近红外摄像机安装在传感器安装板右前端,所述结构光激光器位于结构光摄像机和近红外摄像机中间,安装在传感器安装板中端;所述三轴伺服驱动焊缝跟踪系统包括X轴固定架、Y轴固定架和Z轴固定架,所述X轴固定架上表面安装有焊接工作台,焊接件摆放在所述焊接工作台上,X轴伺服电机安装在所述X轴固定架的右端,所述Z轴固定架的下前端与X轴固定架的中后端连接,Z轴伺服电机安装在所述Z轴固定架的顶端,所述Y轴固定架通过螺栓连接在Z轴固定架右侧,Y轴伺服电机安装在所述Y轴固定架的后端,传感器安装板安装在Y轴固定架的前端,所述传感器安装板背面安装有加强筋,焊炬或激光头安装板通过内六角螺栓安装在Y轴固定架的右前端,焊炬或激光头安装在所述焊炬或激光头安装板的正下方。 In order to realize the method, the present invention also discloses a dual-wavelength binocular visual seam tracking system, which includes a dual-wavelength binocular visual detection system, a three-axis servo-driven seam tracking system and a micro-industrial control machine. The binocular vision detection system includes a near-infrared camera, a structured light camera, a structured light laser, and a sensor mounting plate. The structured light camera is installed on the left front end of the sensor mounting plate, and the near-infrared camera is installed on the right front end of the sensor mounting plate. The structured light laser is located between the structured light camera and the near-infrared camera, and is installed at the middle end of the sensor mounting plate; the three-axis servo-driven seam tracking system includes an X-axis mount, a Y-axis mount, and a Z-axis mount. A welding table is installed on the upper surface of the axis fixing frame, and the welding parts are placed on the welding table. The X-axis servo motor is installed on the right end of the X-axis fixing frame. The middle and rear ends of the fixed frame are connected, the Z-axis servo motor is installed on the top of the Z-axis fixed frame, the Y-axis fixed frame is connected to the right side of the Z-axis fixed frame by bolts, and the Y-axis servo motor is installed on the Y-axis At the rear end of the fixed frame, the sensor mounting plate is installed on the front end of the Y-axis fixed frame, and the back of the sensor mounting plate is provided with reinforcing ribs, and the welding torch or laser head mounting plate is installed on the right front end of the Y-axis fixed frame through hexagon socket bolts. The welding torch or laser head is installed directly below the welding torch or laser head mounting plate.

在上述方案中,所述Z轴固定架右侧表面开有长孔,Z轴伺服电机驱动Y轴固定架在所述长孔中上下运动,通过控制Y轴固定架的上下位置能够调节焊炬距离焊接件的高度或激光焊接时的离焦量的调整。 In the above scheme, a long hole is opened on the right side surface of the Z-axis fixing frame, and the Z-axis servo motor drives the Y-axis fixing frame to move up and down in the long hole, and the welding torch can be adjusted by controlling the up and down position of the Y-axis fixing frame. Adjustment of the height from the welded part or the defocus amount during laser welding.

在上述方案中,所述Y轴固定架左侧表面开有长孔,Y轴伺服电机驱动Y轴固定架在所述长孔中前后运动,通过控制Y轴固定架的前后位置能够对焊炬或激光头实现纠偏。 In the above scheme, a long hole is opened on the left side surface of the Y-axis fixing frame, and the Y-axis servo motor drives the Y-axis fixing frame to move back and forth in the long hole. By controlling the front and rear positions of the Y-axis fixing frame, the welding torch can Or laser head to achieve deviation correction.

在上述方案中,所述X轴伺服电机驱动摆放在焊接工作台上的焊接件左右运动,实现焊接件的进给。 In the above solution, the X-axis servo motor drives the welded parts placed on the welding table to move left and right, so as to realize the feeding of the welded parts.

在上述方案中,应用近红外光(960-990nm)和可视结构光(640-660nm)分别获取熔池形态及熔池前端焊缝信息,并通过双波长双目视觉传感信息融合技术实现焊缝位置识别。在焊缝位置测量的基础上,建立焊炬或激光头伺服运动控制系统,根据焊缝位置坐标,通过伺服驱动系统控制焊炬或激光头位置以及应用卡尔曼滤波控制使其始终对正和跟踪焊缝,实现电弧焊或激光焊的焊缝跟踪。 In the above scheme, near-infrared light (960-990nm) and visible structured light (640-660nm) are used to obtain the shape of the molten pool and the information of the front weld seam of the molten pool respectively, and the information fusion technology of dual-wavelength binocular vision sensing is used to realize Seam position identification. On the basis of welding seam position measurement, establish a welding torch or laser head servo motion control system, according to the welding seam position coordinates, control the position of the welding torch or laser head through the servo drive system and apply Kalman filter control to make it always align and track welding seam, to achieve seam tracking for arc welding or laser welding.

在上述方案中,以对接、搭接、角焊缝等为应用对象,利用双波长双目视觉传感器定标、双带滤光器特性、焊缝图像增强、熔池形态特征提取技术,在恶劣的工业焊接现场下准确检测出焊缝位置。当进行搭接焊、角焊和较大间隙平板对接焊时,主要根据结构光激光器发射到焊缝的可视变形结构光并通过结构光摄像机检测出焊缝位置。当进行紧密对接焊时,结构光不再变形,此时主要根据近红外摄像机摄取的近红外熔池图像中的热分布特征获取焊缝位置。通过融合不同波段的结构光焊缝图像和近红外熔池图像,实现焊缝位置的测量与跟踪。 In the above scheme, with butt joints, lap joints, fillet welds, etc. as the application objects, using dual-wavelength binocular vision sensor calibration, dual-band filter characteristics, weld image enhancement, and molten pool morphological feature extraction technologies, in harsh Accurately detect the position of the weld seam under the industrial welding site. When performing lap welding, fillet welding and butt welding of flat plates with large gaps, the welding seam position is detected mainly based on the visible deformable structured light emitted by the structured light laser to the weld seam and the structured light camera. When performing tight butt welding, the structured light is no longer deformed. At this time, the weld position is mainly obtained based on the heat distribution characteristics in the near-infrared molten pool image captured by the near-infrared camera. By fusing structured light weld images of different bands and near-infrared molten pool images, the measurement and tracking of the weld position is realized.

在上述方案中,针对近红外光辐射下的熔池区域和可视结构光辐射下的焊缝区域,利用双波长图像的特征,增强抗弧光干扰能力。微型工业控制机计算双目视觉传感器测量坐标,进行焊缝图像三维重建,建立焊缝位置测量系统。 In the above solution, for the molten pool area under near-infrared light radiation and the weld seam area under visible structured light radiation, the characteristics of dual-wavelength images are used to enhance the ability to resist arc light interference. The micro-industrial control computer calculates the measurement coordinates of the binocular vision sensor, performs three-dimensional reconstruction of the weld image, and establishes a weld position measurement system.

在上述方案中,建立焊炬或激光头三轴运动及焊缝跟踪控制系统,在此基础上应用卡尔曼滤波进行状态最优估计,准确预测焊缝偏移量和偏移方向,消除过程噪声和测量噪声的随机干扰影响。根据焊缝与电弧或激光头之间的偏移量、偏移方向以及偏移速度等信息,准确预测焊缝状态并构成焊缝跟踪器。 In the above scheme, the three-axis movement of the welding torch or laser head and the seam tracking control system are established. On this basis, the Kalman filter is used for state optimal estimation, accurate prediction of the seam offset and offset direction, and elimination of process noise. and random interference effects of measurement noise. According to the offset, offset direction and offset speed between the weld and the arc or laser head, it can accurately predict the status of the weld and form a weld tracker.

与现有焊缝跟踪方法相比,本发明采用的技术方案具有下述有益效果: Compared with the existing seam tracking method, the technical solution adopted by the present invention has the following beneficial effects:

1)采用近红外和结构光双波长双目视觉传感方法,同时获取熔池和焊缝不同波长的焊缝区域图像,准确测量焊缝三维坐标。该方法可以克服焊接现场的强烈弧光、辐射、飞溅和电磁干扰,提高系统的容错性和可靠性; 1) The dual-wavelength binocular vision sensing method of near-infrared and structured light is used to obtain images of the weld area at different wavelengths of the molten pool and weld at the same time, and accurately measure the three-dimensional coordinates of the weld. This method can overcome strong arc light, radiation, spatter and electromagnetic interference at the welding site, and improve the fault tolerance and reliability of the system;

2)融合视觉跟踪器和伺服驱动器,建立焊炬或激光头三轴运动及焊缝跟踪控制模型,应用卡尔曼滤波算法,消除焊缝图像噪声对测量精度的影响,对焊缝与焊炬或激光头之间的偏差量、偏移方向和偏移速度进行状态最优估计。对于电弧焊接,实现决定电弧位置的焊炬的预测纠偏控制。对于激光焊接,实现决定激光束位置的激光头的预测纠偏控制。 2) Integrate the visual tracker and servo drive, establish the three-axis movement of the welding torch or laser head and the seam tracking control model, apply the Kalman filter algorithm, eliminate the influence of the welding seam image noise on the measurement accuracy, and the welding seam and welding torch or The state optimal estimation of the deviation amount, the deviation direction and the deviation speed between the laser heads is carried out. For arc welding, implements predictive steering control of the welding torch that determines the position of the arc. For laser welding, a predictive guideline control of the laser head that determines the position of the laser beam is implemented.

附图说明 Description of drawings

图1是本发明的立体结构前视图。 Fig. 1 is a front view of the three-dimensional structure of the present invention.

图2是本发明的立体结构后视图。 Fig. 2 is a rear view of the three-dimensional structure of the present invention.

图3是本发明的工作示意图。 Fig. 3 is a working schematic diagram of the present invention.

图中:1- Z轴伺服电机,2- Z轴固定架,3- 传感器安装板, 4- 结构光摄像机,5- 结构光激光器,6- 焊接件,7- X轴固定架,8- Y轴伺服电机,9- Y轴固定架,10- 焊炬或激光头安装板,11- 近红外摄像机,12- 焊炬或激光头,13- X轴伺服电机,14- 焊缝,15- 焊接工作台,16- 加强筋。 In the figure: 1- Z-axis servo motor, 2- Z-axis fixing frame, 3- sensor mounting plate, 4- structured light camera, 5- structured light laser, 6- welding parts, 7- X-axis fixing frame, 8- Y Axis servo motor, 9- Y-axis fixing frame, 10- welding torch or laser head mounting plate, 11- near infrared camera, 12- welding torch or laser head, 13- X-axis servo motor, 14- welding seam, 15- welding Workbench, 16- Rib.

具体实施方式 Detailed ways

下面将结合本发明实施例中的附图,对本发明实施例中的技术方案进行清楚、完整的描述,显然,所描述的实施例仅仅是本发明一部分实施例,而不是全部的实施例。本领域普通人员在没有做出创造性劳动前提下所获得的所有其他实施例,均属于本发明的保护范围。 The technical solutions in the embodiments of the present invention will be clearly and completely described below in conjunction with the accompanying drawings in the embodiments of the present invention. Obviously, the described embodiments are only some, not all, embodiments of the present invention. All other embodiments obtained by ordinary persons in the art without creative efforts belong to the protection scope of the present invention.

实施例1:双波长双目视觉焊缝跟踪方法。 Embodiment 1: Dual-wavelength binocular vision welding seam tracking method.

参照图3所示,图3是本发明双波长双目视觉焊缝跟踪方法的工作示意图。该方法包括如下步骤: Referring to FIG. 3 , FIG. 3 is a working diagram of the dual-wavelength binocular vision welding seam tracking method of the present invention. The method comprises the steps of:

a.图像采集:微型工业控制机发出指令使结构光激光器发射出横跨于焊缝的结构光,同时发出指令启动近红外摄像机、结构光摄像机工作,焊接过程中同步协调近红外摄像机与结构光摄像机通过图像采集卡分别采集熔池区域红外图像与熔池前端焊缝的结构光图像,并将获得的双波长图像传输到微型工业控制机中; a. Image acquisition: The micro-industrial control computer issues instructions to make the structured light laser emit structured light across the weld seam, and at the same time issue instructions to start the near-infrared camera and the structured light camera to work, and coordinate the near-infrared camera and the structured light camera through the welding process synchronously The image acquisition card collects the infrared image of the molten pool area and the structured light image of the welding seam at the front of the molten pool, and transmits the obtained dual-wavelength image to the micro industrial control computer;

b.数据处理:应用多信息融合算法对熔池区域红外图像与熔池前端焊缝的结构光图像进行处理,计算出准确的焊缝位置及跟踪纠偏量; b. Data processing: apply the multi-information fusion algorithm to process the infrared image of the molten pool area and the structured light image of the welding seam at the front end of the molten pool, and calculate the accurate welding seam position and tracking correction amount;

c.焊缝跟踪:应用卡尔曼滤波对焊缝跟踪偏差状态进行最优估计,找到滤波估计误差与测量误差之间的关系,通过伺服驱动器驱动伺服电动机运动从而控制三轴运动工作台产生相应的运动,实现焊缝的精确跟踪。 c. Weld seam tracking: apply Kalman filter to optimally estimate the state of seam tracking deviation, find the relationship between filter estimation error and measurement error, and drive the servo motor to move through the servo drive to control the three-axis motion table to produce corresponding motion. Accurate tracking of weld seams is achieved.

在上述方案中,本发明以对接、搭接、角焊缝等为应用对象,通过双波长双目视觉传感器定标、双带滤光器特性分析、焊缝图像增强、熔池形态特征提取、多信息融合以及卡尔曼滤波等技术,在恶劣的工业焊接现场下准确检测出焊缝位置并实现焊缝跟踪。 In the above scheme, the present invention takes butt joints, lap joints, and fillet welds as application objects, through dual-wavelength binocular vision sensor calibration, dual-band filter characteristic analysis, weld image enhancement, molten pool morphological feature extraction, Multi-information fusion and Kalman filter technology can accurately detect the position of the weld seam and realize weld seam tracking under harsh industrial welding conditions.

在上述方案中,本发明针对近红外光辐射下的熔池区域和可视结构光辐射下的焊缝区域,同时测量熔池和焊缝不同波长的焊缝区域图像,提取双波长图像的特征,融合得到的特征信息,准确计算出焊缝三维坐标。微型工业控制机计算双目视觉传感器测量坐标,进行焊缝图像三维重建,建立焊缝位置测量系统。应用卡尔曼滤波算法,消除焊缝图像噪声对测量精度的影响,对焊缝与电弧或激光束之间的偏差量、偏移方向和偏移速度进行状态最优估计,实现焊炬或激光头位置的预测纠偏控制。 In the above scheme, the present invention aims at the molten pool area under near-infrared radiation and the weld area under visible structured light radiation, simultaneously measures the weld area images of different wavelengths of the molten pool and the weld, and extracts the features of the dual-wavelength image , fused with the obtained feature information to accurately calculate the three-dimensional coordinates of the weld. The micro-industrial control computer calculates the measurement coordinates of the binocular vision sensor, performs three-dimensional reconstruction of the weld image, and establishes a weld position measurement system. Apply the Kalman filter algorithm to eliminate the influence of welding seam image noise on the measurement accuracy, and perform state optimal estimation of the deviation, deviation direction and deviation speed between the welding seam and the arc or laser beam, and realize the welding torch or laser head Predictive steering control of position.

在上述方案中,所述近红外摄像机摄取的近红外光波长范围为960-990nm;所述结构光摄像机摄取的可视结构光波长范围为640-660nm。 In the above scheme, the near-infrared light captured by the near-infrared camera has a wavelength range of 960-990 nm; the visible structured light captured by the structured light camera has a wavelength range of 640-660 nm.

实施例2:双波长双目视觉焊缝跟踪系统。 Embodiment 2: A dual-wavelength binocular visual seam tracking system.

参照图1和图2所示,一种双波长双目视觉焊缝跟踪系统,包括双波长双目视觉检测系统、三轴伺服驱动焊缝跟踪系统和微型工业控制机,该双波长双目视觉检测系统包括近红外摄像机11、结构光摄像机4、结构光激光器5和传感器安装板3,所述结构光摄像机4安装在传感器安装板3左前端,所述近红外摄像机11安装在传感器安装板3右前端,所述结构光激光器5位于结构光摄像机4和近红外摄像机11中间,安装在传感器安装板3中端;所述三轴伺服驱动焊缝跟踪系统包括X轴固定架7、Y轴固定架9和Z轴固定架2,所述X轴固定架7上表面安装有焊接工作台15,焊接件6摆放在所述焊接工作台15上,X轴伺服电机13安装在所述X轴固定架7的右端,所述Z轴固定架2的下前端与X轴固定架7的中后端连接,Z轴伺服电机1安装在所述Z轴固定架2的顶端,所述Y轴固定架9通过螺栓连接在Z轴固定架2右侧,Y轴伺服电机8安装在所述Y轴固定架9的后端,传感器安装板3安装在Y轴固定架9的前端,所述传感器安装板3背面安装有加强筋16,焊炬或激光头安装板10通过内六角螺栓安装在Y轴固定架9的右前端,焊炬或激光头12安装在所述焊炬或激光头安装板10的正下方。 Referring to Figures 1 and 2, a dual-wavelength binocular vision seam tracking system includes a dual-wavelength binocular vision detection system, a three-axis servo-driven seam tracking system and a miniature industrial control computer. The dual-wavelength binocular vision The detection system includes a near-infrared camera 11, a structured light camera 4, a structured light laser 5 and a sensor mounting plate 3, the structured light camera 4 is installed on the left front end of the sensor mounting plate 3, and the near-infrared camera 11 is installed on the sensor mounting plate 3 Right front end, the structured light laser 5 is located between the structured light camera 4 and the near-infrared camera 11, and is installed on the middle end of the sensor mounting plate 3; the three-axis servo-driven seam tracking system includes an X-axis fixing frame 7, a Y-axis fixing frame 9 and Z-axis fixed frame 2, the upper surface of the X-axis fixed frame 7 is equipped with a welding table 15, the weldment 6 is placed on the welding table 15, and the X-axis servo motor 13 is installed on the X-axis The right end of the fixed frame 7, the lower front end of the Z-axis fixed frame 2 is connected with the middle and rear end of the X-axis fixed frame 7, the Z-axis servo motor 1 is installed on the top of the Z-axis fixed frame 2, and the Y-axis is fixed The frame 9 is connected to the right side of the Z-axis fixed frame 2 by bolts, the Y-axis servo motor 8 is installed on the rear end of the Y-axis fixed frame 9, the sensor mounting plate 3 is installed on the front end of the Y-axis fixed frame 9, and the sensor is installed Ribs 16 are installed on the back of the plate 3, and the welding torch or laser head mounting plate 10 is installed on the right front end of the Y-axis fixing frame 9 through an inner hexagonal bolt, and the welding torch or laser head 12 is installed on the welding torch or laser head mounting plate 10 directly below the .

在上述方案中,所述Z轴固定架2右侧表面开有长孔,Z轴伺服电机1驱动Y轴固定架9在所述长孔中上下运动,通过控制Y轴固定架9的上下位置能够调节焊炬距离焊接件6的高度或激光焊接时的离焦量的调整。 In the above scheme, the right side surface of the Z-axis fixing frame 2 has a long hole, and the Z-axis servo motor 1 drives the Y-axis fixing frame 9 to move up and down in the long hole. By controlling the up and down position of the Y-axis fixing frame 9 The height of the welding torch from the weldment 6 or the adjustment of the defocus amount during laser welding can be adjusted.

在上述方案中,所述Y轴固定架9左侧表面开有长孔,Y轴伺服电机8驱动Y轴固定架9在所述长孔中前后运动,通过控制Y轴固定架9的前后位置能够对焊炬或激光头12实现纠偏。 In the above scheme, there is a long hole on the left side surface of the Y-axis fixed frame 9, and the Y-axis servo motor 8 drives the Y-axis fixed frame 9 to move back and forth in the long hole. By controlling the front and rear positions of the Y-axis fixed frame 9 Correction of the welding torch or laser head 12 can be realized.

在上述方案中,所述X轴伺服电机1驱动摆放在焊接工作台15上的焊接件6左右运动,实现焊接件6的进给。 In the above solution, the X-axis servo motor 1 drives the welding piece 6 placed on the welding table 15 to move left and right, so as to realize the feeding of the welding piece 6 .

在上述方案中,三轴联动伺服运动平台包括X轴固定架7,X轴工作台15,Y轴固定架9,Z轴固定架2,X轴伺服电机13,Y轴伺服电机8和Z轴伺服电机1;双波长双目视觉传感装置包括传感器安装板3以及安装于其上的结构光摄像机4、结构光激光器5和近红外摄像机11,结构光摄像机4用于获取横跨焊缝的结构光的图像,近红外摄像机11用于获取焊接过程的熔池动态图像。传感器安装板3与Y轴固定架9及焊炬或激光头安装板10固定并可联动。传感器安装板3与Y轴固定架9之间连接有加强筋16以保证装置的刚度。焊炬或激光头安装板10通过内六角螺栓装设于Y轴固定架9上,能够自由更换的焊炬或激光头12通过内六角螺栓装设于焊炬或激光头安装板10上,根据焊接的材料、厚度等特性,焊炬或激光头12可以选择激光焊接头或焊炬。按照与焊炬或激光头12的水平距离由近到远依次安装的是近红外摄像机11、结构光激光器5和结构光摄像机4,安装时近红外摄像机11轴线与竖直方向成一角度以能够获取熔池区域图像。同理,结构光摄像机4和结构光激光器5也被安装为其轴线与竖直方向成一角度以能够获取结构光图像,结构光图像相对熔池区域图像在焊接方向上有一个导前量。 In the above scheme, the three-axis linkage servo motion platform includes X-axis fixed frame 7, X-axis table 15, Y-axis fixed frame 9, Z-axis fixed frame 2, X-axis servo motor 13, Y-axis servo motor 8 and Z-axis Servo motor 1; the dual-wavelength binocular vision sensing device includes a sensor mounting plate 3 and a structured light camera 4, a structured light laser 5 and a near-infrared camera 11 mounted thereon, and the structured light camera 4 is used to obtain the For the image of the structured light, the near-infrared camera 11 is used to obtain the dynamic image of the molten pool during the welding process. The sensor mounting plate 3 is fixed and can be linked with the Y-axis fixing frame 9 and the welding torch or laser head mounting plate 10 . A reinforcing rib 16 is connected between the sensor mounting plate 3 and the Y-axis fixing frame 9 to ensure the rigidity of the device. The welding torch or laser head mounting plate 10 is installed on the Y-axis fixed frame 9 through the inner hexagonal bolt, and the freely replaceable welding torch or laser head 12 is installed on the welding torch or laser head mounting plate 10 through the inner hexagonal bolt, according to Characteristics such as welding material, thickness, welding torch or laser head 12 can select laser welding head or welding torch. According to the horizontal distance from the welding torch or laser head 12, the near-infrared camera 11, the structured light laser 5 and the structured light camera 4 are installed in turn. When installing, the axis of the near-infrared camera 11 forms an angle with the vertical direction to be able to obtain Image of the melt pool region. Similarly, the structured light camera 4 and the structured light laser 5 are also installed with their axis at an angle to the vertical direction so as to be able to acquire the structured light image, and the structured light image has a leading amount in the welding direction relative to the image of the molten pool area.

在上述方案中,系统的工作原理如下:近红外摄像机11、结构光摄像机4、结构光激光器5、焊炬或激光头12和伺服驱动器分别与微型工业控制机连接。X轴固定架7用于焊接进给,Y轴固定架9用于焊炬或激光头12的纠偏,Z轴固定架2用于调节焊炬距离焊接件6的高度或激光焊接时的离焦量的调整。使用本发明进行焊缝跟踪时,将焊接件6放置于焊接工作台15上,微型工业控制机同时协调启动近红外摄像机11、结构光摄像机4、结构光激光器5、焊炬或激光头12和伺服驱动器工作。利用双波段滤光系统,滤除杂光,采集近红外光和结构光及周围区域信息。微型工业控制机对焊缝和熔池图像进行动态范围调整,并应用图像三维重建方法建立焊缝位置测量方程。根据焊缝位置测量信息,融合三轴伺服驱动技术,建立焊炬或激光头运动控制模型。通过焊缝视觉信息与焊炬或激光头三轴联动控制系统的融合技术,实现焊缝的跟踪控制。建立以视觉传感和焊炬空间变位一体化的焊缝跟踪控制体系,采用近红外光和结构光双波长双目视觉传感器获取熔池和焊缝图像,焊炬或激光头采用三轴(X,Y,Z)变位控制的方法。微型工业控制机应用卡尔曼滤波对焊缝偏差进行最优估计,为焊炬或激光头12的纠偏运动及时反馈控制参量,实现焊炬或激光头12运动的预测纠偏控制。该系统可以克服焊接现场的强光、辐射、飞溅和电磁干扰,提高系统的容错性和可靠性。 In the above scheme, the working principle of the system is as follows: near-infrared camera 11, structured light camera 4, structured light laser 5, welding torch or laser head 12 and servo driver are respectively connected to the micro-industrial control machine. The X-axis fixed frame 7 is used for welding feed, the Y-axis fixed frame 9 is used for deviation correction of the welding torch or laser head 12, and the Z-axis fixed frame 2 is used for adjusting the height of the welding torch from the weldment 6 or the defocus during laser welding Quantity adjustment. When using the present invention for seam tracking, the weldment 6 is placed on the welding workbench 15, and the micro-industrial controller coordinates and starts the near-infrared camera 11, structured light camera 4, structured light laser 5, welding torch or laser head 12 and The servo drive works. The dual-band filter system is used to filter out stray light, collect near-infrared light, structured light and surrounding area information. The micro-industrial control computer adjusts the dynamic range of the weld seam and molten pool images, and uses the image three-dimensional reconstruction method to establish the weld seam position measurement equation. According to the measurement information of the welding seam position, the three-axis servo drive technology is integrated to establish the motion control model of the welding torch or laser head. Through the fusion technology of welding seam visual information and three-axis linkage control system of welding torch or laser head, the tracking control of welding seam is realized. Establish a welding seam tracking control system that integrates visual sensing and welding torch spatial displacement, uses near-infrared light and structured light dual-wavelength binocular vision sensors to obtain images of molten pools and weld seams, and uses three-axis ( X, Y, Z) displacement control method. The micro-industrial control machine applies Kalman filter to optimally estimate the deviation of the welding seam, and timely feeds back the control parameters for the deviation correction movement of the welding torch or laser head 12, so as to realize the predictive correction control of the movement of the welding torch or laser head 12. The system can overcome strong light, radiation, spatter and electromagnetic interference at the welding site, and improve the fault tolerance and reliability of the system.

以上所述为本发明的较佳实施例而已,但本发明不应局限于该实施例和附图所公开的内容,所以凡是不脱离本发明所公开的精神下完成的等效或修改,都落入本发明保护的范围。 The above description is only a preferred embodiment of the present invention, but the present invention should not be limited to the content disclosed in the embodiment and accompanying drawings, so any equivalent or modification that does not depart from the disclosed spirit of the present invention can be done. Fall into the protection scope of the present invention.

Claims (8)

1. a dual wavelength binocular vision welding seam tracking method, is characterized in that, the method comprises the steps:
A) IMAQ: miniature Industrial Control Computer sends instruction makes structured light laser instrument (5) launch the structured light being across weld seam, send instruction simultaneously and start near-infrared video camera (11), structured light video camera (4) work, in welding process, synchronous coordination near-infrared video camera (11) and structured light video camera (4) gather the structure light image of molten bath zone infrared image and front end, molten bath weld seam respectively by image pick-up card, and are transferred in miniature Industrial Control Computer by the double-wavelength images of acquisition;
B) data processing: the structure light image of application Multi-information acquisition algorithm to molten bath zone infrared image and front end, molten bath weld seam processes, calculates position while welding and tracking correction amount accurately;
C) weld joint tracking: application card Kalman Filtering butt welded seam tracing deviation state carries out optimal estimation, find the relation between filtering evaluated error and measure error, moved by servo driver drives servomotor thus control three-axis moving workbench and produce corresponding motion, realize the accurate tracking of weld seam.
2. dual wavelength binocular vision welding seam tracking method according to claim 1, is characterized in that: the near-infrared wavelength scope that described near-infrared video camera (11) is absorbed is 960-990nm; The visual structure optical wavelength range that described structured light video camera (4) is absorbed is 640-660nm.
3. a dual wavelength binocular vision seam tracking system, comprise dual wavelength binocular vision detection system, three axle servo-drive seam tracking systems and miniature Industrial Control Computer, it is characterized in that: described dual wavelength binocular vision detection system comprises near-infrared video camera (11), structured light video camera (4), structured light laser instrument (5) and sensor installing plate (3), described structured light video camera (4) is arranged on sensor installing plate (3) left front end, described near-infrared video camera (11) is arranged on sensor installing plate (3) right front ends, described structured light laser instrument (5) is positioned in the middle of structured light video camera (4) and near-infrared video camera (11), be arranged on sensor installing plate (3) middle-end, described three axle servo-drive seam tracking systems comprise X-axis fixed mount (7), Y-axis fixed mount (9) and Z axis fixed mount (2), described X-axis fixed mount (7) upper surface is provided with welding bench (15), weldment (6) is placed on described welding bench (15), X-axis servomotor (13) is arranged on the right-hand member of described X-axis fixed mount (7), the lower front end of described Z axis fixed mount (2) is connected with the middle rear end of X-axis fixed mount (7), Z axis servomotor (1) is arranged on the top of described Z axis fixed mount (2), described Y-axis fixed mount (9) is connected to Z axis fixed mount (2) right side, Y-axis servomotor (8) is arranged on the rear end of described Y-axis fixed mount (9), sensor installing plate (3) is arranged on the front end of Y-axis fixed mount (9), described sensor installing plate (3) back side is provided with reinforcement (16), welding torch or laser head installing plate (10) are arranged on the right front ends of Y-axis fixed mount (9), welding torch or laser head (12) are arranged on immediately below described welding torch or laser head installing plate (10).
4. dual wavelength binocular vision seam tracking system according to claim 3, is characterized in that: described Z axis fixed mount (2) right lateral surface has elongated hole, and Z axis servomotor (1) drives Y-axis fixed mount (9) to move up and down in described elongated hole.
5. dual wavelength binocular vision seam tracking system according to claim 3, is characterized in that: described Y-axis fixed mount (9) left-hand face has elongated hole, and Y-axis servomotor (8) drives Y-axis fixed mount (9) to seesaw in described elongated hole.
6. dual wavelength binocular vision seam tracking system according to claim 3, is characterized in that: weldment (6) side-to-side movement that the driving of described X-axis servomotor (13) is placed on welding bench (15).
7. dual wavelength binocular vision seam tracking system according to claim 3, is characterized in that: described dual wavelength binocular vision detection system is connected with miniature Industrial Control Computer respectively by bus with three axle servo-drive seam tracking systems.
8. dual wavelength binocular vision seam tracking system according to claim 3, is characterized in that: the control system that described dual wavelength binocular vision detection system forms with three axle servo-drive seam tracking systems and miniature Industrial Control Computer is closed-loop control system.
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