CN106181162A - A kind of real-time weld joint tracking detecting system based on machine vision and method - Google Patents

A kind of real-time weld joint tracking detecting system based on machine vision and method Download PDF

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CN106181162A
CN106181162A CN201610672098.4A CN201610672098A CN106181162A CN 106181162 A CN106181162 A CN 106181162A CN 201610672098 A CN201610672098 A CN 201610672098A CN 106181162 A CN106181162 A CN 106181162A
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image
welding
video camera
ccd video
real
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CN106181162B (en
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刘新华
王润泽
王勇
郝敬宾
司垒
徐荣鑫
高鹏
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China University of Mining and Technology CUMT
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China University of Mining and Technology CUMT
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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
    • B23K37/00Auxiliary devices or processes, not specially adapted to a procedure covered by only one of the preceding main groups
    • B23K37/02Carriages for supporting the welding or cutting element
    • 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
    • B23K37/00Auxiliary devices or processes, not specially adapted to a procedure covered by only one of the preceding main groups
    • B23K37/02Carriages for supporting the welding or cutting element
    • B23K37/0252Steering means

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  • Physics & Mathematics (AREA)
  • Optics & Photonics (AREA)
  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Image Analysis (AREA)
  • Manipulator (AREA)
  • Length Measuring Devices By Optical Means (AREA)

Abstract

The invention discloses a kind of real-time weld joint tracking detecting system based on machine vision, it includes: it includes: control the industrial computer of equipment as the system core;The image acquisition units being made up of light source controller, LED light source, image pick-up card and ccd video camera;And the motion control unit being made up of robot controller, welding robot;Present invention additionally comprises the detection of a kind of real-time weld joint tracking based on machine vision, the step such as including image acquisition → image procossing → data process → motor control;The present invention uses the method that real-time online detects, it is not necessary to manually carry out unnecessary operation, comparison correction at the expectation seam track generated by groove image with actual welds track;And in the case of Site Welding environment and manual teaching environment, off-line programing simulated environment have different, it is possible to carry out real-time weld joint tracking, overcome all kinds of interference of welding scene, it is ensured that the accuracy of welding effect and reliability.

Description

A kind of real-time weld joint tracking detecting system based on machine vision and method
Technical field
The present invention relates to a kind of real-time weld joint tracking detecting system based on machine vision and method, belong to machine vision and Technical field of mechanical automation.
Background technology
Welding plays the most most important role the most in the industrial production, and along with robot and vision-based detection process The development of technology, the automatization level of solder technology improves day by day, and weld joint tracking detection method also develops into meter from manual detection Calculation machine Intelligent Measurement.
Existing welding robot belongs to on-site manual teaching type or off-line programing type, welding robot in both approaches mostly The welding parameter of people and path of welding are all to plan before producing, and make the welding robot can be high-precision in work space Degree ground repeats programming movement.
And the weld seam path of planning is contrasted by traditional weld joint tracking detection method with the actual weld seam path produced Error correction, it is achieved the tracking of weld seam.Such welding seam tracking method can ensure that the high accuracy fortune of welding robot in planning region Row and weld joint tracking, but path planning can only be tracked, the adaptability to changes for emergency case is poor.
During actual welding, the interference of welding scene is more, and the shape of weldment can be along with the change of production environment The collision etc. of burst in the high temperature that change, such as molten bath produce, relatively low assembly precision, welding process, all can be to welding production Cause corresponding impact;When Site Welding environment and manual teaching environment, off-line programing simulated environment have the situation of different Under, the effect that conventional weld is followed the tracks of is the most undesirable, this restrict the further development of existing THE WELD SEAM TRACKING TECHNOLOGY.
Summary of the invention
The problem existed for above-mentioned prior art, the present invention provides a kind of real-time weld joint tracking based on machine vision to examine Examining system and method, it has high accuracy and adaptivity, it is possible to carries out real-time weld joint tracking, overcome all kinds of of welding scene Interference, thus ensure accuracy and the reliability of welding effect.
To achieve these goals, the technical solution used in the present invention is: a kind of real-time weld seam based on machine vision with Track detecting system, it includes:
The industrial computer of equipment is controlled as the system core;
The image acquisition units being made up of light source controller, LED light source, image pick-up card and ccd video camera;
And the motion control unit being made up of robot controller, welding robot;
Described Industrial Control Computer is responsible for image, the process of data and calculating;Described light-source controller controls LED light source Mobile with the movement of welding gun, make light source cover at weld seam and groove to be welded, it is ensured that the daylighting degree of image acquisition region;
Described ccd video camera includes ccd video camera one, ccd video camera two;Ccd video camera one, ccd video camera two are respectively It is arranged on the both sides of welding robot welding gun, mobile with the movement of welding gun;And ccd video camera one is to be welded towards welding gun front end At groove, welding position below the positive Butt welding gun of ccd video camera two.
A kind of real-time weld joint tracking detection method based on machine vision, uses above-mentioned system, comprises the following steps:
1) image acquisition: before welding starts, light-source controller controls LED light source is irradiated to groove in the way of front illumination And commissure, ccd video camera gathers the image in groove region to be welded at the beginning, and after time t, ccd video camera two starts to gather weldering Connecing the weld image of part, two initial pictures are according to being all transferred in industrial computer;
Wherein t is the delay shot by ccd video camera two after groove a region is photographed the welding of a region by ccd video camera one Time;
2) image procossing: obtain groove by image filtering, image segmentation, Morphological scale-space and edge detection process method Edge image with welded seam area partial enlargement;
3) data process: process the edge image of groove region partial enlargement, judge groove class according to algorithm for pattern recognition Type, calculates planned expectation seam track, processes the weld image of welding portion, the weld seam rail that calculating equipment actually generates Mark, filtered after obtain two smooth Weld pipe mill tracks, two seam tracks are contrasted and calculate tracking correction amount;
4) motor control: industrial computer carries out real-time deviation correcting according to correction amount, controls the motion of welding robot with further Welding, thus realize the accurate tracking of weld seam.
Described step 2) image procossing detailed process as follows:
(1) use gaussian filtering method that initial pictures is carried out denoising;
Digital picture can (x, y), x, y represent pixel coordinate, f (x, y) table respectively to be expressed as form f of two-dimensional array The gray scale of diagram picture;
fs(x, y)=G (and x, y) * f (x, y)
fs(x y) represents the digital picture after gaussian filtering;
(2) use maximum variance between clusters that image carries out image segmentation:
Use a threshold value that whole data are divided into two classes, if the variance between two classes is maximum, then this threshold Value is exactly optimal threshold value;
σ 2 ( T * ) = max T ∈ G σ 2 ( T )
I.e. select to make σ2(Tb) maximum T*As optimal segmenting threshold;
(3) use dilation erosion algorithm that image carries out Morphological scale-space:
First with structural element, to f, (x, y) carries out dilation operation, then with structural element, result is carried out erosion operation;Profit Can eliminate, with dilation erosion algorithm, the hole that target object is unnecessary, connect close object, fill up tiny on contour line simultaneously Indent wedge angle with the border of smooth object;
(4) Canny edge detection algorithm is used to enter image line rim detection:
Calculate gradient magnitude and the direction of filtering image,
▿ f = g r a n d ( f ) = [ g x g y ] = [ ∂ f ∂ x ∂ f ∂ y ]
Gradient amplitude:
Gradient direction:
Again gradient magnitude is carried out non-maxima suppression, if M (x, value y) less than pixel any two neighborhood it One, then make gN(x, y)=0;Otherwise, g is madeN(x, y)=M (x, y).gN(x y) represents the image after carrying out non-maximum suppression;
Finally use dual threshold algorithm process decision chart as marginal point: to set a threshold value upper bound THWith threshold value lower bound TL, in image Pixel then think necessarily border (g if greater than the threshold value upper boundN(x, y) >=TH), then think the most not less than threshold value lower bound It is border (gN(x, y)≤TL), between the two be then considered candidate item.
Compared with existing welding seam tracking method, the method and system that the present invention uses has the following advantages and effect:
1. the present invention uses the method that real-time online detects, it is not necessary to manually carry out unnecessary operation, after welding starts Welding robot can fully automatically carry out weld joint tracking detection;
2. the present invention utilizes groove image to generate expectation seam track, strong to the adaptivity of Site Welding environment, when existing In the case of field welding surroundings has different with manual teaching environment, off-line programing simulated environment, it is possible to carry out real-time weld seam Follow the tracks of, overcome all kinds of interference of welding scene, it is ensured that the accuracy of welding effect and reliability.
Accompanying drawing explanation
Fig. 1 is the solution of the present invention general principles schematic diagram.
Fig. 2 is the system principle schematic diagram of the present invention.
Detailed description of the invention
The invention will be further described below in conjunction with the accompanying drawings.
Below in conjunction with the accompanying drawing in the embodiment of the present invention, the technical scheme in the embodiment of the present invention is carried out clear, complete Describe, it is clear that described embodiment is only a part of embodiment of the present invention rather than whole embodiments wholely.Based on Embodiment in the present invention, it is every other that those of ordinary skill in the art are obtained under not making creative work premise Embodiment, broadly falls into the scope of protection of the invention.
If Fig. 2 is a kind of real-time weld joint tracking detecting system based on machine vision, it includes:
The industrial computer of equipment is controlled as the system core;
The image acquisition units being made up of light source controller, LED light source, image pick-up card and ccd video camera;
And the motion control unit being made up of robot controller, welding robot;
Described Industrial Control Computer is responsible for image, the process of data and calculating;Described light-source controller controls LED light source Mobile with the movement of welding gun, make light source cover at weld seam and groove to be welded, it is ensured that the daylighting degree of image acquisition region;
Described ccd video camera includes ccd video camera one, ccd video camera two;Ccd video camera one, ccd video camera two are respectively It is arranged on the both sides of welding robot welding gun, mobile with the movement of welding gun;And ccd video camera one is to be welded towards welding gun front end At groove, welding position below the positive Butt welding gun of ccd video camera two.
Being illustrated in figure 1 a kind of real-time weld joint tracking detection method based on machine vision, it uses above-mentioned system, bag Include following steps:
1) image acquisition: before welding starts, light-source controller controls LED light source is irradiated to groove in the way of front illumination And commissure, ccd video camera gathers the image in groove region to be welded at the beginning, and after time t, ccd video camera two starts to gather weldering Connecing the weld image of part, two initial pictures are according to being all transferred in industrial computer;
Wherein t is the delay shot by ccd video camera two after groove a region is photographed the welding of a region by ccd video camera one Time;
2) image procossing: obtain groove by image filtering, image segmentation, Morphological scale-space and edge detection process method Edge image with welded seam area partial enlargement;
3) data process: process the edge image of groove region partial enlargement, judge groove class according to algorithm for pattern recognition Type, calculates planned expectation seam track, processes the weld image of welding portion, the weld seam rail that calculating equipment actually generates Mark, filtered after obtain two smooth Weld pipe mill tracks, two seam tracks are contrasted and calculate tracking correction amount;
4) motor control: industrial computer carries out real-time deviation correcting according to correction amount, controls the motion of welding robot with further Welding, thus realize the accurate tracking of weld seam.
In such scheme, step 1), 2), 3) all two different regions are detected and are processed: groove district to be welded Territory and welded seam region.
Groove region to be welded is with the root face at groove as application, by root face and remainder gray feature value Difference, extract the morphological characteristic of groove part root face, it is judged that groove type also calculates expectation Weld pipe mill track;Welding weldering Seam region, with weld seam as application, calculates actual welds centrode by the marginal information of weld seam.
In such scheme, if step 1) do not collect root face information, i.e. welding object square groove, then in step 3) Data Data process, with the set of object both sides to be welded breach central point for expectation Weld pipe mill track.
In such scheme, t is that groove a region is photographed after a region is welded by ccd video camera two by ccd video camera one The time delay of shooting, relevant with the welding procedure of welding equipment, speed of welding, computer disposal speed etc., it is ensured that to be contrasted Expectation, actual welds track be the same area, the seam track that is mutually matched.
Wherein, step 2) image procossing be broadly divided into image filtering, image segmentation, Morphological scale-space and rim detection 4 Part, detailed process is as follows:
(1) use gaussian filtering method that initial pictures is carried out denoising;
Digital picture can (x, y), x, y represent pixel coordinate, f (x, y) table respectively to be expressed as form f of two-dimensional array The gray scale of diagram picture;
fs(x, y)=G (and x, y) * f (x, y)
fs(x y) represents the digital picture after gaussian filtering;
(2) use maximum variance between clusters that image carries out image segmentation:
Use a threshold value that whole data are divided into two classes, if the variance between two classes is maximum, then this threshold Value is exactly optimal threshold value;
σ 2 ( T * ) = max T ∈ G σ 2 ( T )
I.e. select to make σ2(Tb) maximum T*As optimal segmenting threshold;
(3) use dilation erosion algorithm that image carries out Morphological scale-space:
First with structural element, to f, (x, y) carries out dilation operation, then with structural element, result is carried out erosion operation;Profit Can eliminate, with dilation erosion algorithm, the hole that target object is unnecessary, connect close object, fill up tiny on contour line simultaneously Indent wedge angle with the border of smooth object;
(4) Canny edge detection algorithm is used to enter image line rim detection:
Calculate gradient magnitude and the direction of filtering image,
▿ f = g r a n d ( f ) = [ g x g y ] = [ ∂ f ∂ x ∂ f ∂ y ]
Gradient amplitude:
Gradient direction:
Again gradient magnitude is carried out non-maxima suppression, if M(x, value y) less than pixel any two neighborhood it One, then make gN(x, y)=0;Otherwise, g is madeN(x, y)=M (x, y).gN(x y) represents the image after carrying out non-maximum suppression;
Finally use dual threshold algorithm process decision chart as marginal point: to set a threshold value upper bound THWith threshold value lower bound TL, in image Pixel then think necessarily border (g if greater than the threshold value upper boundN(x, y) >=TH), then think the most not less than threshold value lower bound It is border (gN(x, y) >=TL), between the two be then considered candidate item.
In such scheme, step 3) judge groove type by algorithm for pattern recognition, further according to the welding of different grooves Feature, integrating step 2) the groove image that obtains calculates expectation seam track;Expect that seam track and actual welds track are through excellent Compare after changing smoothing processing, its departure, bias direction and tolerance speed are carried out Optimal calculation.
Compared with existing welding seam tracking method, the method and system that the present invention uses has the following advantages and effect:
1. the present invention uses the method that real-time online detects, it is not necessary to manually carry out unnecessary operation, after welding starts Welding robot can fully automatically carry out weld joint tracking detection;
2. the present invention utilizes groove image to generate expectation seam track, strong to the adaptivity of Site Welding environment, when existing In the case of field welding surroundings has different with manual teaching environment, off-line programing simulated environment, it is possible to carry out real-time weld seam Follow the tracks of, overcome all kinds of interference of welding scene, it is ensured that the accuracy of welding effect and reliability.
It is obvious to a person skilled in the art that the invention is not restricted to the details of above-mentioned one exemplary embodiment, Er Qie In the case of the spirit or essential attributes of the present invention, it is possible to realize the present invention in other specific forms.Therefore, no matter From the point of view of which point, all should regard embodiment as exemplary, and be nonrestrictive, the scope of the present invention is by appended power Profit requires rather than described above limits, it is intended that all by fall in the implication of equivalency and scope of claim Change is included in the present invention.Should not be considered as limiting involved claim by any reference in claim.
The above, only presently preferred embodiments of the present invention, not in order to limit the present invention, every skill according to the present invention Any trickle amendment, equivalent and the improvement that above example is made by art essence, should be included in technical solution of the present invention Protection domain within.

Claims (3)

1. a real-time weld joint tracking detecting system based on machine vision, it is characterised in that it includes:
The industrial computer of equipment is controlled as the system core;
The image acquisition units being made up of light source controller, LED light source, image pick-up card and ccd video camera;
And the motion control unit being made up of robot controller, welding robot;
Described Industrial Control Computer is responsible for image, the process of data and calculating;Described light-source controller controls LED light source is with weldering The movement of rifle and move, make light source cover at weld seam and groove to be welded, it is ensured that the daylighting degree of image acquisition region;
Described ccd video camera includes ccd video camera one, ccd video camera two;Ccd video camera one, ccd video camera two are respectively mounted In the both sides of welding robot welding gun, mobile with the movement of welding gun;And ccd video camera one is towards welding gun front end groove to be welded Place, welding position below the positive Butt welding gun of ccd video camera two.
2. a real-time weld joint tracking detection method based on machine vision, it is characterised in that use as claimed in claim 1 System, comprises the following steps:
1) image acquisition: before welding starts, light-source controller controls LED light source is irradiated to groove and weldering in the way of front illumination At seam, ccd video camera gathers the image in groove region to be welded at the beginning, and after time t, ccd video camera two starts to gather weld part The weld image divided, two initial pictures are according to being all transferred in industrial computer;
When wherein t is the delay shot by ccd video camera two after groove a region is photographed the welding of a region by ccd video camera one Between;
2) image procossing: obtain groove and weldering by image filtering, image segmentation, Morphological scale-space and edge detection process method The edge image of seam region partial enlargement;
3) data process: process the edge image of groove region partial enlargement, judge groove type according to algorithm for pattern recognition, meter Calculate planned expectation seam track;Process the weld image of welding portion, the seam track that calculating equipment actually generates, warp Obtain two smooth Weld pipe mill tracks after filtering, two seam tracks are contrasted and calculate tracking correction amount;
4) motor control: industrial computer carries out real-time deviation correcting according to correction amount, controls motion and the further weldering of welding robot Connect, thus realize the accurate tracking of weld seam.
A kind of real-time weld joint tracking detection method based on machine vision the most according to claim 2, it is characterised in that institute The step 2 stated) image procossing detailed process as follows:
(1) use gaussian filtering method that initial pictures is carried out denoising;
Digital picture can (x, y), x, y represent pixel coordinate respectively, and (x y) represents figure to f to be expressed as form f of two-dimensional array The gray scale of picture;
fs(x, y)=G (and x, y) * f (x, y)
fs(x y) represents the digital picture after gaussian filtering;
(2) use maximum variance between clusters that image carries out image segmentation:
Use a threshold value that whole data are divided into two classes, if the variance between two classes is maximum, then this threshold value is just It it is optimal threshold value;
σ 2 ( T * ) = max T ∈ G σ 2 ( T )
I.e. select to make σ2(Tb) maximum T*As optimal segmenting threshold;
(3) use dilation erosion algorithm that image carries out Morphological scale-space:
First with structural element, to f, (x, y) carries out dilation operation, then with structural element, result is carried out erosion operation;Utilize swollen Swollen erosion algorithm can eliminate the hole that target object is unnecessary, connects close object, fills up tiny interior on contour line simultaneously Recessed wedge angle is with the border of smooth object;
(4) Canny edge detection algorithm is used to enter image line rim detection:
Calculate gradient magnitude and the direction of filtering image,
▿ f = g r a n d ( f ) = [ g x g y ] = [ ∂ f ∂ x ∂ f ∂ y ]
Gradient amplitude:
Gradient direction:
Again gradient magnitude is carried out non-maxima suppression, if M (x, value y) is less than one of any two neighborhood of pixel, Then make gN(x, y)=0;Otherwise, g is madeN(x, y)=M (x, y);gN(x y) represents the image after carrying out non-maximum suppression;
Finally use dual threshold algorithm process decision chart as marginal point: to set a threshold value upper bound THWith threshold value lower bound TL, picture in image Vegetarian refreshments then thinks necessarily border (g if greater than the threshold value upper boundN(x, y) >=TH), then thinking inevitable less than threshold value lower bound is not limit Boundary (gN(x, y)≤TL), between the two be then considered candidate item.
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