CN106238969B - Automatic welding processing system of non-standard part based on structured light vision - Google Patents
Automatic welding processing system of non-standard part based on structured light vision Download PDFInfo
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- CN106238969B CN106238969B CN201610096272.5A CN201610096272A CN106238969B CN 106238969 B CN106238969 B CN 106238969B CN 201610096272 A CN201610096272 A CN 201610096272A CN 106238969 B CN106238969 B CN 106238969B
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K37/00—Auxiliary devices or processes, not specially adapted to a procedure covered by only one of the preceding main groups
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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
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K37/00—Auxiliary devices or processes, not specially adapted to a procedure covered by only one of the preceding main groups
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Abstract
A structured light vision based non-standard automated welding processing system, comprising: the welding line visual detection system is used for identifying welding lines, detecting positions, monitoring progress and transmitting images to the communication and control system; the welding execution system is used for executing welding actions, and comprises a six-degree-of-automation industrial robot, a welding machine and a welding gun; the communication and control system is used for realizing communication and process control, and takes the industrial personal computer as main control equipment to complete the functions of welding process display, image processing, data operation and instruction transmission; the robot controller receives the instruction signal from the industrial personal computer and controls the joint movement of the six-degree-of-automation industrial robot to adjust the pose of the welding gun; the welding machine controller receives command signals from the industrial personal computer and controls welding parameters such as welding current, wire feeding speed and the like; the invention can accurately detect and identify the characteristics of the type, the position, the shape and the like of the welding seam, stably improve the welding processing quality of non-standard parts and greatly improve the labor productivity.
Description
Technical Field
The invention belongs to the technical field of automatic welding, relates to automatic welding processing integrated equipment, and particularly relates to a non-standard automatic welding processing system based on structured light vision.
Background
At present, in addition to standard components in the production and manufacture of modern enterprises, a large number of non-standard components exist, particularly in the production of steel structure products, the number of the non-standard components is large, and the manufacturing and processing precision and quality of the non-standard components directly influence the quality of the final products.
In the processing of non-standard parts of steel structures, in order to ensure the strength of components, welding connection modes are adopted among all parts, and the welding processing has an important position in the manufacturing of the steel structures. Because the steel structural member has the characteristics of large thickness, complex structure and many non-standard parts, the requirements on the strength, the precision and the manufacturability of welding processing are very high, the processing difficulty is high, and the technical requirements on workers are high. At present, the large-scale steel structure processing still takes manual welding as a main part, and is processed by a certain special welding device, so that the automation degree is low. The manual welding has the defects of high labor intensity of workers, hard working environment, low production efficiency, high labor cost and the like; the special welding machine is expensive in equipment, only welds in fixed positions can be processed, position adjustment is difficult, and the actual processing requirement cannot be met.
In order to solve the existing problems, production enterprises such as a plurality of domestic automobiles, ships, engineering machinery and the like refer to the production and processing methods of the modern manufacturing industry, and a welding robot system is introduced into a production line, so that the welding quality is greatly improved, and the welding cost is reduced. However, most welding robots still adopt a teaching online programming mode at present, and although online teaching is widely applied to tasks of spot welding, carrying, paint spraying and the like which are simple and have no path requirements. However, these programming techniques suffer from the two problems of (1) unstable teaching accuracy, affecting weld quality; and (2) the programming time is long, and the welding efficiency is low. In the processing of non-standard parts, due to the uncertainty of welding positions, the disadvantage of teaching programming is more obvious, in order to ensure the accuracy of tracks, operators need to teach a plurality of points to ensure that the welding robot runs smoothly, the total welding time is long, and the stability of the accuracy cannot be ensured.
Therefore, aiming at the characteristics of non-standard parts, an automatic welding system meeting the requirements of industrial sites and meeting the requirements of non-standard part processing is established to be a problem which needs to be solved urgently.
Disclosure of Invention
In order to overcome the defects of the prior art, the invention aims to provide a non-standard automatic welding processing system based on structured light vision, which solves the problems of unstable weld teaching precision and low welding efficiency in the existing non-standard welding processing.
In order to achieve the above purpose, the technical scheme adopted by the invention is as follows:
a structured light vision based non-standard automated welding processing system, comprising:
the welding line visual detection system is used for identifying welding lines, detecting positions, monitoring progress and transmitting images to the communication and control system;
the welding execution system is used for executing welding actions and comprises a six-degree-of-automation industrial robot 1, a welding machine 6 arranged at the end part of a main driving arm of the six-degree-of-automation industrial robot 1 and a welding gun 8 arranged on an end effector of the six-degree-of-automation industrial robot 1, wherein the six-degree-of-automation industrial robot 1 drives the welding gun 8 to adjust the space position and the gesture, and the welding machine 6 performs welding processing on a nonstandard workpiece 14 through the welding gun 8; the welding power source supplies power to the welder 6 and the nonstandard workpiece 14;
the communication and control system is used for realizing communication and process control and comprises an industrial personal computer 11, a robot controller 2, a welding machine controller 7 and a communication cable 9, wherein the industrial personal computer 11 is a main control device and is used for completing the functions of welding process display, image processing, data operation and instruction sending; the robot controller 2 is connected with the body of the six-degree-of-automation industrial robot 1 and the industrial personal computer 11 through the second communication cable 9-2, receives instruction signals from the industrial personal computer 11, and controls the joint movement of the six-degree-of-automation industrial robot 1 to adjust the pose of the welding gun 8; the welding machine controller 7 is connected with the welding machine 6 and the industrial personal computer 11 through the communication cable III 9-3, receives command signals from the industrial personal computer 11, and controls welding parameters such as welding current, wire feeding speed and the like.
The welding line visual detection system comprises a line structure light sensor 3, a monitoring CCD camera 4 and an image acquisition card 5, wherein the line structure light sensor 3 is fixedly arranged on an end effector of the industrial robot 1 and keeps a fixed position relative to a welding gun 8 unchanged, and a robot hand eye is formed for welding line identification and position detection; the monitoring CCD camera 4 is used for monitoring the welding process and the molten pool, the image acquisition card 5 is arranged on a main board of the industrial personal computer 11, and image transmission and communication between the monitoring CCD camera 4 and the line structure light vision sensor 3 and the industrial personal computer 11 are realized through a first communication cable 9-1.
The line structure light sensor 3 comprises a laser diode projector 3-1, a diaphragm 3-2, a CCD camera 3-3, a lens 3-4 and a filter plate 3-5, wherein the laser diode projector 1 is used for projecting line structure light to a welding line 15 and a nonstandard workpiece 14 to form laser stripes 16 reflecting the surface profile of the welding line, the diaphragm 2 is used for adjusting and controlling the intensity of light beams, the CCD camera 3-3 is used for collecting the image of the welding line with the laser stripes 16, the lens 3-4 and the filter plate 3-5 are additionally arranged in front of the CCD camera 3-3, the lens 3-4 is used for focusing the image, a clear image is formed on the CCD image surface, and the filter plate 3-5 is used for filtering a large amount of arc light, splash and smoke dust generated in the welding process to enter the lens, so that the image noise is reduced.
The nonstandard workpiece 14 is clamped and fixed by the nonstandard workpiece fixture device 10, the nonstandard workpiece fixture device 10 comprises 3 flexible multi-telescopic rod clamps 10-2 and 1 set of quick release clamping actuators 10-1, the quick release clamping actuators 10-1 are arranged on one flexible multi-telescopic rod clamp 10-2 and used for clamping the nonstandard workpiece 14, and the other two flexible multi-telescopic rod clamps 10-2 are used for positioning the nonstandard workpiece 14. The quick release clamp actuator 10-1 may optionally be a two degree of freedom positioner for supporting the flexible multi-telescopic rod holder 10-2 for adjusting the overall position and attitude of the nonstandard workpiece 14.
The industrial personal computer 11 is provided with a visual information processing system 12 and an offline programming system 13, wherein the visual information processing system 12 comprises:
the visual system calibration module is used for completing parameter measurement calibration of the welding seam visual detection system and comprises CCD camera parameter calibration, structure light sensor parameter calibration and robot hand-eye parameter calibration;
the welding seam image processing module takes a structural light welding seam image acquired by the welding seam visual detection system as input, and performs welding seam image preprocessing and welding seam stripe extraction;
the weld joint identification positioning module is used for carrying out weld joint type identification and weld joint three-dimensional reconstruction by taking data results obtained by the visual system calibration module and the weld joint image processing module as input;
the offline programming system 13 comprises:
the CAD modeling module takes the result of the welding seam identification positioning module and the six-degree-of-automation industrial robot 1 parameter as input to perform robot three-dimensional modeling and welding environment three-dimensional modeling, so as to realize system design and arrangement;
the programming module is used for planning a robot path and programming a task program;
the graphic simulation module receives the task program compiled by the programming module, performs dynamic simulation graphic simulation on the three-dimensional model of the CAD modeling module, and checks the correctness of the task program;
and the post-processing module compiles the task program compiled by the programming module into an industrial robot target program and a welding instruction, and sends the industrial robot target program and the welding instruction to the robot controller 2 and the welding machine controller 7 to control welding operation, and simultaneously stores the acquired field information for later analysis.
The weld image preprocessing comprises image filtering and threshold segmentation, and then weld laser streak line refinement and feature extraction are carried out;
the weld joint recognition type comprises linear weld joints formed by butt joint, lap joint, angle joint and the like, and curve-shaped weld joints formed by intersecting cylinders or cylinders and spheres.
The three-dimensional reconstruction of the welding seam adopts a line structured light active vision method, the pixel coordinates of the welding seam on an image are obtained through image processing, the pixel coordinates are converted into camera coordinates through a camera internal parameter model and a line structured light plane equation, and then the camera coordinates are further converted into a robot base coordinate system through a robot kinematic equation and a hand-eye calibration relation, so that the three-dimensional reconstruction of the welding seam is realized;
the task program comprises a weld image processing program, a camera internal parameter calibration program, a line structured light plane equation calibration program, a robot kinematics equation calculation program and a robot hand-eye calibration program.
Compared with the prior art, the invention has the beneficial effects that:
1) The welding line type, position, shape and other characteristics can be accurately detected and identified, and the welding processing quality of non-standard parts is stably improved;
2) The welding processing process is monitored in real time, and visual management of the processing process is realized;
3) The processing time is greatly saved, and the labor productivity is improved;
4) Improving the labor intensity and working environment of workers.
Drawings
Fig. 1 is a block diagram of a robot automated welding processing system based on structured light vision according to the present invention.
Fig. 2 is a block diagram of a structured light vision sensor system.
FIG. 3 is a block diagram of a non-standard tooling fixture apparatus.
Fig. 4 is a schematic block diagram of a visual information processing module.
Fig. 5 is a schematic block diagram of an offline programming module.
Detailed Description
Embodiments of the present invention will be described in detail below with reference to the accompanying drawings and examples.
The invention discloses a non-standard automatic welding processing system based on structured light vision, which comprises a welding line vision detection system, a welding execution system and a communication and control system.
The weld vision detection system is used for weld recognition, position detection, process monitoring and image transmission to the communication and control system; as shown in fig. 1, the welding gun comprises a line structure light sensor 3, a monitoring CCD camera 4 and an image acquisition card 5, wherein the line structure light sensor 3 is fixedly arranged on an end effector of an industrial robot 1 and keeps a fixed position relative to a welding gun 8, and forms a robot hand eye for weld joint identification and position detection; the monitoring CCD camera 4 is independently and fixedly installed and used for monitoring the welding process and a molten pool, the image acquisition card 5 is installed on a main board of the industrial personal computer 11, and image transmission and communication between the monitoring CCD camera 4 and the structured light vision sensor 3 and the industrial personal computer 11 are realized through a first communication cable 9-1.
The welding execution system is used for executing welding actions, and as shown in fig. 1, the welding execution system comprises a six-degree-of-automation industrial robot 1, a welding machine 6 arranged at the end part of a main driving arm of the six-degree-of-automation industrial robot 1 and a welding gun 8 arranged on an end effector of the six-degree-of-automation industrial robot 1, the six-degree-of-automation industrial robot 1 drives the welding gun 8 to adjust the spatial position and the posture, and the welding machine 6 performs welding processing on a nonstandard workpiece 14 through the welding gun 8; the welding power source provides power to the welder 6 and the nonstandard workpiece 14.
The communication and control system is used for realizing communication and process control, and as shown in fig. 1, the communication and control system comprises an industrial personal computer 11, a robot controller 2, a welding machine controller 7 and a communication cable 9, wherein the industrial personal computer 11 is a main control device and is used for completing the functions of welding process display, image processing, data operation and instruction transmission; the robot controller 2 is connected with the body of the six-degree-of-automation industrial robot 1 and the industrial personal computer 11 through the second communication cable 9-2, receives instruction signals from the industrial personal computer 11, and controls the joint movement of the six-degree-of-automation industrial robot 1 to adjust the pose of the welding gun 8; the welding machine controller 7 is connected with the welding machine 6 and the industrial personal computer 11 through the communication cable III 9-3, receives command signals from the industrial personal computer 11, and controls welding parameters such as welding current, wire feeding speed and the like.
The linear structure light sensor 3 is shown in fig. 2, and comprises a laser diode projector 3-1, a diaphragm 3-2, a CCD camera 3-3, a lens 3-4 and a filter plate 3-5, wherein the laser diode projector 3-1 is used for projecting linear structure light to a welding line 15 and a nonstandard workpiece 14 to form laser stripes 16 reflecting the contours of the welding line surface, the diaphragm 2 is used for adjusting the intensity of a control light beam, the CCD camera 3-3 is used for collecting a welding line image with the laser stripes 16, the lens 3-4 and the filter plate 3-5 are additionally arranged in front of the CCD camera 3-3, the lens 3-4 is used for focusing the image, a clear image is formed on a CCD image plane, and the filter plate 3-5 is used for filtering a large amount of arc light, splash and smoke dust generated in the welding process to enter the lens, so that image noise is reduced.
The nonstandard workpiece 14 is clamped and fixed by the nonstandard workpiece fixture device 10, the nonstandard workpiece fixture device 10 is shown in fig. 3, and the 3 flexible multi-telescopic rod clamps 10-2 and 1 set of quick release clamping actuators 10-1 are arranged on one flexible multi-telescopic rod clamp 10-2 and used for clamping the nonstandard workpiece 14, and the other two flexible multi-telescopic rod clamps 10-2 are used for positioning the nonstandard workpiece 14. The quick release clamp actuator 10-1 may optionally be a two degree of freedom positioner for supporting the flexible multi-telescopic rod holder 10-2 for adjusting the overall position and attitude of the nonstandard workpiece 14.
All the systems are controlled by a computer, the telescopic rods of all the modules are firstly driven to the surface of the nonstandard workpiece 14 with fixed determined positions, then the clamping actuator 10-1 capable of quickly releasing is started to safely clamp the nonstandard workpiece 14, and when any change exists in the nonstandard workpiece 14, the position of the telescopic rods is changed, so that the combined clamp realizes automatic reconstruction.
The flexible multi-telescopic rod holder 10-2 comprises a motor and a four-telescopic rod mechanism, wherein the four-telescopic rod mechanism consists of four single-telescopic rod mechanisms with the same structure, each single-telescopic rod mechanism comprises a telescopic rod, a motion mechanism and a power transmission mechanism, the four single-telescopic rod mechanisms are distributed in two rows and two columns, the telescopic rods in the two single-telescopic rod mechanisms in one column are connected with the motor and are directly driven by the motor, and the telescopic rods in the two single-telescopic rod mechanisms in the other column are driven by the motor through power transmission circular shafts, so that each telescopic rod can independently move along the respective X, Y axial direction, and 8 different motions are controlled.
The motion mechanism consists of two parts, wherein one part is formed by controlling the telescopic rod to move along the Y-axis direction through a threaded shaft, and the other part is formed by controlling the telescopic rod to move along the X-axis direction through a square shaft and a set of worm gear device. Specifically, the telescopic rod is arranged on a supporting plate driven by a threaded shaft, the telescopic rod is provided with external threads which are meshed with internal threads on a worm wheel shaft, the worm wheel shaft is tightly matched with a worm wheel, the worm wheel is driven by a worm arranged on a square shaft, a thrust bearing is arranged on the worm wheel shaft and used for resisting the reaction force during clamping, and the square shaft and the threaded shaft are independently driven by a motor through a power transmission mechanism.
The power transmission mechanism comprises a power transmission system, a shaft transformation system and a clutch system, and specifically, the power transmission system comprises a driving wheel, an idle wheel and six face wheels, a motor shaft extends through a shaft sleeve, the driving wheel is fixedly arranged on the shaft sleeve, the face wheels three are fixed on the idle wheel shaft, the face wheels four, the face wheels five, the face wheels six, the face wheels seven and the face wheels eight are respectively arranged on four driving shafts and a power transmission circular shaft of the telescopic link, and when the face wheels three are meshed with one of the face wheels four, the face wheels five, the face wheels six, the face wheels seven and the face wheels eight, the power of the motor is transmitted to a shaft corresponding to the meshed face wheels; the shaft transformation system comprises two face wheels, an idler wheel arm and a ball pin, wherein the first face wheel is arranged on the shaft sleeve, the second face wheel is arranged at one end of the idler wheel arm, and when the first face wheel is meshed with the second face wheel, the idler wheel arm rotates to the position of a selected shaft, and the ball pin limits the idler wheel arm to continue to move; the clutch system consists of a clutch arm and two electromagnetic valve switches, wherein the electromagnetic switch A is used for driving the clutch arm to push the idler arm to apply force so as to enable the face wheel I to be meshed with the face wheel II, and the electromagnetic switch B is used for driving the clutch arm to push the idler arm to apply force so as to enable the face wheel III to be meshed with the face wheel where the selected shaft is located.
The flexible multi-telescopic rod holder 10-2 can be controlled by a computer, the telescopic rods of each module are firstly driven to the surface of a fixed workpiece at a determined position, then an actuator is started to safely clamp the workpiece, and when any change exists in the workpiece, the position of the telescopic rods is changed, so that the combined clamp realizes automatic reconstruction.
The weld vision detection system, the welding execution system, the communication and control system and the non-standard workpiece fixture device form a hardware device part of the non-standard workpiece automatic welding processing system with structured light vision, besides the hardware device, the system also needs a software part, a vision information processing system 12 and an off-line programming system 13 are arranged in the industrial personal computer 11 as the software part of the whole welding system, wherein, as shown in fig. 4, the vision information processing system 12 comprises:
the visual system calibration module is used for completing parameter measurement calibration of the welding seam visual detection system and comprises CCD camera parameter calibration, structure light sensor parameter calibration and robot hand-eye parameter calibration;
the welding seam image processing module takes a structural light welding seam image acquired by the welding seam visual detection system as input, and performs welding seam image preprocessing and welding seam stripe extraction;
the weld joint identification positioning module is used for carrying out weld joint type identification and weld joint three-dimensional reconstruction by taking data results obtained by the visual system calibration module and the weld joint image processing module as input;
as shown in fig. 5, the offline programming system 13 includes:
the CAD modeling module takes the result of the welding seam identification positioning module and the six-degree-of-automation industrial robot 1 parameter as input to perform robot three-dimensional modeling and welding environment three-dimensional modeling, so as to realize system design and arrangement;
the programming module is used for planning a robot path and programming a task program;
the graphic simulation module receives the task program compiled by the programming module, performs dynamic simulation graphic simulation on the three-dimensional model of the CAD modeling module, and checks the correctness of the task program;
and the post-processing module compiles the task program compiled by the programming module into an industrial robot target program and a welding instruction, and sends the industrial robot target program and the welding instruction to the robot controller 2 and the welding machine controller 7 to control welding operation, and simultaneously stores the acquired field information for later analysis.
Claims (5)
1. A structured light vision based non-standard automated welding processing system, comprising:
the welding line visual detection system is used for identifying welding lines, detecting positions, monitoring progress and transmitting images to the communication and control system;
the welding execution system is used for executing welding actions and comprises a six-degree-of-freedom industrial robot (1), a welding machine (6) arranged at the end part of a main driving arm of the six-degree-of-freedom industrial robot (1) and a welding gun (8) arranged on an end effector of the six-degree-of-freedom industrial robot (1), wherein the six-degree-of-freedom industrial robot (1) drives the welding gun (8) to adjust the spatial position and the posture, and the welding machine (6) performs welding processing on a nonstandard workpiece (14) through the welding gun (8);
the communication and control system is used for realizing communication and process control and comprises an industrial personal computer (11), a robot controller (2), a welding machine controller (7) and a communication cable (9), wherein the industrial personal computer (11) is a main control device and is used for completing the functions of welding process display, image processing, data operation and instruction transmission; the robot controller (2) is connected with the six-degree-of-freedom industrial robot (1) body and the industrial personal computer (11) through a second communication cable (9-2), receives instruction signals from the industrial personal computer (11), and controls the joint movement of the six-degree-of-freedom industrial robot (1) to adjust the pose of the welding gun (8); the welding machine controller (7) is connected with the welding machine (6) and the industrial personal computer (11) through a communication cable III (9-3) and receives command signals from the industrial personal computer (11) to control welding parameters;
the non-standard workpiece (14) is clamped and fixed by a non-standard workpiece fixture device (10), the non-standard workpiece fixture device (10) consists of 3 flexible multi-telescopic rod clamps (10-2) and 1 set of quick release clamping actuators (10-1), the quick release clamping actuators (10-1) are arranged on one flexible multi-telescopic rod clamp (10-2) and used for clamping the non-standard workpiece (14), and the other two flexible multi-telescopic rod clamps (10-2) are used for positioning the non-standard workpiece (14);
the flexible multi-telescopic rod holder (10-2) comprises a motor and a four-telescopic rod mechanism, wherein the four-telescopic rod mechanism consists of four single-telescopic rod mechanisms with the same structure, each single-telescopic rod mechanism comprises telescopic rods, a motion mechanism and a power transmission mechanism, the four single-telescopic rod mechanisms are distributed in two rows and two columns, the telescopic rods in two single-telescopic rod mechanisms in one column are connected with the motor and are directly driven by the motor, and the telescopic rods in two single-telescopic rod mechanisms in the other column are driven by the motor through power transmission circular shafts, so that each telescopic rod can independently move along the respective X, Y axial direction, and 8 different motions are controlled;
the motion mechanism consists of two parts, wherein one part is formed by controlling the telescopic rod to move along the Y-axis direction through a threaded shaft, and the other part is formed by controlling the telescopic rod to move along the X-axis direction through a square shaft and a set of worm gear device;
the industrial personal computer (11) is provided with a visual information processing system (12) and an offline programming system (13), wherein the visual information processing system (12) comprises:
the visual system calibration module is used for completing parameter calibration of the welding seam visual detection system, and comprises CCD camera parameter calibration, structural light sensor parameter calibration and robot hand-eye parameter calibration;
the welding seam image processing module takes a structural light welding seam image acquired by the welding seam visual detection system as input, and performs welding seam image preprocessing and welding seam stripe extraction;
the weld joint identification positioning module is used for carrying out weld joint type identification and weld joint three-dimensional reconstruction by taking data results obtained by the visual system calibration module and the weld joint image processing module as input;
the offline programming system (13) comprises:
the CAD modeling module takes the result of the welding seam identification positioning module and the six-degree-of-freedom industrial robot (1) parameters as input to perform three-dimensional modeling of the robot and three-dimensional modeling of a welding environment, so as to realize system design and arrangement;
the programming module is used for planning a robot path and programming a task program;
the graphic simulation module receives the task program compiled by the programming module, performs dynamic simulation graphic simulation on the three-dimensional model of the CAD modeling module, and checks the correctness of the task program;
the post-processing module compiles a task program compiled by the programming module into an industrial robot target program and a welding instruction, and sends the industrial robot target program and the welding instruction to the robot controller (2) and the welding machine controller (7) to control welding operation, and simultaneously stores the acquired field information for later analysis;
the weld image preprocessing comprises image filtering and threshold segmentation, and then weld laser streak line refinement and feature extraction are carried out;
the weld joint identification type comprises a linear weld joint and a curve type weld joint;
the three-dimensional reconstruction of the welding seam adopts a line structured light active vision method, the pixel coordinates of the welding seam on an image are obtained through image processing, the pixel coordinates are converted into camera coordinates through a camera internal parameter model and a line structured light plane equation, and then the camera coordinates are further converted into a robot base coordinate system through a robot kinematic equation and a hand-eye calibration relation, so that the three-dimensional reconstruction of the welding seam is realized;
the task program comprises a weld image processing program, a camera internal parameter calibration program, a line structured light plane equation calibration program, a robot kinematics equation calculation program and a robot hand-eye calibration program.
2. The structured light vision-based non-standard automated welding processing system of claim 1, wherein: the welding line visual detection system comprises a line structure light sensor (3), a monitoring CCD camera (4) and an image acquisition card (5), wherein the line structure light sensor (3) is fixedly arranged on an end effector of the industrial robot (1) and keeps a relative fixed position with a welding gun (8) unchanged, so as to form a robot hand eye for welding line identification and position detection; the monitoring CCD camera (4) is used for monitoring the welding processing process, the image acquisition card (5) is arranged on a main board of the industrial personal computer (11), and image transmission and communication between the monitoring CCD camera (4) and the line structure optical sensor (3) and the industrial personal computer (11) are realized through a first communication cable (9-1).
3. A structured light vision based non-standard automated welding processing system as defined in claim 2, wherein: the line structure light sensor (3) comprises a laser diode projector (3-1), a diaphragm (3-2), a CCD camera (3-3), a lens (3-4) and a filter plate (3-5), wherein the laser diode projector (3-1) is used for projecting line structure light to a welding line (15) to form laser stripes (16) reflecting the surface profile of the welding line, the diaphragm (3-2) is used for adjusting the intensity of control light beams, the CCD camera (3-3) is used for collecting the welding line image with the laser stripes (16), the lens (3-4) and the filter plate (3-5) are additionally arranged in front of the CCD camera (3-3), the lens (3-4) is used for focusing the image, a clear image is formed on a CCD image plane, and the filter plate (3-5) is used for filtering a large amount of arc light, splashes and smoke dust generated in the welding process to enter the lens, so that image noise is reduced.
4. The structured light vision-based non-standard automated welding processing system of claim 1, wherein: the telescopic rod is arranged on a supporting plate driven by a threaded shaft, an external thread is arranged on the telescopic rod and meshed with an internal thread on a worm wheel shaft, the worm wheel shaft is tightly matched with a worm wheel, the worm wheel is driven by a worm arranged on a square shaft, a thrust bearing is arranged on the worm wheel shaft and used for resisting the reaction force during clamping, and the square shaft and the threaded shaft are independently driven by a motor through a power transmission mechanism.
5. The structured light vision-based non-standard automated welding processing system of claim 1, wherein: the power transmission mechanism comprises a power transmission system, a shaft transformation system and a clutch system, wherein the power transmission system comprises a driving wheel, an idle wheel and six face wheels, a motor shaft extends through a shaft sleeve, the driving wheel is fixedly arranged on the shaft sleeve, the face wheels III are fixed on the idle wheel shaft, the face wheels IV, the face wheels V, the face wheels VI, the face wheels seven and the face wheels eight are respectively arranged on four driving shafts and power transmission circular shafts of the telescopic links, and when the face wheels III are meshed with one of the face wheels IV, the face wheels V, the face wheels VI, the face wheels seven and the face wheels eight, the power of the motor is transmitted to the shaft corresponding to the meshed face wheels; the shaft transformation system comprises two face wheels, an idler wheel arm and a ball pin, wherein the first face wheel is arranged on the shaft sleeve, the second face wheel is arranged at one end of the idler wheel arm, and when the first face wheel is meshed with the second face wheel, the idler wheel arm rotates to the position of a selected shaft, and the ball pin limits the idler wheel arm to continue to move; the clutch system consists of a clutch arm and two electromagnetic valve switches, wherein the electromagnetic switch A is used for driving the clutch arm to push the idler arm to apply force so as to enable the face wheel I to be meshed with the face wheel II, and the electromagnetic switch B is used for driving the clutch arm to push the idler arm to apply force so as to enable the face wheel III to be meshed with the face wheel where the selected shaft is located.
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