CN107077799B - 用于表征在管道和其他弯曲结构上的人工焊接操作的系统 - Google Patents
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Abstract
一种用于表征人工焊接练习并且给焊工提供有价值的训练的系统(10),该系统包括用于生成、捕捉和处理数据的部件。该数据生成部件还包括固定装置、工件、具有与其整合的至少两个点标记的至少一个校准装置以及焊接工具。该数据捕捉部件还包括用于捕捉这些点标记的图像的成像系统,并且该图像处理部件可操作来接收来自该图像捕捉部件的信息并且执行不同的位置和取向计算。
Description
相关申请的交叉引用
本申请作为非临时专利申请提交,要求在35U.S.C.§119(e)下于2014年9月26日提交的美国临时专利申请号62/055,724的优先权以及任何其他权益,其全部披露内容通过引用结合在此。
以下共同转让的、共同待决的美国专利申请也通过引用以其全文结合在此:于2012年7月6日提交的并且标题为“System for Characterizing Manual WeldingOperations(用于表征人工焊接操作的系统)”的美国非临时专利申请号13/543,240。
领域
总体发明概念,除其他事项之外,涉及用于远程控制焊接装置的运行的方法、设备、系统、程序和技术。
背景
所描述的发明总体上涉及一种用于表征人工焊接操作的系统,并且更具体地涉及一种用于通过捕捉、处理并且以用可见的格式来呈现由焊接受训者在人工执行实际焊接时实时产生的数据的方式将有用的信息提供给焊接受训者的系统。
制造业对高效且经济的焊工培训的期望在过去的十年一直是在文档中充分记录的主题,因为在今天的工厂、造船厂和建筑工地,技术焊工严重短缺的现状正变得惊人地明显。迅速退休的劳动力,结合传统的基于指导者的焊工培训的缓慢步伐,已经成为更有效的培训技术发展的推动力。允许加速训练针对焊接的人工灵巧技术的创新,连同对电弧焊接基本原理的快速教导,正在变得必要。本文所披露的表征和培训系统应对改进焊工培训的这个至关重要的需求并且使得能够监测人工焊接过程来确保这些过程是在可允许的限制内,所述限制对满足全行业的质量要求是必要的。迄今为止,多数焊接过程都是人工实行的,然而该领域仍缺乏实用的、可商购的工具来跟踪这些人工过程的表现。因此,对用于培训焊工来在各种条件下适当地执行各种类型的焊接的有效系统存在持续的需求。
概述
以下内容提供对本发明的某些示例性实施例的概述。这个概述不是广泛的综述并且不旨在确定本发明的关键的或决定性的方面或元素或者限定其范围。
根据本发明的一个方面,提供了一种用于表征人工和/或半自动焊接操作和练习的系统。这种系统包括数据生成部件;数据捕捉部件;以及数据处理部件。该数据生成部件还包括:固定装置,其中该固定装置的几何特征是预先确定的;被适配成安装在该固定装置上的工件,其中该工件包括有待焊接的至少一个接头,并且其中沿有待焊接的该接头延伸的矢量限定操作路径,其中该操作路径是直线的、曲线的、圆形的或其组合;至少一个校准装置,其中每个校准装置还包括与其整合的至少两个点标记,并且其中在这些点标记与该操作路径之间的几何关系是预先确定的;以及焊接工具,其中该焊接工具可操作来在有待焊接的该接头处形成焊接,其中该焊接工具限定工具点和工具矢量,并且其中该焊接工具还包括被附接到该焊接工具的目标,其中该目标还包括以预先确定的图案来安装在其上的多个点标记,并且其中点标记的该预先确定的图案可操作来限定刚体。该数据捕捉部件还包括用于捕捉这些点标记的图像的成像系统。该数据处理部件可操作来接收来自该数据捕捉部件的信息并且然后计算:该操作路径相对于通过该成像系统可见的三维空间的位置和取向;该工具点相对于该刚体的位置以及该工具矢量相对于该刚体的取向;以及该工具点相对于该操作路径的位置以及该工具矢量相对于该操作路径的取向。
根据本发明的另一个方面,还提供了一种用于表征人工和/或半自动焊接操作和练习的系统。这种系统包括数据生成部件;数据捕捉部件;以及数据处理部件。该数据生成部件还包括:固定装置,其中该固定装置的几何特征是预先确定的;被适配成安装在该固定装置上的工件,其中该工件包括有待焊接的至少一个接头,并且其中沿有待焊接的该接头延伸的矢量限定操作路径,其中该操作路径是直线的、曲线的、圆形的或其组合;至少一个校准装置,其中每个校准装置还包括与其整合的至少两个点标记,并且其中在这些点标记与该操作路径之间的几何关系是预先确定的;以及焊接工具,其中该焊接工具可操作来在有待焊接的该接头处形成焊接,其中该焊接工具限定工具点和工具矢量,并且其中该焊接工具还包括被附接到该焊接工具的目标,其中该目标还包括以预先确定的图案来安装在其上的多个点标记,并且其中点标记的该预先确定的图案可操作来限定刚体。该数据捕捉部件还包括用于捕捉这些点标记的图像的成像系统,并且该成像系统还包括多个数字相机。至少一个带通滤波器结合到用于该多个数字相机中的每一者的光学序列中,以用于仅允许从这些点标记反射或发射的波长的光,从而用于改善图像的信噪比。该数据处理部件可操作来接收来自该数据捕捉部件的信息并且然后计算:该操作路径相对于通过该成像系统可见的三维空间的位置和取向;该工具点相对于该刚体的位置以及该工具矢量相对于该刚体的取向;以及该工具点相对于该操作路径的位置以及该工具矢量相对于该操作路径的取向。
基于阅读和理解下面的对示例性实施例的详细描述,本发明的附加特征和方面对于本领域的技术人员而言将变得明晰。如将被技术人员所理解的,在不脱离本发明的范围和精神的情况下,本发明的进一步的实施例是可能的。因而,附图和相关联的描述在本质上被认为是展示性的而不是限制性的。
附图简要说明
附图(其被并入到说明书中并且形成说明书的一部分)示意性地展示了本发明的一个或多个示例性实施例以及上面所给出的总体描述和下面所给出的详细描述、用于解释本发明的原理,并且其中:
图1是展示了通过本发明的示例性实施例的数据处理和可视化部件的信息流的流程图。
图2根据本发明的示例性实施例提供了用于表征人工焊接操作的便携式或半便携式系统的等距视图。
图3提供了图2的系统的平坦组装的等距视图。
图4提供了图2的系统的水平组装的等距视图。
图5提供了图2的系统的竖直组装的等距视图。
图6展示了在图2的平坦组装上的两个点标记的布置。
图7展示了示例性工件操作路径。
图8展示了用于确定工件操作路径的在示例性工件上的两个主动或被动点标记的布置。
图9是详述了在本发明的第一校准部件的示例性实施例中涉及的过程步骤的流程图。
图10展示了此发明的示例性实施例的焊接工具,示出了用于限定刚体的点标记的布置。
图11展示了此发明的示例性实施例的焊接工具,示出了用于限定工具矢量和刚体的点标记的布置。
图11A展示了图10的焊接工具以及用于与其交接的示例性工具校准装置。
图12是详述了在本发明的第二校准部件的示例性实施例中涉及的过程步骤的流程图。
图13根据本发明的示例性实施例提供了用于表征人工焊接操作的便携式或半便携式系统的等距视图。
详细说明
现在参照附图描述本发明的示例性实施例。参考符号在详细说明中自始至终被用来指代不同元件和结构。在其他情况中,出于简化描述的目的,众所周知的结构和装置以方框图的形式被示出。尽管出于展示的目的,下面的详细说明含有许多出于展示目的的具体内容,但本领域的技术人员将理解的是,对下面细节的许多变化和变更在本发明的范围内。因此,在没有对所要求保护的发明的一般性造成任何损失并且没有对所要求保护的发明进行限定的情况下,阐述下面的本发明实施例。
本发明涉及一种用于观测和表征人工焊接练习和操作的先进系统。这种系统对于焊接指令以及提供负担得起的工具来用于测量人工焊接技术并且将该技术与所建立的程序进行对比的焊工训练而言是特别有用的。此发明的训练应用包括:(i)筛选申请人的技能水平;(ii)评估受训者随时间的进度;(iii)提供实时辅导以减少训练时间和成本;并且(iv)通过可量化的结果周期性地重新测试焊工的技能水平。过程监测和质量控制应用包括:(i)实时识别与优选条件的偏差;(ii)随时间记录和跟踪与程序的符合度;(iii)出于统计过程控制的目的来捕捉过程内数据(例如,热量输入测量值);并且(iv)识别需要额外训练的焊工。本发明的系统提供了能够确定与不同的认可焊接程序的符合度的独特益处。
本发明在不同的示例性实施例中在焊接练习过程中使用单个或多个相机跟踪系统基于点云图像分析来测量炬的移动并且收集过程数据。此发明可应用于宽范围的过程,包括但不必限于GMAW、FCAW、SMAW、GTAW和切割。本发明可拓展至工件构型的范围,包括大尺寸、不同的接头类型、管道、板以及复杂的形状和组件。测量参数可以包括但不限于工作角度、行进角度、工具平衡、行进速度、焊道布置、编排、电压、电流、焊丝给送速度、电弧长度、热量输入、气体流动(计量的)、接触尖端到工件距离(CTWD)和熔敷速率(例如,磅/小时、英寸/道次)。本发明的训练部件可以预填充有特定的焊接程序或者可以由指导者定制。自动保存并记录数据,焊接后分析对表现进行评分,并且跟踪随时间的进度。可以贯穿整个焊接训练程序来使用这个系统。该系统可以用于提供任何类型的(典型地为实时)反馈,包括但不限于以下各项中的一者或多者:头盔内视觉反馈、屏幕上视觉反馈、音频反馈(例如,辅导)以及焊接工具(例如,炬)视觉、音频或触觉反馈。现在参照附图,应更加详细地描述此发明的一个或多个具体实施例。
如在图1中示出的,在本发明的示例性实施例中,通过焊接表征系统10的数据生成部件100、数据捕捉部件200和数据处理(和可视化)部件300的基本信息流在六个基本步骤中发生:(1)图像捕捉110;(2)图像处理112;(3)输入电弧焊接数据210,例如已知或优选的焊接参数;(4)数据处理212;(5)数据存储214;和(5)数据显示310。图像捕捉步骤110包括通过一个或多个现成的高速视觉相机捕捉目标98(典型地包括彼此处于固定几何关系中的至少两个点标记)的图像,其中输出方面典型地包括以每秒多(例如超过100)帧产生图像文件。图像处理步骤112的输入方面包括对包括三个或更多个点标记的刚体(即,校准目标)进行逐帧点云分析。一旦辨识已知刚体,则计算相对于相机原点和“受训”刚体取向的位置和取向。捕捉和对比来自两个或更多个相机的图像允许基本上精确地确定刚体在三维空间中的位置和取向。典型地以每秒多于100次的速率对图像进行处理。本领域普通技术人员将理解,可以使用更小的采样速率(例如,10图像/秒)或更大的采样速率(例如,1000图像/秒)。图像处理步骤112的输出方面包括创建数据阵列,该数据阵列包括x轴、y轴和z轴位置数据以及横滚、俯仰和偏航取向数据、以及时间戳和软件标记。(包括前述6D数据的)文本文件可以以期望频率流式传送或发送。数据处理步骤212的输入方面包括典型地以预先确定的速率来请求的原始位置和取向数据,而输出方面包括通过针对选定的过程和接头类型的算法将这种原始数据变换成有用的焊接参数。数据存储步骤214的输入方面包括存储焊接试验数据(例如,存储为*.dat文件),而输出方面包括保存用于检查和跟踪的数据、保存用于在稍后的时间在监视器上检查的数据和/或在稍后的时间检查学员的进度。学员进度可以包括但不限于总练习时间、总电弧时间、总电弧启动、和针对单独参数的随时间的表现。数据显示步骤310的输入方面包括焊接试验数据,这些焊接试验数据可以还包括但不限于工作角度、行进角度、工具平衡、行进速度、焊道布置、编排、电压、电流、焊丝给送速度、电弧长度、热量输入、气体流动(计量的)、接触尖端到工件距离(CTWD)和熔敷速率。输出方面涉及任何类型的反馈,包括但不限于以下各项中的一者或多者:可以在监视器、头盔内显示器、抬头显示器或其组合上查看的视觉数据;音频数据(例如,音频辅导);和触觉反馈。该反馈典型地是实时呈现的。所跟踪的参数被绘制在基于时间的轴线上并且与上阈值和下阈值或优选变化进行对比,例如通过记录专业焊工的移动而训练的那些变化。本领域普通技术人员将理解,本发明的总体概念考虑到将这些参数绘制在不基于时间的轴线上,例如基于焊接的长度来绘制或以其他方式处理这些参数。可以结合行进速度来测量电流和电压以确定热量输入,并且可以使用这些焊接过程参数来估算电弧长度。可以将位置数据变换为焊接起始位置、焊接停止位置、焊接长度、焊接序列、焊接进度或其组合,并且可以结合行进速度来测量电流和电压以确定热量输入。
图2至图5提供了根据本发明的示例性实施例的焊接表征系统10的说明性视图。如在图2中示出的,便携式训练支架20包括用于与地面或其他水平基底接触的基本上平坦的底座22、刚性竖直支撑柱24、相机或成像装置支撑件26、以及用于调整成像装置支撑件26的高度的齿条齿轮组件31。在多数实施例中,焊接表征系统10预期是便携式的或者至少可以从一个位置移动至另一个位置,因此底座22的总占地面积相对较小,从而允许关于安装和使用的最大灵活性。如在图2至图6中示出的,焊接表征系统10可以用于训练练习,这些训练练习包括任何适当的工件安排,包括但不限于平坦的、水平的、竖直的、头顶的和不适当位置定向的工件。在附图中示出的示例性实施例中,训练支架20被描绘为能够支撑系统的其他部件的单一或整合的结构。在其他实施例中,支架20是不存在的,并且系统的不同部件是由可用的无论什么适当的结构或支撑装置来支撑的。因此,在此发明的上下文内,“支架”20被限定为能够支撑焊接表征系统10的部件的任何单个结构或替代性的多个结构。
参照图2至图3,某些焊接练习将利用平坦组件30,该平坦组件通过套环34可滑动地附接到竖直支撑柱24,该套环在支撑柱24上向上或向下滑动。套环34进一步通过齿条齿轮31来支撑在柱24上,该齿条齿轮包括用于使齿条齿轮组件31在支撑柱24上向上或向下移动的轴32。平坦组件30包括训练平台38,该训练平台由一个或多个托架(不可见)支撑。在一些实施例中,防护件42附接到训练平台38以用于保护支撑柱24的表面免受热损坏。训练平台38还包括用于将焊接特定位置固定装置/夹具46紧固到训练平台的表面上的至少一个夹钳44。针对焊接位置的夹具46的结构构型或一般特征是基于焊接过程的类型而可变的,该焊接过程的类型是具体焊接练习的主题,并且在图2至图3中,固定装置46被配置成用于填角焊接练习。在图2至图3中示出的示例性实施例中,针对焊接位置的固定装置46的第一结构部件48和第二结构部件50被设置为彼此呈直角。针对位置的固定装置46可以包括用于帮助将焊接试样(工件)54适当布置在固定装置上的一个或多个桩钉47。与系统10一起使用的任何焊接试样54的特征是基于人工焊接过程的类型而可变的,该人工焊接过程的类型是具体训练练习的主题,并且在图7至图8中示出的示例性实施例中,焊接试样54的第一部分56和第二部分58也被设置为彼此呈直角。参照图4至图5,某些其他的焊接练习将利用水平组件30(参见图4)或竖直组件30(参见图5)。在图4中,水平组件30支撑对接固定装置46,该对接固定装置将工件54保持在适当位置中以用于对接焊接练习。在图5中,竖直组件30支撑竖直固定装置46,该竖直固定装置将工件54保持在适当位置中以用于搭接焊接练习。
本发明的数据处理部件300典型地包括用于接收和分析由数据捕捉部件200捕捉的信息的至少一个计算机,该数据捕捉部件自身包括被容纳在保护性壳体中的至少一个数字相机。在焊接表征系统10的运行过程中,这个计算机典型地运行软件,该软件包括训练方案模块、图像处理和刚体分析模块、以及数据处理模块。训练方案模块包括各种各样的焊接类型以及与产生每种焊接类型相关联的一系列可接受的焊接过程参数。在训练方案模块中可以包括任何数量的已知或AWS焊接接头类型以及与这些焊接接头类型相关联的可接受参数,该训练方案模块在开始训练练习之前由课程指导者访问并配置。由指导者选择的焊接过程和/或类型确定了对于任何给定的训练练习使用哪种针对焊接过程的固定装置、校准装置和焊接试样。对象识别模块可操作来将系统训练成识别已知的刚体目标98(包括两个或更多个点标记)并且然后当由受训者完成实际人工焊接时使用目标98来计算用于焊枪90的位置和取向数据。数据处理模块将训练方案模块中的信息与由对象识别模块处理的信息进行对比并且将对比数据输出至显示设备(例如监视器或抬头显示器)。监视器允许受训者实时可视化所处理的数据,并且可视化的数据可操作来为受训者提供关于焊接的特征和质量的有用反馈。焊接表征系统10的视觉界面可以包括与信息输入、登录、设置、校准、练习、分析和进度跟踪有关的各种各样的特征。分析屏典型地显示在训练方案模块中存在的焊接参数,包括(但不限于)工作角度、行进角度、工具平衡、行进速度、焊道布置、编排、电压、电流、焊丝给送速度、电弧长度、热量输入、气体流动(计量的)、接触尖端到工件距离(CTWD)和熔敷速率(例如,磅/小时、英寸/道次)。根据本发明,可以有多种显示变体。
在多数(如非所有)的情况下,焊接表征系统10将在使用之前经受一系列的校准步骤/过程。系统校准的一些方面将典型地在递交客户之前由系统10的制造商执行,并且系统校准的其他方面将典型地在任何焊接训练练习之前由焊接表征系统10的使用者执行。系统校准典型地涉及两个相关和整体的校准过程:(i)对于有待在不同的焊接训练练习中使用的每种接头/位置组合来确定有待在工件上创建的操作路径的三维位置和取向;以及(ii)通过计算在位于目标98上的多个被动(例如,反射)或主动(例如,发光)点标记与由位于焊接工具90上的点标记表示的至少两个关键点之间的关系来确定焊接工具的三维位置和取向。
本发明的第一校准方面典型地涉及相对于全局坐标系(即,相对于焊接表征系统10的其他结构部件及由其占据的三维空间)对焊接操作进行校准。在跟踪/表征人工焊接练习之前,将确定每个期望操作路径在任何给定工件上的全局坐标(即,矢量)。在一些实施例中,这是在工厂执行的校准过程,将包括存储在数据处理部件200上的对应配置文件。在其他实施例中,该校准过程将在场所中(即,在现场)执行。为了获得所期望的矢量,在不同的平台位置中的每一者中(例如,平坦、水平和竖直),可以在至少两个定位标记上插入包含主动或被动标记的校准装置。图6至图8在一个可能的平台位置中展示了这个校准步骤。针对接头的固定装置46相应地包括第一结构部件48(水平)和第二结构部件50(竖直)。焊接试样或工件54相应地包括第一部分56(水平)和第二部分58(竖直)。本领域普通技术人员将理解,本发明的总体概念扩展至任何适合的夹具/试样构型和取向。例如,在一些示例性实施例中,可以使用手持或可移动装置来执行夹具或接头校准,该手持或可移动装置将“教授”软件多个点(即,位置)来确定操作路径。以此方式,使用两个或更多个点将允许焊接件定向在任何位置中。
工件操作路径从点X延伸至点Y并且被示出为图7中的双线59。定位点标记530和532被放置为如图6(和图8)中所示出的,并且每个标记的位置是使用数据捕捉部件100来获得的。例如可以使用任何适合的捕捉系统,例如,(由俄勒冈州科瓦利斯的NaturalPoint公司提供的)Optitrack跟踪工具或者提供三维标记和实时的六自由度物体移动跟踪的类似的可商购或专有硬件/软件系统。这种技术典型地利用以预先确定的图案安排的反射和/或发光点标记,从而创建由系统成像硬件和系统软件解读为“刚体”的点云,尽管其他合适的方法与此发明兼容。
在由图9的流程图表示的校准过程中,在步骤280,将桌子38固定到位置i(0,1,2);在步骤282,将校准装置放置在定位销钉上;在步骤284,捕捉所有标记位置;在步骤286,计算对应定位符位置的坐标;在步骤288计算并在290存储对应填角操作路径的坐标;在步骤292计算并在294存储对应搭接操作路径的坐标;并且在步骤296计算并在298存储对应凹槽操作路径的坐标。所有坐标相对于由数据捕捉部件200可见的三维空间来计算。
在此发明的一个实施例中,工件的位置和取向通过将两个或更多个被动或主动点标记应用于校准装置来校准,该校准装置被放置在距固定装置的已知的平移和旋转偏移处,该固定装置将工件保持在已知的平移和旋转偏移处。在此发明的另一个实施例中,工件的位置和取向通过将两个或更多个被动或主动点标记应用于固定装置来校准,该固定装置将工件保持在已知的平移和旋转偏移处。在又另外的实施例中,该工件是非直线的,并且其位置和取向可以使用具有两个或更多个被动或主动点标记来映射并且可以存储以用于稍后的使用。工件操作路径的位置和取向可以基于在整个工作操作中的序列步骤而经历从其原始校准平面的预先确定的平移和旋转偏移。
在一些示例性实施例中,提取和使用焊接件上的呈电子表格(例如,在CAD中渲染)的数据来确定工件的位置和/或取向。此外,还对为焊接件指定焊接参数的相关焊接程序规范(WPS)进行处理。以此方式,系统可以映射CAD绘图和WPS以用于(实时)评估与WPS的符合度。
通过分析以上描述的随时间的连续工具位置和取向以及不同的工件操作路径,可以确定诸如位置、取向、速度、加速度和与工件操作路径的空间关系等重要的工具操纵参数。可以将工具操纵参数与预先确定的优选值进行对比,以确定与已知和优选程序的偏差。还可以将工具操纵参数与其他制造过程参数结合以确定与优选程序的偏差,并且可以使用这些偏差来评估技能水平、为训练提供反馈、评估朝技能目标的进度或者出于质量控制目的。可以出于统计过程控制目的,从多个操作汇总与工件操作路径有关的记录的移动参数。可以出于统计过程控制目的,从多个操作汇总与优选程序的偏差。还可以记录与工件操作路径有关的重要工具操纵参数以及工具位置和取向,从而用于建立有经验操作者的移动信号,该信号被用作评估与优选程序的符合度的基线。
第二校准方面典型地涉及焊接工具90相对于目标98的校准。焊接工具90典型地是焊炬或焊枪或者SMAW电极保持器,但还可以是任何数量的其他器具,包括烙铁、割炬、成型工具、材料移除工具、喷漆枪或扳手。参照图10至图11,焊枪/焊接工具90包括工具点91、喷嘴92、本体94、扳机96和目标98。在A位置和B位置中(参见图11)包括两个整合的主动或被动点标记的工具校准装置93被附接、插入喷嘴92或以其他方式与该喷嘴交接。例如,工具点91可以被加工成使得可以出于校准目将工具校准装置93螺纹拧入焊接工具90的喷嘴92中。
在另一个示例性实施例中,工具校准装置93附连到套管1100,如在图11A中示出的。套管1100的形状和大小可以确定成配合在焊接工具90的喷嘴92的至少一部分之上。在一些实施例中,套管1100可以配合在喷嘴92之上而无需移除工具点91。在一些示例性实施例中,套管1100配合在焊接工具90的并非该喷嘴92的部分之上或以其他方式与该部分交接。套管1100以任何合适的方式(例如,通过摩擦配合、螺纹等)可移除地连接至焊接工具90。套管1100的形状和大小可以确定成配合在多个不同的焊接工具之上而无需修改所述焊接工具。以此方式,套管1100和附接的工具校准装置93形成“通用”类型的工具校准装置。
此外,通过将多个主动或被动点标记502、504和506(以及可能的额外点标记)附接至目标98的上表面来构造刚体点云(即,“刚体”)。
如在此描述的,其他点标记布置是可能的并且落入本发明的总体概念的范围内。如果所使用的这些点标记是主动的并且需要电源,则目标98可以包括功率输入。数据捕捉部件200使用跟踪系统(例如,前述的Optitrack跟踪工具)或类似的硬件/软件来定位刚体以及表示工具矢量位置的点标记522(A)和520(B)。可以从系统10的软件中提取这些位置,并且可以计算在点标记A和B与刚体之间的关系。
在由图12的流程图表示的示例性校准过程中,在步骤250移除焊接喷嘴92和接触管91;在步骤252,将校准装置插入本体94中;将焊接工具90放置在工作包络中并且通过图像捕捉部件100捕捉刚体(图12中标记为“S”)以及点标记A和B;并且在步骤256计算在A与S和B与S之间的关系;其中在258存储As的关系数据,并且在260存储Bs的关系数据。
在此发明的一个实施例中,通过在沿距工具点有已知偏移的工具矢量的位置处将两个或更多个被动或主动点标记应用于校准装置来执行对工具点和工具矢量的校准。在另一个实施例中,对工具点和工具矢量的校准通过将工具插入相对于工件有已知的位置和取向的校准框来执行。例如,对工具点和工具矢量的校准可以通过以特定方式将工具点91插入焊接接头中来执行。
关于由点标记(例如,502、504、506)限定的刚体,在一个实施例中,这些被动或主动点标记以多分面方式附连至工具,从而可以在图像系统的视场内适应宽范围的旋转和取向变化。在另一个实施例中,这些被动或主动点标记以球形方式附连至工具,从而可以在图像系统的视场内适应宽范围的旋转和取向变化。在又另一个实施例中,这些被动或主动点标记以环形方式附连至工具,从而可以在图像系统的视场内适应宽范围的旋转和取向变化。
可以将许多额外的有用特征结合到本发明中。例如,出于图像滤波的目的,可以将带通滤波器或高通滤波器结合到用于数据捕捉部件200中的该多个数字相机中的每一者的光学序列中,以用于仅允许从这些点标记反射或发射的波长的光,从而改善图像的信噪比。可以通过仅分析由具有与预先已知的刚体位置的受限偏移的动态兴趣区域内获得的图像信息来排除杂乱数据。这个动态兴趣区域可以结合到或以其他方式预定义(即,预编程为宽度x和高度y并且定中心在目标98的已知位置上的方框或区域)在每个数字相机的视场内,从而仅处理来自这个预定义区域的图像信息。该兴趣区域将随着刚体移动而改变并且因此基于刚体的预先已知的位置。这种方法允许成像系统在搜索点标记时仅查看动态兴趣区域内的像素,而忽视或阻止在未包括在动态兴趣区域中的较大图像帧中的像素。减少处理时间是本发明的此方面的益处。
在本发明的一些实施例中,操作路径或其预先确定的区段相对于通过成像系统可视的三维空间的位置和取向是由三维CAD模型获得的,该三维CAD模型的坐标系相对于该成像系统的坐标系是已知的。该三维CAD模型还可以包括预定义的直线点或曲线点,这些直线点或曲线点限定操作路径区段,并且至少三个校准点位于三维CAD模型和固定装置两者上。位置和取向转移可以通过用成像系统测量在固定装置上的该至少三个校准点的位置并且然后将这些测量值与该三维CAD模型的原始校准点进行对比来应用于该三维CAD模型。在其他实施例中,直线或曲线操作路径或者其预先确定的区段相对于通过成像系统可见的三维空间的位置和取向可以使用三维CAD模型获得,其中该三维CAD模型的坐标系相对于成像系统的坐标系是预先确定的,并且其中在三维CAD模型上的焊接位置是预定义的。关于CAD模型创建,在CAD模型与所讨论的部分之间典型地存在一对一关系,并且校准序列可以是焊接练习的一个方面。模型存在于虚拟空间中,并且使用者将指示系统关于这两点的位置。创建链接以消除CAD模型与该部分之间的任何差异,或者利用工具加工时的部分或具体数据。还可以包括用于离线地教导该系统的程序。
对于此发明,操作路径的一种定义描述了用于操作的单个连续路径。在某些实施例中,操作路径被划分为多个分开的区段以用于横过拐角或总体方向改变的焊接。在此背景下,多个点(至少两个)构成操作路径区段,并且连续的操作路径区段构成操作路径链。因此,操作路径的位置和取向可以由形成链的一个或多个操作路径区段构成,并且连续的区段在一个区段的末尾和下一个区段的开始处共享操作路径点。在这种实施例中,系统提供在多个校准平面之间移动的能力;每个操作平面取决于哪个校准平面正在被利用,并且每个操作路径与预先确定的坐标系相关联。
此外,可以对图2的示例性焊接表征系统10进行修改以更好地处理圆(例如,圆形的)操作路径(诸如管道焊接)和/或更复杂的工件组装的情况。
如图13中示出的,焊接表征系统10包括与图2中示出的支架20类似或完全相同的训练支架,该训练支架具有基本上平坦的底座22。此外,框架1302、笼架等等也与支架20(直接或间接)交接。例如,框架1302可以连接至相机或成像装置支撑件26。
在一些实施例中,框架1302可以容易地与支架20分开,从而促进系统10的便携性。框架1302包括一个或多个支腿1304以用于进一步支撑框架1302以及支架20。这些支腿1304可以是高度可调的。该框架限定不同的位置,相机(例如,数字高速视觉相机)可以按照这些位置来安装。如在图13中示出的,多个相机1306按照工件54周围的不同位置(和高度)来安装在框架1302上。以此方式,框架1302至少部分地围绕工件54。在一些示例性实施例中,工件54的至少一半(即,在管道情况下为180度)被框架1302围绕。在一些示例性实施例中,工件54的至少75%(即,在管道情况下为270度)被框架1302围绕。在一些示例性实施例中,工件54基本上全部(即,~100%)被框架1302围绕。
这些相机1306形成数据捕捉部件200的一部分。在一些示例性实施例中,焊接表征系统10包括2个或更多个(例如,2个至20个)相机。在一些示例性实施例中,焊接表征系统10包括4个或更多个相机、5个或更多个相机、6个或更多个相机、7个或更多个相机、8个或更多个相机、9个或更多个相机、10个或更多个相机、11个或更多个相机、或者12个或更多个相机。在一些示例性实施例中,焊接表征系统10包括至少4个相机、至少5个相机、至少6个相机、至少7个相机、至少8个相机、至少9个相机、至少10个相机、至少11个相机、或者至少12个相机。在校准相机之后(当需要时),如在此所描述地对焊接试样54和焊接工具10进行校准。这些相机1306在工件54(例如,管道)周围的分布允许对工件54上的焊接操作进行精确跟踪。
虽然已经通过描述本发明的示例性实施例展示了本发明,并且虽然这些实施例已经被某种程度上详细地描述,但是本申请人的意图并不是要将所附权利要求书的范围局限于或以任何方式限制为这样的细节。另外的优点和修改是本领域技术人员容易了解的。因此,本发明在其更广的方面不限于所示出和描述的这些特定细节、代表性装置和方法、以及/或者展示性实例中的任一者。因此,在不偏离申请人的本发明总体概念的精神和范围的情况下,可以与这些细节有所偏差。
参考号
10焊接表征系统 93工具校准装置
20训练支架 94本体
22底座 96扳机
24支撑柱 98目标
26相机或成像装置支撑件 98目标
30组件 100数据生成部件
31齿条齿轮组件 110图像捕捉
32轴 112图像处理
34套环 200数据捕捉部件
38训练平台 210电弧焊接数据
42防护件 212数据处理
44夹钳 214数据存储
46夹具 250步骤
47桩钉 256步骤
48部件 258步骤
50部件 252步骤
54焊接试样 260步骤
56部分 280步骤
58部分 282步骤
90焊枪 284步骤
91工具点 288步骤
92喷嘴 290步骤
292 步骤
294 步骤
296 步骤
298 步骤
300 数据处理部件
310 数据显示
502 点标记
504 点标记
506 点标记
522 点标记
520 点标记
530 点标记
532 点标记
1100 套管
1302 框架
1304 支腿
1306 相机
Claims (22)
1.一种用于表征焊接操作的系统(10),包括:
(a)数据生成部件(100),其中该数据生成部件(100)还包括:
(i)固定装置,其中该固定装置的几何特征是预先确定的;
(ii)被适配成安装在该固定装置上的工件,其中该工件包括管道并且包括有待焊接的至少一个接头,其中沿有待焊接的该接头延伸的矢量限定操作路径;该操作路径是直线的、曲线的、圆形的或其组合;
(iii)至少一个校准装置(93),其中每个校准装置(93)还包括与其整合的至少两个点标记,并且其中在这些点标记与该操作路径之间的几何关系是预先确定的;以及
(iv)焊接工具,其中该焊接工具可操作来在有待焊接的该接头处形成焊接,其中该焊接工具限定工具点和工具矢量,并且其中该焊接工具还包括被附接到该焊接工具的目标,其中该目标还包括以预先确定的图案安装在其上的多个点标记,并且其中点标记的该预先确定的图案可操作来限定刚体;以及
(b)数据捕捉部件(200),其中该数据捕捉部件(200)还包括用于捕捉这些点标记的图像的成像系统;以及
(c)数据处理部件(300),其中该数据处理部件(300)可操作来接收来自该数据捕捉部件(200)的信息并且然后计算:
(i)该操作路径相对于通过该成像系统可见的三维空间的位置和取向;
(ii)该工具点相对于该刚体的位置以及该工具矢量相对于该刚体的取向;以及
(iii)该工具点相对于该操作路径的位置以及该工具矢量相对于该操作路径的取向;
其中该成像系统包括多个数字相机(1306);
其中该固定装置包括框架(1302);
其中该多个数字相机包括定位在该工件上方的至少一个数字相机和定位在该工件下方的至少一个数字相机;
其中该框架(1302)包括在其不同的位置处并且围绕该工件(54)在不同的位置和高度处安装在该框架上的多个数字相机(1306);
其中该框架(1302)与数字相机(1306)围绕该工件(54)的至少一半;并且
其中每个数字相机(1306)从不同的角度捕捉该工件的图像。
2.如权利要求1所述的系统,其中至少一个滤波器结合到用于该多个数字相机中的每一者的光学序列中,以用于仅允许从这些点标记反射或发射的波长的光,从而用于改善图像的信噪比。
3.如权利要求1所述的系统,其中该成像系统还包括通过该多个数字相机可见的至少一个动态兴趣区域,其中该动态兴趣区域通过使用该刚体的预先已知的位置来确定,并且其中仅从该动态兴趣区域内收集并处理图像信息。
4.如权利要求2所述的系统,其中该成像系统还包括通过该多个数字相机可见的至少一个动态兴趣区域,其中该动态兴趣区域通过使用该刚体的预先已知的位置来确定,并且其中仅从该动态兴趣区域内收集并处理图像信息。
5.如权利要求1至4之一所述的系统,其中该操作路径的位置和取向使用整合到校准装置的至少两个点标记来校准,该校准装置被放置在距该固定装置的已知平移和旋转偏移处,并且其中该固定装置将该工件保持在距该操作路径的已知平移和旋转偏移处。
6.如权利要求1至4之一所述的系统,其中该操作路径的位置和取向使用位于固定装置上的至少两个点标记来校准,该固定装置将该工件保持在距该操作路径的已知平移和旋转偏移处。
7.如权利要求1至4之一所述的系统,其中该操作路径是非直线的,其中该操作路径在三维空间中的位置和取向能够使用校准装置来映射,该校准装置包括至少两个点标记,并且其中该操作路径指示该校准装置的在其上的多个不同点处的布置。
8.如权利要求7所述的系统,其中该操作路径是圆形的。
9.如权利要求1至4以及8之一所述的系统,其中该操作路径的位置和取向基于被包括在整个系统操作中的预先确定的序列步骤而经历从其原始校准平面的预先确定的平移和旋转偏移。
10.如权利要求1至4以及8之一所述的系统,其中该操作路径或其预先确定的区段相对于通过该成像系统可视的三维空间的位置和取向由三维CAD模型获得,该三维CAD模型的坐标系相对于该成像系统的坐标系是已知的。
11.如权利要求10所述的系统,其中该三维CAD模型包含对限定该操作路径区段的直线点或曲线点的定义。
12.如权利要求10所述的系统,其中至少三个校准点位于该三维CAD模型和该固定装置两者上。
13.如权利要求12所述的系统,其中位置和取向转移通过用该成像系统测量在该固定装置上的该至少三个校准点的位置并且然后将这些测量值与该三维CAD模型的原始校准点进行对比来应用于该三维CAD模型。
14.如权利要求1至4、8以及11至13之一所述的系统,其中该操作路径的位置和取向由形成链的一个或多个操作路径区段构成,并且其中连续的区段在一个区段的末尾和下一个区段的开始处共享操作路径点。
15.如权利要求1至4、8以及11至13之一所述的系统,其中对该焊接工具的工具点和工具矢量的校准使用整合到可移动校准装置中的两个或更多个点标记来执行,并且其中在该校准装置中的这些点标记沿距该校准工具的工具点具有已知偏移的工具矢量来定位。
16.如权利要求1至4、8以及11至13之一所述的系统,其中对该焊接工具的工具点的校准通过将该焊接工具的尖端插入到校准装置中来执行,该校准工具相对于该工件的位置和取向是预先确定的。
17.如权利要求16所述的系统,其中该系统计算相对于该操作路径的工具位置、取向、速度和加速度中的至少一者的值,其中这些值然后与预先确定的优选值进行对比以确定与已知和优选程序的偏差,并且其中这种偏差被用于评估技能水平、为训练提供反馈、评估朝技能目标的进度、和质量控制目的中的至少一者。
18.如权利要求1至4、8、11至13以及17之一所述的系统,其中限定该刚体的这些点标记以多分面构型附连到该焊接工具,该多分面构型在使用时适应该焊接工具的宽范围的旋转和取向变化。
19.如权利要求1至4、8、11至13以及17之一所述的系统,其中限定该刚体的这些点标记以球形构型附连到该焊接工具,该球形构型在使用时适应该焊接工具的宽范围的旋转和取向变化。
20.如权利要求1至4、8、11至13以及17之一所述的系统,其中这些被动点标记或主动点标记以环形构型附连到该焊接工具,该环形构型在使用时适应该焊接工具的宽范围的旋转和取向变化。
21.如权利要求1至4、8、11至13以及17之一所述的系统,其中该系统计算相对于该操作路径的工具位置、取向、速度和加速度中的至少一者的值,其中这些值然后与预先确定的优选值进行对比以确定与已知和优选程序的偏差,并且其中这种偏差被用于评估技能水平、为训练提供反馈、评估朝技能目标的进度、和质量控制目的中的至少一者。
22.一种用于表征焊接操作的方法,其特征为使用前述权利要求之一所述的系统。
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US (2) | US20160093233A1 (zh) |
EP (1) | EP3197625B1 (zh) |
JP (2) | JP2017531558A (zh) |
KR (1) | KR20170058369A (zh) |
CN (1) | CN107077799B (zh) |
BR (1) | BR112017005714A2 (zh) |
ES (1) | ES2793020T3 (zh) |
WO (1) | WO2016046623A1 (zh) |
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- 2015-09-28 JP JP2017515935A patent/JP2017531558A/ja active Pending
- 2015-09-28 EP EP15787667.3A patent/EP3197625B1/en active Active
- 2015-09-28 KR KR1020177007132A patent/KR20170058369A/ko active IP Right Grant
- 2015-09-28 BR BR112017005714A patent/BR112017005714A2/pt not_active Application Discontinuation
- 2015-09-28 CN CN201580050408.2A patent/CN107077799B/zh not_active Expired - Fee Related
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US20160093233A1 (en) | 2016-03-31 |
US10475353B2 (en) | 2019-11-12 |
US20180233065A1 (en) | 2018-08-16 |
ES2793020T3 (es) | 2020-11-12 |
EP3197625A1 (en) | 2017-08-02 |
JP2017531558A (ja) | 2017-10-26 |
JP2020099949A (ja) | 2020-07-02 |
CN107077799A (zh) | 2017-08-18 |
KR20170058369A (ko) | 2017-05-26 |
EP3197625B1 (en) | 2020-04-08 |
BR112017005714A2 (pt) | 2018-01-23 |
WO2016046623A1 (en) | 2016-03-31 |
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