CN109514141B - Ocean engineering module structure welding method based on VR technology - Google Patents
Ocean engineering module structure welding method based on VR technology Download PDFInfo
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- CN109514141B CN109514141B CN201811571327.9A CN201811571327A CN109514141B CN 109514141 B CN109514141 B CN 109514141B CN 201811571327 A CN201811571327 A CN 201811571327A CN 109514141 B CN109514141 B CN 109514141B
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Abstract
The invention discloses a marine engineering module structure welding method based on VR technology, which comprises the following steps: creating a digital model of a real workpiece through 3D scanning, and generating a corresponding 3D physical model; capturing a real welding process by using a camera, and visually displaying on the 3D physical model by using a projector; ) A skilled welder operates the virtual welding gun to complete the welding process by observing the molten pool image; the welding robot completes real welding through the welding parameters of the virtual welding gun; the external monitoring system transmits welding information in the welding process of the robot to the computer, and the computer forms a speed-current relation model through welding data; the primary welder operates the virtual welding device to complete the weld according to the speed-current. The method carries out virtual reality welding on the ocean engineering module structure, so that the section steel, the pipeline and the like in the ocean engineering module can be welded more quickly and accurately, and the personnel safety and the welding efficiency in the welding process are ensured.
Description
Technical Field
The invention relates to a welding method in ocean engineering, in particular to a VR technology-based welding method for an ocean engineering module structure.
Background
The welding technology is one of the important processing processes of machine manufacturing, and is widely applied to the industrial fields of aerospace, rail transit, petrochemical engineering, ocean engineering, energy engineering and the like. The mechanized and automatic welding technology can obviously improve the production efficiency, the product quality reliability and the consistency of the mass product processing, and reduce the quality loss caused by human errors in the manual welding process. However, for complex structures or low volume product processing, manual welding still has the advantages of high flexibility and accessibility. In aerospace enterprises, certain products have relatively complex structures, cannot be produced in batches, and are still manually welded by advanced welders to complete the processing process. In ocean engineering equipment, the welding environment of some shaped steel and pipelines is more complicated, the welding is not convenient enough, and the safety of the welding process is poor, so that manual welding can continuously play an irreplaceable role, but the problem to be solved is also existed. The most important of these problems is the dependence of manual welding quality on the skill of the welder and the performance of the field, and the lack of skilled welders makes this problem even more prominent.
Disclosure of Invention
The invention aims to overcome the defects of the prior art and provides a marine engineering module structure welding method based on VR technology. The method can quickly, accurately and safely weld the structure of the ocean engineering module, the safety can be greatly improved by using VR technology to perform off-site operation, meanwhile, the whole welding process is more accurate by the aid of a model of a computer in the welding process, the efficiency of welding personnel is improved, and the construction requirements of the technical personnel are reduced.
In order to achieve the purpose, the invention adopts the technical scheme that:
the invention relates to a marine engineering module structure welding method based on VR technology, which comprises the following steps:
(1) creating a digital model of a real welding workpiece through 3D scanning, and processing a real welding workpiece model by using the obtained digital model of the real welding workpiece, so that the shape and the size of the real welding workpiece model are consistent with those of the real welding workpiece, and a 3D physical model of the real welding workpiece of the workpiece is obtained;
(2) capturing a real welding process by using a camera, keeping the placing postures of the 3D physical model of the real welding workpiece consistent with the placing postures of the real welding workpiece, and then projecting a molten pool image shot by the camera on the surface of the 3D physical model of the real welding workpiece by using a projector to be consistent with the real welding workpiece, so that the molten pool image information in the real welding process is visually displayed;
(3) the method comprises the following steps that a skilled welder operates a virtual welding gun to complete welding in a simulated welding environment formed by a projector, the virtual welding gun and a 3D physical model of a real welding workpiece by observing image information of a molten pool shot by the camera and projected by the projector connected with the camera, wherein the virtual welding gun is a welding gun model with the same shape and size as the real welding gun, and the position relation between the virtual welding gun and the 3D physical model of the real welding workpiece is consistent with the position relation between the welding gun and the real welding workpiece in the real welding environment;
(4) in the process that a skilled welder finishes welding by adopting a virtual welding gun, the three-dimensional coordinate and the welding speed information of the virtual welding gun are transmitted to a computer through a motion sensor arranged on the virtual welding gun, then the computer converts the obtained three-dimensional coordinate and the welding speed information into a robot language, and the robot finishes the actual welding process through the obtained three-dimensional coordinate and the welding speed information of the virtual welding gun;
(5) the external monitoring system consisting of a camera, a current sensor and an ammeter collects welding information in the real welding process of the robot in real time, the camera collects a molten pool image in the real welding process, the current sensor arranged on a real welding gun collects the numerical value of welding current and is displayed by the ammeter connected with the current sensor, then the external monitoring system transmits the relevant welding information in the welding process of the robot to a computer, the computer performs curve fitting according to the data of welding speed and welding current by using MATLAB software, so that a relation model of the welding speed and the welding current is established, and an approximate function is obtained according to a data curve: v ═ aI + b, where I is the welding current, v is the corresponding welding speed, and a and b are fitting coefficients of a function, thereby obtaining the speed-current control experience of the robot when a skilled welder welds;
(6) and (4) when the primary welder operates the virtual welding device to weld, adjusting the welding speed under different welding currents according to the functional relation between the welding speed and the welding current obtained in the step (5), so that the primary welder is assisted by experience of a skilled welder provided by a computer in the welding process, and the required welding state is gradually adjusted to complete welding.
The invention has the beneficial effects that:
the method can perform virtual reality welding on the ocean engineering module structure, so that the section steel, the pipeline and the like in the ocean engineering module can be welded more quickly and accurately, and the personnel safety and the welding efficiency in the whole welding process can be ensured. The application through VR virtual reality technique makes whole welding process become swift, has solved the problem that security does not have the guarantee among the welding process. In addition, the problem that skills of technicians are excessively relied on when welding is carried out is solved through the generation of a relational model of a computer, the derelization of the welding process is realized, the high dependence of constructors on operation skills is eliminated, and the purpose of man-machine complementation is achieved. The invention greatly improves the welding efficiency of the ocean engineering module structure, greatly reduces the difficulty of the welding process, reduces the risk of personnel in the welding process, and is suitable for the welding process in the field.
Drawings
Fig. 1 is a flowchart of a method for welding an ocean engineering module structure based on VR technology.
FIG. 2 is a schematic diagram of a VR based welding platform system configuration in accordance with the present invention.
Detailed Description
The invention is described in detail below with reference to the figures and specific embodiments.
The invention discloses a marine engineering module structure welding method based on VR technology, which comprises the following steps:
(1) creating a digital model of a real welding workpiece through 3D scanning, and processing a real welding workpiece model by using the obtained digital model of the real welding workpiece, so that the shape and the size of the real welding workpiece model are consistent with those of the real welding workpiece, and a 3D physical model of the real welding workpiece is obtained;
(2) the real welding process is captured by the aid of the camera, the 3D physical model of the real welding workpiece is kept consistent with the placing posture of the real welding workpiece, and then the position of the molten pool image shot by the camera, projected on the surface of the 3D physical model of the real welding workpiece, is consistent with the real welding workpiece in real time by the aid of the projector, so that molten pool image information in the real welding process is visually displayed. The combination of the image information of the molten pool and the surface of the 3D physical model of the real welding workpiece achieves the purpose of simulating the surface of the real welding workpiece, and the welder can visually see the real-time information of the real welding process by simulating the surface of the real welding workpiece, thereby forming a VR virtual welding environment;
(3) the method comprises the following steps that a skilled welder operates a virtual welding gun to complete welding in a simulated welding environment formed by a projector, the virtual welding gun and a 3D physical model of a real welding workpiece by observing image information of a molten pool shot by the camera and projected by the projector connected with the camera, wherein the virtual welding gun is a welding gun model with the same shape and size as the real welding gun, and the position relation between the virtual welding gun and the 3D physical model of the real welding workpiece is consistent with the position relation between the welding gun and the real welding workpiece in the real welding environment;
(4) in the process that a skilled welder finishes welding by adopting a virtual welding gun, the three-dimensional coordinate and welding speed information of the virtual welding gun are transmitted to a computer through a motion sensor arranged on the virtual welding gun, then the computer converts the obtained three-dimensional coordinate and welding speed information into robot language, the robot finishes the actual welding process through the obtained three-dimensional coordinate and welding speed information of the virtual welding gun, the three-dimensional coordinate information and the welding speed information of the real welding gun and the virtual welding gun are consistent in the welding process, and the motion synchronism of the virtual welding gun and the real welding gun is ensured;
(5) an external monitoring system consisting of a camera, a current sensor and an ammeter collects welding information in real welding process of the robot in real time, the camera collects molten pool images in the real welding process, the current sensor mounted on a real welding gun collects the numerical value of welding current and is displayed by the ammeter connected with the current sensor, then the external monitoring system transmits the relevant welding information in the welding process of the robot to a computer, and the computer performs curve fitting according to the welding speed (the welding speed of the robot is consistent with the welding speed of a virtual welding gun) and the data of the welding current by using MATLAB software to establish a relation model of the welding speed and the welding current, and obtains an approximate function according to a data curve: v ═ aI + b, where I is the welding current, v is the corresponding welding speed, and a and b are fitting coefficients of a function, thereby obtaining the speed-current control experience of the robot when a skilled welder welds;
(6) and (3) adjusting the welding speeds under different welding currents according to the functional relation between the welding speed and the welding current obtained in the step (5) when the primary welder operates the virtual welding device to weld because the welding speed and the welding current simultaneously influence the welding result, so that the primary welder is assisted by experience of a skilled welder provided by a computer in the welding process, and the required welding state is gradually adjusted to complete welding.
Claims (1)
1. A marine engineering module structure welding method based on VR technology is characterized by comprising the following steps:
(1) creating a digital model of a real welding workpiece through 3D scanning, and processing a real welding workpiece model by using the obtained digital model of the real welding workpiece, so that the shape and the size of the real welding workpiece model are consistent with those of the real welding workpiece, and a 3D physical model of the real welding workpiece of the workpiece is obtained;
(2) capturing a real welding process by using a camera, keeping the placing postures of the 3D physical model of the real welding workpiece consistent with the placing postures of the real welding workpiece, and then projecting a molten pool image shot by the camera on the surface of the 3D physical model of the real welding workpiece by using a projector to be consistent with the real welding workpiece, so that the molten pool image information in the real welding process is visually displayed;
(3) the method comprises the following steps that a skilled welder operates a virtual welding gun to complete welding in a simulated welding environment formed by a projector, the virtual welding gun and a 3D physical model of a real welding workpiece by observing image information of a molten pool shot by the camera and projected by the projector connected with the camera, wherein the virtual welding gun is a welding gun model with the same shape and size as the real welding gun, and the position relation between the virtual welding gun and the 3D physical model of the real welding workpiece is consistent with the position relation between the welding gun and the real welding workpiece in the real welding environment;
(4) in the process that a skilled welder finishes welding by adopting a virtual welding gun, the three-dimensional coordinate and the welding speed information of the virtual welding gun are transmitted to a computer through a motion sensor arranged on the virtual welding gun, then the computer converts the obtained three-dimensional coordinate and the welding speed information into a robot language, and the robot finishes the actual welding process through the obtained three-dimensional coordinate and the welding speed information of the virtual welding gun;
(5) the external monitoring system consisting of a camera, a current sensor and an ammeter collects welding information in the real welding process of the robot in real time, the camera collects a molten pool image in the real welding process, the current sensor arranged on a real welding gun collects the numerical value of welding current and is displayed by the ammeter connected with the current sensor, then the external monitoring system transmits the relevant welding information in the welding process of the robot to a computer, the computer performs curve fitting according to the data of welding speed and welding current by using MATLAB software, so that a relation model of the welding speed and the welding current is established, and an approximate function is obtained according to a data curve: v ═ aI + b, where I is the welding current, v is the corresponding welding speed, and a and b are fitting coefficients of a function, thereby obtaining the speed-current control experience of the robot when a skilled welder welds;
(6) and (4) when the primary welder operates the virtual welding device to weld, adjusting the welding speed under different welding currents according to the functional relation between the welding speed and the welding current obtained in the step (5), so that the primary welder is assisted by experience of a skilled welder provided by a computer in the welding process, and the required welding state is gradually adjusted to complete welding.
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| CN112270860B (en) * | 2020-10-23 | 2022-08-12 | 武汉湾流科技股份有限公司 | Virtual welding training method and system based on flexible material |
| CN112496582B (en) * | 2020-11-23 | 2022-05-10 | 博迈科海洋工程股份有限公司 | Ocean engineering complex node multi-robot welding cooperative control method |
| CN112743276B (en) * | 2020-12-02 | 2022-08-16 | 海门市帕源路桥建设有限公司 | Welding method for welding spot virtualization and welding spot rehearsal |
| CN112917058A (en) * | 2021-02-19 | 2021-06-08 | 恒大新能源汽车投资控股集团有限公司 | Auxiliary monitoring method and device for welding assembly station and electronic equipment |
| CN115007975B (en) * | 2022-06-09 | 2023-10-27 | 天津大学 | TIG wire feeding welding system based on VR equipment assistance |
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| US9875665B2 (en) * | 2014-08-18 | 2018-01-23 | Illinois Tool Works Inc. | Weld training system and method |
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