CN109865968B - Welding operation detection method and system - Google Patents
Welding operation detection method and system Download PDFInfo
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- CN109865968B CN109865968B CN201910236945.6A CN201910236945A CN109865968B CN 109865968 B CN109865968 B CN 109865968B CN 201910236945 A CN201910236945 A CN 201910236945A CN 109865968 B CN109865968 B CN 109865968B
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Abstract
The invention discloses a welding operation detection method and a system, wherein the method comprises the following steps: collecting first state data of a target welding spot; after welding operation is carried out on the target welding spot through welding equipment, second state data of the target welding spot after the welding operation is carried out are collected; and determining whether the target welding point is welded or not based on the first state data and the second state data so as to determine whether the welding equipment is in a normal welding state or not, thereby realizing detection of the welding operation of the welding equipment.
Description
Technical Field
The invention relates to the technical field of welding, in particular to a welding operation detection method and system.
Background
The welding equipment is mainly used for welding by replacing an industrial robot manually operated by workers in the welding field. The invention of the welding equipment is thought to replace manual welding of workers, reduce the labor amount of the operators, ensure the quality of welding tasks and improve the welding efficiency.
When the welding equipment is used for welding, if the soldering tin on the welding equipment cannot be accurately placed on the position to be welded, irreparable loss can be caused to the workpiece to be processed, and the welding operation of the welding equipment needs to be detected.
Disclosure of Invention
The embodiment of the invention provides a welding operation detection method, which aims to solve the problem that the welding operation of welding equipment cannot be detected in the prior art.
In order to solve the technical problem, the invention is realized as follows:
in a first aspect, the present invention provides a welding operation detection method, comprising:
collecting first state data of a target welding spot;
after welding operation is carried out on the target welding spot through welding equipment, second state data of the target welding spot after the welding operation is carried out are collected;
and determining whether the target welding point is welded completely or not based on the first state data and the second state data.
In a second aspect, the present invention provides a welding operation detection system for a welding device, the system comprising:
the first acquisition module is used for acquiring first state data of the target welding spot;
the second acquisition module is used for acquiring second state data of the target welding spot after the welding operation is performed on the target welding spot by welding equipment;
and the determining module is used for determining whether the target welding spot is welded or not based on the first state data and the second state data.
The technical scheme of the invention can achieve the following beneficial effects:
the embodiment of the invention collects the first state data of the target welding spot; after welding operation is carried out on the target welding spot through welding equipment, second state data of the target welding spot after the welding operation is carried out are collected; and determining whether the target welding spot is welded completely based on the first state data and the second state data so as to determine whether the welding equipment is in a normal welding state, thereby realizing detection of the welding operation of the welding equipment.
Drawings
FIG. 1 is a flow chart of a welding operation detection method provided by an embodiment of the present invention;
fig. 2 is one of operation diagrams of a welding operation detection method provided in an embodiment of the present invention in a practical application scenario;
fig. 3 is a second schematic operation diagram of the welding operation detection method in a practical application scenario according to the embodiment of the present invention;
fig. 4 is a third schematic operation diagram of the welding operation detection method provided in the embodiment of the present invention in an actual application scenario;
fig. 5 is a schematic structural diagram of a welding operation detection system according to an embodiment of the present invention.
Detailed Description
The technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the drawings in the embodiments of the present invention, and it is obvious that the described embodiments are some, not all, embodiments of the present invention. All other embodiments, which can be derived by a person skilled in the art from the embodiments given herein without making any creative effort, shall fall within the protection scope of the present invention. The technical solutions provided by the embodiments of the present invention are described in detail below with reference to the accompanying drawings.
Fig. 1 is a flowchart of a welding operation detection method according to an embodiment of the present invention, and as shown in fig. 1, the method may include:
The shape of the target weld spot may be any geometric figure, such as a circle, square, rectangle, etc.
The first state data refers to state data of the target welding point before welding.
For example, the first state data may be a height value of the target welding point before welding, or the first state data may be image data of the target welding point before welding.
According to the difference of the first state data, the acquisition mode of acquiring the first state data of the target welding spot is also different. Following the above-described example of the above,
acquiring the original height value of the target welding spot by adopting a laser height measurement acquisition mode if the first state data is the height value of the target welding spot; and if the first state data is the image data of the target welding spot, acquiring the original image data of the target welding spot by the image acquisition device in the manner of acquiring the image data.
102, after welding operation is carried out on the target welding point through welding equipment, collecting second state data of the target welding point after the welding operation.
The welding device may be a welding robot. Of course, the welding device may also be other welding devices in the prior art, and the embodiment of the present invention is not particularly limited.
The second state data refers to the state data of the target welding spot after welding.
The second state data is collected in the same manner as the first state data in the above step. If the second state data is the height value of the target welding spot after welding, acquiring the welding height value of the target welding spot by adopting a laser height measurement acquisition mode; and if the second state data is the image data of the target welding spot after welding, the welding image data of the target welding spot is acquired by the image acquisition device in the mode of acquiring the image data.
And 103, determining whether the target welding point is welded completely based on the first state data and the second state data.
The steps can be realized as follows: comparing the first state data with the second state data to obtain a comparison result; and determining whether the target welding spot is welded or not according to the comparison result.
The embodiment of the invention collects the first state data of the target welding spot; after welding operation is carried out on the target welding spot through welding equipment, second state data of the target welding spot after the welding operation is carried out are collected; and determining whether the target welding spot is welded completely based on the first state data and the second state data so as to determine whether the welding equipment is in a normal welding state, thereby realizing detection of the welding operation of the welding equipment.
Optionally, as an embodiment, the step 103 may be specifically implemented as: the first state data and the second state data are both numerical data;
comparing the first state data and the second state data;
determining whether a difference between the value of the first state data and the value of the second state data is greater than or equal to a threshold;
if the difference value between the numerical value of the first state data and the numerical value of the second state data is larger than or equal to a threshold value, determining that the welding of the target welding spot is finished;
and if the difference value between the numerical value of the first state data and the numerical value of the second state data is smaller than a threshold value, generating alarm information.
Wherein the threshold value can be set according to the actual scene. For example, if the first state data is an original height value and the second state data is an updated height value, the threshold may be any value from 0 to 10 mm.
If the first state data is the original height value and the second state data is the updated height value, step 101 may be implemented as:
collecting the original height value of the target welding spot in a laser height measurement mode;
and after the target welding spot is welded by welding equipment, acquiring an updated height value of the target welding spot in a laser height measurement mode.
A first application scenario: illustratively, taking the threshold value as 1.0mm and the difference value greater than or equal to 1.0mm as an example: :
firstly, as shown in fig. 2, a target welding point before welding is subjected to height measurement by using laser, and an original height value of 10mm is obtained;
secondly, welding the target welding spot through welding equipment;
thirdly, as shown in fig. 2, measuring the height of the welded target welding spot by using laser to obtain an updated height value of 9 mm;
fourthly, comparing the difference value between the original height value and the updated height value to be 10mm-9 mm-1 mm;
and fifthly, determining that the welding of the target welding spot is finished and the welding equipment is in a normal welding state when the difference (1mm) is larger than or equal to 1.00 mm.
A second application scenario: illustratively, taking the threshold value as 0.5mm and the difference value less than 0.5mm as an example:
firstly, as shown in fig. 2, a laser 1 is adopted to measure the height of a target welding spot 2 before welding, and the original height value is 10 mm;
secondly, welding the target welding spot through welding equipment;
thirdly, as shown in fig. 2, the height of the welded target welding spot 2 is measured by using a laser 1, and the updated height value is 9.9 mm;
fourthly, comparing the difference value between the original height value and the updated height value to be 10-9.9 mm-0.1 mm;
and fifthly, determining that the target welding point is not welded completely and the welding equipment is in an abnormal welding state when the difference (0.1mm) is smaller than 0.5mm, and generating alarm information.
According to the embodiment of the invention, the height values of the target welding spot before and after welding are acquired by adopting a laser height measurement mode, the data acquisition mode is simple and accurate, whether the welding operation of the welding equipment is normal or not is conveniently and accurately judged, and the detection accuracy of the welding operation of the welding equipment is improved.
Optionally, as an embodiment, the step 103 may be specifically implemented as: the first state data and the second state data are both image data;
determining a first similarity value of the first state data and the second state data;
if the first similarity value is larger than or equal to a first preset value, determining that the welding equipment executes the welding operation on the next target welding spot;
and if the first similarity value is smaller than a first preset value, generating alarm information.
Wherein the first preset value is any one value of 0-100%.
For example, the first state data may be raw image data, and the second state data may be welding image data, then step 101 may be specifically implemented as:
acquiring original image data of the target welding spot in an image acquisition mode;
step 102 may be specifically implemented as:
and after the welding operation is carried out on the target welding point by the welding equipment, the welding image data of the target welding point is acquired in an image acquisition mode.
A third application scenario: illustratively, taking the first preset value as 40%, the method comprises the following steps:
firstly, as shown in fig. 3, an image acquisition device 3 is used for acquiring an image of a target welding point 2 before welding to obtain original image data; wherein, the image acquisition device 3 can be a camera;
secondly, welding the target welding spot through welding equipment;
thirdly, as shown in fig. 3, image acquisition is carried out on the welded target welding spot 2 through an image acquisition device 3 to obtain welding image data;
comparing the difference between the original image data and the welding image data; for example, the profile data of the original image and the profile data of the welding image are compared, or the gradation value of the original image and the gradation value of the welding image are compared.
Fifthly, if the difference exceeds 40%, determining that the welding of the target welding spot is finished, and determining that the welding equipment is in a normal welding state; if the difference is less than 40%, determining that the target welding point is not welded completely, determining that the welding equipment is in an abnormal welding state, and generating alarm information.
Optionally, as an embodiment, before performing step 101, the welding operation detection method provided by the embodiment of the present invention further includes:
the working state detection method of the tin wire feeding device of the welding equipment comprises the following specific steps:
after the welding equipment finishes welding N welding spots, acquiring initial state information of a solder wire with an exposed solder nozzle on a solder wire feeding device on the welding equipment, wherein N is a positive integer larger than zero;
after the soldering equipment executes the solder wire returning operation, acquiring the current state information of the solder wire with the exposed solder nozzle on a solder wire feeding device of the soldering equipment;
determining a second similarity value of the initial state information and the current state information;
and if the second similarity value is smaller than or equal to a second preset value, determining that the welding equipment can execute the welding operation.
Wherein the second preset value is any one value of 0-100%.
The initial state information of the solder wires with the exposed solder nozzles on the solder wire feeding device on the welding equipment can be acquired through an image acquisition device, and the image acquisition device can be a video camera or a camera.
In a fourth application scenario, for example, after the customer sets in the program and welds N pads, the image capturing device performs image recognition of the state of the solder wire. Wherein N is a positive integer greater than or equal to 1.
Assuming that the length of the solder wire to be detected is 100% (i.e. the distance from the solder wire to the solder feeding nozzle is a), and setting the second preset value to be 70%, when the length similarity of the solder wire is greater than or equal to 70%, the solder wire feeding device of the soldering equipment is determined to be in an abnormal working state, and if the length similarity of the solder wire is less than 70%, the solder wire feeding device of the soldering equipment is determined to be in a normal working state.
The specific implementation process is as follows:
step one, as shown in fig. 4, when the soldering apparatus finishes soldering N pads, the image acquisition device 3 acquires the state of the solder wire exposed from the solder nozzle on the solder wire feeding device of the soldering apparatus 4, and the length of the solder wire exposed from the solder nozzle is a, which is taken as 100% of the initial state of the solder wire; wherein, the image acquisition device 3 can be a camera or a video camera;
secondly, after the initial state of the solder wire is collected, a software program in the welding equipment executes the solder wire returning operation, and at the moment, the length of the solder wire on a solder wire feeding device of the welding equipment is b;
thirdly, as shown in fig. 4, the current state of the solder wire with the length of the solder wire b exposed from the solder nozzle on the solder wire feeding device of the welding equipment 4 is collected by the image collecting device 3;
fourthly, comparing the initial state of the solder wire with the current state of the solder wire, and determining whether the similarity of the lengths a and b of the solder wire is more than or equal to 70 percent;
fifthly, if the similarity is determined to be less than or equal to 70%, the solder wire feeding device of the welding equipment is determined to be in a normal working state, and a software program in the welding equipment executes the solder wire feeding operation, at the moment, the solder wire returns to an initial state, and the welding robot can continue to weld;
and sixthly, if the similarity is determined to be larger than 70%, determining that the tin wire feeding device of the welding equipment is in an abnormal working state, executing an alarm operation by a software program in the welding robot, and stopping the welding operation of the welding equipment so as to check the fault reason of the tin wire feeding device.
According to the embodiment of the invention, before the first state data of the target welding point is acquired, whether the tin wire feeding device is in a normal working state or not is determined by comparing the states of the exposed tin wires of the tin wire feeding nozzles on the tin wire feeding device acquired twice continuously so as to determine whether the welding equipment can execute the welding operation or not, the influence of the subsequent detection on the welding operation of the welding equipment is avoided, and meanwhile, the fault of the tin wire feeding device can be corrected in time.
The welding operation detection method according to the embodiment of the present invention is described in detail with reference to fig. 1 to 4, and the welding operation detection system of the welding apparatus according to the embodiment of the present invention is described in detail with reference to fig. 5.
Fig. 5 is a schematic structural diagram of a welding operation detection system of a welding device according to an embodiment of the present invention, which is shown in fig. 5 and includes:
the first collecting module 501 is configured to collect first state data of a target welding point;
a second collecting module 502, configured to collect second state data of the target welding spot after the welding operation is performed on the target welding spot by the welding device;
a first determining module 503, configured to determine whether the target welding point is welded based on the first status data and the second status data.
As an embodiment, the first determining module 503 includes:
a first comparison unit for comparing the first state data and the second state data;
a first determination unit configured to determine whether a difference between the value of the first state data and the value of the second state data is greater than or equal to a threshold;
and the second determining unit is used for determining that the welding of the target welding spot is finished if the difference value between the numerical value of the first state data and the numerical value of the second state data is greater than or equal to a threshold value.
As an embodiment, the first state data and the second state data are both numerical data;
the first determining module 503 includes:
and the first generating unit is used for generating alarm information if the difference value between the numerical value of the first state data and the numerical value of the second state data is smaller than a threshold value.
As an embodiment, the first acquisition module 501 includes:
the first acquisition unit is used for acquiring the original height value of the target welding spot in a laser height measurement mode;
the second acquisition module 502 comprises:
and the second acquisition unit is used for acquiring the updated height value of the target welding spot in a laser height measurement mode after the target welding spot is welded by the welding equipment.
In one embodiment, the threshold is any value of 0 to 10 mm.
As an embodiment, the first state data and the second state data are both image data;
the first determining module 503 includes:
a third determination unit configured to determine a first similarity value between the first state data and the second state data;
and the fourth determining unit is used for determining that the welding of the target welding spot is finished if the first similarity value is larger than or equal to a first preset value.
As an embodiment, the first determining module 503 includes:
and the second generating unit is used for generating alarm information if the first similarity value is smaller than a first preset value.
As an embodiment, the welding operation detection system of the welding device further comprises:
a third collecting module 504, configured to collect initial state information of a solder wire with an exposed solder nozzle on a solder wire feeding device of the soldering apparatus after the soldering apparatus has soldered N solder joints, where N is a positive integer greater than zero;
a fourth collecting module 505, configured to collect current state information of a solder wire with an exposed solder nozzle on a solder wire feeding device of the soldering apparatus after the soldering apparatus executes a solder wire rollback operation;
a second determining module 506, configured to determine a second similarity value between the initial state information and the current state information;
a third determining module 507, configured to determine that the welding device may perform the welding operation if the second similarity value is less than or equal to a second preset value.
As an embodiment, the first preset value is any one of 0 to 100%; the second preset value is any one value of 0-100%.
The embodiment of the invention collects the first state data of the target welding spot; after welding operation is carried out on the target welding spot through welding equipment, second state data of the target welding spot after the welding operation is carried out are collected; and determining whether the target welding spot is welded completely based on the first state data and the second state data so as to determine whether the welding equipment is in a normal welding state, thereby realizing detection of the welding operation of the welding equipment.
It should be noted that, in this document, the terms "comprises," "comprising," or any other variation thereof, are intended to cover a non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements does not include only those elements but may include other elements not expressly listed or inherent to such process, method, article, or apparatus. Without further limitation, an element defined by the phrase "comprising an … …" does not exclude the presence of other like elements in a process, method, article, or apparatus that comprises the element.
While the present invention has been described with reference to the embodiments shown in the drawings, the present invention is not limited to the embodiments, which are illustrative and not restrictive, and it will be apparent to those skilled in the art that various changes and modifications can be made therein without departing from the spirit and scope of the invention as defined in the appended claims.
Claims (9)
1. A welding operation detection method, comprising:
collecting first state data of a target welding spot;
after welding operation is carried out on the target welding spot through welding equipment, second state data of the target welding spot after the welding operation is carried out are collected;
determining whether the target welding spot is welded completely based on the first state data and the second state data;
before acquiring first state data of the target welding spot, the method further comprises the following steps: comparing the collected solder wire states of the exposed solder nozzles on the solder wire feeding device twice continuously to determine whether the solder wire feeding device is in a normal working state so as to determine whether welding equipment can execute welding operation;
the working state detection method of the tin wire feeding device of the welding equipment comprises the following specific steps: after the welding equipment finishes welding N welding spots, acquiring initial state information of a solder wire with an exposed solder nozzle on a solder wire feeding device of the welding equipment, wherein N is a positive integer larger than zero;
after the soldering equipment executes the solder wire returning operation, acquiring the current state information of the solder wire with the exposed solder nozzle on a solder wire feeding device of the soldering equipment;
determining a second similarity value of the initial state information and the current state information;
if the second similarity value is smaller than or equal to a second preset value, determining that the welding equipment can execute welding operation; the welding equipment is a welding robot; the initial state information and the current state information are both lengths of exposed solder wires.
2. The method of claim 1, wherein the first state data and the second state data are both numerical data;
determining whether the target welding point is welded completely based on the first state data and the second state data, comprising:
comparing the first state data and the second state data;
determining whether a difference between the value of the first state data and the value of the second state data is greater than or equal to a threshold;
and if the difference value between the numerical value of the first state data and the numerical value of the second state data is larger than or equal to a threshold value, determining that the welding of the target welding spot is finished.
3. The method of claim 2,
determining whether the target welding point is welded completely based on the first state data and the second state data, comprising:
and if the difference value between the numerical value of the first state data and the numerical value of the second state data is smaller than a threshold value, generating alarm information.
4. The method of claim 2, wherein the acquiring first status data of the target weld spot comprises:
collecting the original height value of the target welding spot in a laser height measurement mode;
after the welding operation is performed on the target welding spot through the welding equipment, second state data of the target welding spot after the welding operation is acquired, wherein the second state data comprises:
and after the target welding spot is welded by welding equipment, acquiring an updated height value of the target welding spot in a laser height measurement mode.
5. The method according to claim 4, wherein the threshold value is any one of 0.5-10 mm.
6. The method of claim 1, wherein the first state data and the second state data are both image data;
determining whether the target welding point is welded completely based on the first state data and the second state data, comprising:
determining a first discrepancy value of the first state data and the second state data;
and if the first difference value is larger than or equal to a first preset value, determining that the welding of the target welding spot is finished.
7. The method of claim 6,
determining whether the target welding point is welded completely based on the first state data and the second state data, comprising:
and if the first difference value is smaller than a first preset value, generating alarm information.
8. The method according to claim 6, wherein the first preset value is any one of 40-100%; the second preset value is any one of 0-70%.
9. A welding operation detection system for a welding device, the system comprising:
the first acquisition module is used for acquiring first state data of the target welding spot;
the second acquisition module is used for acquiring second state data of the target welding spot after the welding operation is performed on the target welding spot by welding equipment;
the determining module is used for determining whether the target welding spot is welded or not based on the first state data and the second state data;
before the first acquisition module acquires first state data of a target welding spot, comparing the acquired solder wire states of the exposed solder nozzles on the solder wire feeding device twice continuously to determine whether the solder wire feeding device is in a normal working state so as to determine whether welding equipment can execute welding operation;
specifically, the welding operation detection system of the welding device further comprises: the third acquisition module is used for acquiring initial state information of the solder wires exposed from the solder feeding nozzles on the solder wire feeding device of the welding equipment after the welding equipment finishes welding N welding spots, wherein N is a positive integer larger than zero;
the fourth acquisition module is used for acquiring the current state information of the solder wires with exposed solder nozzles on the solder wire feeding device of the welding equipment after the welding equipment executes the solder wire returning operation;
a second determining module, configured to determine a second similarity value between the initial state information and the current state information;
the third determining module is used for determining that the welding equipment can execute the welding operation if the second similarity value is smaller than or equal to a second preset value; the welding equipment is a welding robot; the initial state information and the current state information are both lengths of exposed solder wires.
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