CN109967834B - Welding seam tracking method based on point laser distance sensor - Google Patents
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- 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
- B23K9/00—Arc welding or cutting
- B23K9/12—Automatic feeding or moving of electrodes or work for spot or seam welding or cutting
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Abstract
The invention particularly relates to a welding seam tracking method based on a point laser distance sensor. The system comprises a welding power supply, a point laser distance sensor, an acceleration sensor, a linear guide rail, a slide block, a welding gun, a signal processor, an arithmetic unit, a controller, a sensor protection device, a wire feeder and a driver. The welding seam tracking method based on the point laser distance sensor is characterized in that: the system scans the groove area through the point laser distance sensor and the acceleration sensor fixed on the sliding block, extracts a vertical distance signal from a laser emission point of a characteristic point to the groove and a sliding distance signal of the sliding block, calculates the left and right deviation, the upper and lower deviation and the welding gun working angle deviation of a welding seam by using a characteristic point distance difference method and an inverse trigonometric function, and realizes accurate tracking of the welding seam. The system is simple, the automatic welding efficiency is high, and the welding seam tracking of different groove shapes in space can be realized.
Description
Technical Field
The invention relates to the technical field of welding automation, in particular to a welding seam tracking method based on a point laser distance sensor.
Background
The welding technology is an important research field in the technical field of mechanical manufacturing, and with the advent of the intelligent era, the welding technology gradually tends to intelligent and automatic development. The welding robot is the most common industrial robot in practical application, and in recent years, the development is very rapid, and different forms of welding robots are developed in order to meet the requirements of different industries on welding operation. Along with the improvement of welding quality and efficiency requirement, the improvement of manual welding cost, the demand of each trade to welding robot is very high. Meanwhile, higher requirements are provided for the environment adaptation capability and the automation degree of the welding robot, the welding robot is developed into a sensing type from a teaching type, the sensing type welding robot utilizes various sensors to acquire signals of sound, light, electricity and the like in the welding process, the signals are processed to realize automatic detection of the welding seam, and the sensing type welding robot identifies deviation signals of a welding gun deviating from the welding seam according to the various sensors to automatically track the welding seam.
At present, a welding gun pose control technology and a welding seam tracking technology mainly depend on a vision sensor and a rotary arc sensor robot. The weld joint tracking control is a key problem to be solved in the welding process and is also an important component for automatically controlling the welding quality in the modern arc welding process. To realize the seam tracking control, the seam recognition technology is one of the core technologies. The sensors applied to the welding seam identification process have many kinds, the application of the traditional sensor can not meet the requirement of the welding seam tracking technology, and the sensors which are simpler, have small errors and are more practical need to be developed to realize automatic and accurate tracking of the welding seam.
In summary, it is necessary to develop or introduce different sensors, improve the welding seam tracking system and method to realize automatic welding seam tracking of the welding robot, and improve the welding seam tracking accuracy.
Disclosure of Invention
The invention aims to make an operation system of a welding robot simpler and make weld tracking more accurate. A welding seam tracking system method based on a point laser distance sensor is designed by combining the point laser distance sensor and an acceleration sensor according to methods such as a characteristic point distance difference method and an inverse trigonometric function. The system comprises a welding power supply, a point laser distance sensor, an acceleration sensor, a linear guide rail, a slide block, a welding gun, a signal processor, an arithmetic unit, a controller, a sensor protection device, a wire feeder and a driver, and is simple in structure and high in welding seam tracking precision.
A welding seam tracking method based on a point laser sensor is characterized in that: a linear guide rail of the system is fixed on a welding gun and is vertically and equally divided with the central line of the welding gun, a point laser distance sensor and an acceleration sensor which are fixed on a sliding block reciprocate left and right on the linear guide rail, the system scans a groove area through the point laser distance sensor and the acceleration sensor which are fixed on the sliding block, a distance signal which passes through a characteristic point between a laser emission point and the groove and is vertical to the linear guide rail and a sliding distance signal of the sliding block are extracted by the system, and a mathematical model can be constructed.
The specific flow for realizing the welding seam tracking method of the invention is as follows:
the point laser distance sensor and the acceleration sensor are respectively fixed on the upper side and the lower side of the sliding block, and a sensor protection device is arranged outside the linear guide rail to avoid damage to the detection device caused by sparks, splashing and the like in the welding process. Under the control of a controller, a sliding block reciprocates on a linear guide rail in a certain form at one end of the linear guide rail at an initial speed v of 0, an acceleration a collects distance signals in a direction perpendicular to the linear guide rail and a direction parallel to the linear guide rail respectively by a point laser sensor and an acceleration sensor in the moving process of the sliding block, wherein the direction perpendicular to the linear guide rail is longitudinal, the direction parallel to the linear guide rail is transverse, the system inputs the collected distance information into a signal processor by current signals, and the starting time of the two sensors moving along with the sliding block is the same, so that the distance information of each characteristic point is automatically collected by the system according to the fixed length of the linear guide rail; sending the obtained characteristic point signals to an arithmetic unit together, wherein the characteristic points in the system comprise two inflection points A, B of the groove, a weld joint center point C, two end points D, E of the linear guide rail and a linear guide rail center point O, and each characteristic point is characterized in that: the distance value between the laser emission point at the corner point and the groove and perpendicular to the linear guide rail is an extreme point, the distance value between the laser emission point at the center point of the welding line and the groove and perpendicular to the linear guide rail is a maximum value, and the end point and the middle point of the linear guide rail are determined according to the acceleration sensor. And extracting left and right deviations of the welding line according to a vertical distance value | OC | ═ m between the laser line at the central point of the welding line and the laser line at the central point of the linear guide rail, extracting upper and lower deviations of the welding line according to a distance difference | CC | -OO | ═ n between a laser emission point and a groove and vertical to the linear guide rail, and extracting the deviation of a working angle of the welding gun according to the geometrical relationship between an inflection point A, B or an end point D, E and the central point C of the welding line according to different groove appearances. And inputting the welding seam deviation value and the working angle deviation value of the welding gun into a controller, and adjusting the posture of the welding gun to realize real-time accurate tracking of the welding seam.
The invention has the advantages that: the whole welding seam tracking system is simple, strong in operability, simpler than the traditional welding seam tracking system, and simpler in algorithm, an acceleration sensor is fused on the basis of a point laser distance sensor, and each deviation signal of the welding seam is extracted based on the difference value of each characteristic point distance and an inverse trigonometric function, so that the accurate tracking of the welding seam is realized.
Drawings
FIG. 1 is a schematic diagram of the system operation of the present invention;
FIG. 2 is a schematic view of a weld gun configuration and a cross-sectional view of the weld gun of the present invention;
FIG. 3 is a geometric model diagram of weld tracking when the groove is bilaterally symmetric according to the present invention;
FIG. 4 is a geometric model diagram of weld tracking when the bevel is asymmetric from side to side according to the present invention;
FIG. 5 is a functional diagram of a weld tracking process implemented by the weld gun of the present invention.
In the figure: (1) acceleration sensor, (2) point laser distance sensor, (3) slider, and (4) linear guide.
Detailed description of the preferred embodiments
In order to better express the technical scheme and the beneficial results of the invention, the invention is further described in detail with reference to the accompanying drawings and embodiments.
Example 1: the system working principle diagram of the welding seam tracking method based on the point laser distance sensor is shown in figure 1, which mainly solves the problems of complex structure, poor positioning effect and the like of a welding seam tracking system and is characterized in that: the system comprises a welding power supply, a point laser distance sensor, an acceleration sensor, a linear guide rail, a slide block, a welding gun, a signal processor, an arithmetic unit, a controller, a sensor protection device, a wire feeder and a driver. With reference to fig. 2, it can be seen that the acceleration sensor is located above the side of the slider, which is beneficial to sensing the lateral movement of the slider, and the signal processor and the arithmetic unit can clearly and rapidly calculate the sliding distance of the slider; a small-power single-pulse point laser distance sensor is arranged below the side of the sliding block, as shown in figure 2, the point laser can measure the vertical distance from a laser emission point to the surface of a workpiece, and the two sensors are fixed on the sliding block and reciprocate on a linear guide rail along with the sliding block, so that the surface of the workpiece is scanned, and the deviation of a welding seam is extracted. The invention combines the acceleration sensor on the original laser sensor, so that the welding seam tracking effect is more accurate, and the system structure is simpler and more efficient.
Example 2: as shown in fig. 3 and 4, the process of correcting the welding gun posture is specifically described.
When the groove shape is regular, as shown in fig. 3(a), DE is a linear guide, when the slider moves back and forth on the linear guide at a high speed, the distance from the sensor to the groove surface of the workpiece can be calculated by a laser ranging principle, and as can be seen from the figure, the distance from the point laser ranging sensor to the surface of the workpiece appears from left to right: the first gradually decreases, the second gradually increases after reaching the point A, the third gradually decreases at a certain speed after reaching the point C, and the third gradually decreases at another speed when reaching the point B. The signal processor can extract the distance value of each characteristic point, namely the distance value at the point A, B, C, D, E according to the measured change rule, and in addition, the point O is the central point of the linear guide rail and is also the characteristic point in the invention.
When the welding gun is in the state (a) in fig. 3, the laser distance of the center of the welding gun, i.e. the middle point O of the linear guide rail, is | OO '|, the laser distance | CC' | when the slide block moves to the point C 'is the most value, and the left and right deviation of the welding gun is identified and calculated under the action of the processor and the arithmetic unit, wherein the right deviation of the welding gun is | OC' |.
If the slide block starts to move from the end E of the linear guide rail, the slide block makes uniform variable speed motion with the initial speed of 0 and the acceleration of a, then | OC | - | EC | - | EO | -1/2 at1 2-1/2at0 2＝1/2a(t1 2-t0 2) The motion time and the acceleration of the sliding block are respectively obtained by the induction of a controller and an acceleration sensor.
Meanwhile, the vertical deviation of the welding gun can be identified and calculated according to the distance from the sensor to the workpiece at the characteristic point C, O, and the welding gun can be judged whether to have the vertical deviation according to the distance measured by the point laser distance sensor because the wire feeding length is unchanged during automatic welding of the robot. In this case, the distance difference between | CC '| and | OO' | is the up-down deviation of the welding gun, which is the upward deviation of the welding gun. According to the distance measured by the sensor, the system inputs a distance signal of the welding gun into the signal processor by combining the point laser distance sensor with the acceleration sensor, the processor identifies the signal, the arithmetic unit calculates a characteristic point distance value and calculates the welding seam deviation, as shown in fig. 3, the controller processes the acquired deviation signal and controls the driver to drive the welding gun to automatically track the welding seam center, namely, (a) → (b).
As shown in fig. 3(b), by correcting the position and posture of the welding gun, the center of the welding gun is aligned with the center of the welding seam, and in order to realize accurate tracking of the welding seam and achieve an actual welding effect, the influence of the working angle of the welding gun on the welding seam forming is important, the invention realizes the correction of the working angle of the welding gun based on the inverse trigonometric function through the previously established geometric model to achieve the welding seam tracking effect. In fig. 3(B), in the rectangles AFC 'a' and BGC 'B', | AF | ═ a 'C |, and | BG | ═ B' C |, the distance values of | a 'C |, and | C' B |, can be measured by the acceleration sensor; the laser distance values | AA ' |, | BB ' |, and | CC ' | of the characteristic point A, B, C can be used to obtain | FC | ═ CC ' -AA ' |, | GC | ═ CC ' -BB ' |, and can be obtained in the right triangle Δ FAC and Δ BGC according to the anti-sine function:
∠α＝arctan(|AF|/|FC|)，
∠β＝arctan(|BG|/|GC|)，
according to the actual welding seam forming condition, when the alpha is equal to the beta, the working angle of the welding gun is optimal, and the welding seam forming effect is optimal. The arithmetic unit calculates the welding gun working angle according to the distance value measured by the sensor, inputs the welding gun angle deviation into the controller, and the controller drives the welding gun to adjust the posture through the control driver so as to achieve accurate tracking of the welding seam, namely (b) → (c).
In the same way, when the groove appearance is irregular, as shown in fig. 4, the slide block moves under the action of the controller, the point laser distance sensor scans the surface of the workpiece, the system processes the characteristic points, and then the left deviation, the right deviation and the up-down deviation of the welding gun are obtained, and the driver drives the real-time deviation rectifying posture of the welding gun, namely, the value of | OO '| ═ CC' |, so that the welding gun centers on the center of the welding seam. When the included angle between the welding gun and the groove is arc (| AF |/| FC |), | β ═ arc (| BG |/| GC |), | α ≠ β, the deviation of the two angles indicates that the working angle of the welding gun has deviation, and the system corrects the deviation according to the deviation of the two included angles, so that accurate welding seam tracking is realized, namely (d) → (e) → (f).
Example 3: as shown in FIG. 5, L-t represents a function image of the change of the distance from a laser emission point at the center of the linear guide rail to the groove along with time when the welding gun performs the seam tracking, α/β -t represents a function image of the change of the included angle between the laser at the center of the linear guide rail and the two sides of the groove along with time when the welding gun performs the seam tracking, and X-t represents a function image of the change of the distance from the laser at the center of the linear guide rail to the longest laser along with time when the welding gun performs the seam tracking, actually is a function image of the change of the posture of the welding gun along with time when the welding gun performs the seam tracking, so that the deviation correcting process of the welding gun can be visually reflected, the deviation signal of the welding gun can.
Claims (2)
1. A welding seam tracking method based on a point laser distance sensor is characterized in that: the method adopts a welding seam tracking system which comprises a welding power supply, a point laser distance sensor, an acceleration sensor, a linear guide rail, a slide block, a welding gun, a signal processor, an arithmetic unit, a controller, a sensor protection device, a wire feeder and a driver, wherein the linear guide rail is fixed on the welding gun and is vertically and equally divided with the central line of the welding gun, the point laser distance sensor is arranged below the slide block, the acceleration sensor is arranged above the slide block, and the point laser distance sensor and the acceleration sensor which are fixed on the slide block do left-right reciprocating motion on the linear guide rail; the method is characterized in that a sliding block reciprocates on a linear guide rail under the control of a controller in a mode of making uniform variable speed motion with an initial speed v of 0 and an acceleration a at one end of the linear guide rail, a point laser sensor and an acceleration sensor respectively acquire distance signals in a direction perpendicular to the linear guide rail and a direction parallel to the linear guide rail in the moving process of the sliding block, wherein the direction perpendicular to the linear guide rail is longitudinal, the direction parallel to the linear guide rail is transverse, and a groove is divided by the point laser distance sensor fixed on the sliding blockThe area is scanned, the signal processor can extract the longitudinal distance of each characteristic point according to the change rule of the scanning result, the characteristic points comprise two inflection points A, B of the groove, a welding seam center point C, two end points D, E of the linear guide rail and a middle point O of the linear guide rail, the left deviation, the right deviation, the up deviation and the down deviation and the working angle deviation of the welding gun are extracted by utilizing a characteristic point distance difference method and an inverse trigonometric function, the characteristic point distance difference method is characterized in that when a sliding block moves from one end of a guide rail to the other end, a middle point O of the linear guide rail is used as a reference characteristic point, the difference between a distance | OO ' | from a straight line passing through the O point and perpendicular to the linear guide rail to an intersection point O ' of a groove and a distance | CC ' | from a center point C of a welding seam to a laser emission point C ' perpendicular to the linear guide rail is the vertical deviation of a welding gun, the left-right deviation of the welding gun is | OC ' |, and the specific calculation method of the left-right deviation is as follows: when the slide block starts to move from the end E of the linear guide rail, the position of | OC | - | EC | -EO | -1/2 at1 2-1/2at0 2＝1/2a(t1 2-t0 2) Wherein t is0、t1The system respectively indicates the time when the sliding block moves to the point O and the point C', the time and the acceleration are respectively obtained by the induction of the controller and the acceleration sensor, the system inputs the distance signal of the welding gun into the signal processor by combining the point laser distance sensor and the acceleration sensor according to the distance measured by the sensor, the signal processor identifies and processes the signal, the arithmetic unit calculates the distance value of the characteristic point and calculates the left and right and up and down deviation of the welding gun, the controller processes the acquired deviation signal, and the control driver drives the welding gun to automatically track the center of the welding seam; the method for extracting the welding gun working angle deviation by using the inverse trigonometric function specifically comprises the following steps: f is the intersection point of the characteristic point A to the perpendicular line of the straight line CC ', G is the intersection point of the characteristic point B to the perpendicular line of the straight line CC ', the distance from the characteristic point A to the laser emission point A ' vertical to the straight line guide rail is | AA ' |, the distance from the characteristic point B to the laser emission point B ' vertical to the straight line guide rail is | BB ' |, FC | ═ CC ' -AA ' |, | GC | ═ CC ' -BB | can be obtained according to the geometrical relation, and the distance can be obtained according to the inverse trigonometric function in the right triangle Δ FAC and Δ BGC: the arithmetic unit calculates the welding gun working angle according to the distance value measured by the sensor,when the ACF is not equal to the BCG, the deviation of the working angle of the welding gun is explained, the arithmetic unit calculates the working angle of the welding gun according to the distance value measured by the sensor, the angular deviation of the welding gun is input into the controller, and the controller drives the welding gun to adjust the posture through the control driver, so that the welding seam is accurately tracked.
2. The seam tracking method based on the point laser distance sensor as claimed in claim 1, wherein the laser output mode of the point laser distance sensor is a low-power single pulse.
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| JPS5982172A (en) * | 1982-11-04 | 1984-05-12 | Mitsubishi Heavy Ind Ltd | Detection of welding position and welding |
| CN1006935B (en) * | 1985-08-29 | 1990-02-21 | 松下电器产业株式会社 | Apparatus for measuring the cross-section area of welded grooves |
| JPH08276269A (en) * | 1995-03-31 | 1996-10-22 | Nippon Steel Corp | Copy welding method |
| CN102528231A (en) * | 2011-12-30 | 2012-07-04 | 南昌大学 | Double-line cross laser sensing method for seam tracking |
| US9375808B2 (en) * | 2013-09-16 | 2016-06-28 | Lincoln Global, Inc. | Welding and cutting laser displacement compensation system |
| CN107442900A (en) * | 2017-08-04 | 2017-12-08 | 淮安信息职业技术学院 | A kind of laser vision welding seam tracking method |
| CN108213788B (en) * | 2018-01-03 | 2019-08-02 | 湘潭大学 | A kind of full pose corrugated plating intelligence weld seam tracking sensor of three mesh |
| CN109514042B (en) * | 2018-12-07 | 2020-05-05 | 北京博清科技有限公司 | PID-based weld joint position tracking control method and device |
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