CN110064842B - Automatic calibration method for positioning trihedral weld joint - Google Patents
Automatic calibration method for positioning trihedral weld joint Download PDFInfo
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- CN110064842B CN110064842B CN201910452844.2A CN201910452844A CN110064842B CN 110064842 B CN110064842 B CN 110064842B CN 201910452844 A CN201910452844 A CN 201910452844A CN 110064842 B CN110064842 B CN 110064842B
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K26/00—Working by laser beam, e.g. welding, cutting or boring
- B23K26/08—Devices involving relative movement between laser beam and workpiece
- B23K26/082—Scanning systems, i.e. devices involving movement of the laser beam relative to the laser head
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K26/00—Working by laser beam, e.g. welding, cutting or boring
- B23K26/20—Bonding
- B23K26/21—Bonding by welding
- B23K26/24—Seam welding
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K26/00—Working by laser beam, e.g. welding, cutting or boring
- B23K26/70—Auxiliary operations or equipment
- B23K26/702—Auxiliary equipment
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Abstract
The invention discloses an automatic calibration method for positioning a trihedral weld joint, and relates to the field of automatic positioning calibration. Respectively scanning and shooting three edges of a trihedral weld joint by using a robot carrying an optical system, establishing a linear equation of the three edges in a corresponding robot moving coordinate system and a structured light reconstruction coordinate system, converting the three edges into the moving coordinate system according to a reconstruction-movement relation, and further converting into a global coordinate system; and (3) calculating a point with the minimum sum of squares of the distances between the point and the three edges in the global coordinate system, and calculating by using an optimization method to obtain a reconstruction-movement relation by taking the sum of squares of the distances between the point and the three edges as an objective function. The method can simplify the calibration process for the welding positioning of the trihedral weld joint robot, and reduce the coupling degree of the optical system and the robot system; and meanwhile, the automatic calibration precision can be iteratively optimized.
Description
Technical Field
The invention relates to the field of positioning automatic calibration, in particular to an automatic calibration method for positioning a trihedral weld joint.
Background
The trihedral structure is widely used in application occasions such as box welding, and a linear structured optical system based on a triangulation method is a measuring method with higher precision in the automatic welding of the trihedral structure. However, because the trihedral structure has the characteristics of large spatial fluctuation and more rotation and offset dimensions, the traditional single-scanning triangulation method cannot be directly applied to automatic positioning of trihedral weld seams, but a method of scanning different areas for multiple times and then unifying the scanning results of multiple times into a coordinate system must be adopted, wherein the necessary step is to reconstruct coordinate system calibration, namely the corresponding relationship between the coordinate system reconstructed in the triangulation method and the robot moving coordinate system.
The traditional method for calibrating the reconstructed coordinate system is to use the hand-eye relationship calibration to indirectly obtain the corresponding relationship between the reconstructed coordinate system and the robot tool coordinate system. The existing calibration method needs to repeatedly shoot the same point for many times, or needs to determine the accurate position parameters of the calibration point in advance to calibrate the eyes and hands, and the determination of the accurate position parameters of the calibration point in advance needs additional targets even for accurate positioning; therefore, the traditional coordinate system calibration method is complex, low in efficiency and easy to be influenced by human factors.
Therefore, those skilled in the art are dedicated to develop an automatic calibration method for positioning a trihedral weld, which can simplify the existing calibration process, achieve decoupling of the optical device and the robot system, and continuously correct the calibration result in the subsequent actual measurement process, thereby improving the calibration accuracy.
Disclosure of Invention
In view of the above-mentioned defects in the prior art, the technical problem to be solved by the present invention is how to provide an automatic calibration method for positioning a trihedral weld, which can simplify the existing calibration process, realize the decoupling of an optical device and a robot system, and continuously correct the calibration result in the subsequent actual measurement process, thereby improving the calibration accuracy.
In order to achieve the aim, the invention provides an automatic calibration method for positioning a trihedral weld joint, which comprises the following steps:
step 1, respectively scanning and shooting three edges of a trihedral weld by using a robot with an optical system, respectively establishing linear equations of the three edges in a corresponding robot moving coordinate system and a structured light reconstruction coordinate system aiming at the scanning and shooting processes of the three edges, and expressing a spatial linear equation of the three edges in a global coordinate system in a form including a reconstruction-movement relation, wherein the reconstruction-movement relation is a conversion relation between the structured light reconstruction coordinate system and the robot moving coordinate system;
step 2, obtaining the coordinate representation of the point which is the minimum of the square sum of the distances from the three edges in the global coordinate system under the representation of the step 1;
and 5, performing calibration method self-optimization, wherein after a group of trihedral weld structure is positioned, the reconstruction-movement relationship is finely adjusted and corrected by combining the newly obtained reconstruction-movement relationship of the calibration and the previously obtained reconstruction-movement relationship under the condition of not interfering normal production.
Further, the optical system includes a line structured light laser and a camera.
Further, the optical system should perform optical system parameter calibration before the optical system is used for the first time, where the optical system parameter calibration includes parameters of the camera, and a relative position relationship between a plane where the line structured light of the line structured light laser is located and the camera.
Further, the step 1 of establishing a linear equation of the three edges in the corresponding structured light reconstruction coordinate system includes the following steps:
step 1.1, recording position information of the robot during scanning shooting of the three edges, wherein the position information of the robot comprises a starting position coordinate, an ending position coordinate, an image shooting position interval and a coordinate system parameter of an end effector of the robot;
step 1.2, obtaining a line structure light image corresponding to three edges according to the shot image;
step 1.3, converting the laser line image coordinate of the line structure light image into the coordinate of the line structure light plane and the surface intersection line of the trihedron on the line structure light plane according to the calibration information of the optical system and the principle of a triangulation method;
step 1.4, calculating the motion vector of the light plane of the line structure every two times of image shooting according to the position information of the robot recorded in the step 1.1, and calculating the space linear equation of the three edges of the trihedron in the corresponding structured light reconstruction coordinate system respectively according to the motion vector.
Further, the position coordinates of the end effector of the robot refer to the coordinates of the origin of the robot tool coordinate system in the global coordinate system, and the coordinate system parameters of the robot end effector refer to the unit vectors of the z-axis of the robot tool coordinate system in the global coordinate system.
Further, the line structured light plane refers to a plane on which line structured light emitted by the line structured light laser of the optical system is located.
Further, the expression of the objective function in step 3 is as follows:
in the formula (I), the compound is shown in the specification,
indicating the coordinates of the ith edge starting point in the global coordinate system, assuming that the structured light reconstruction coordinate system and the robot movement coordinate system coincide,
representing the z-axis direction of the ith robot motion coordinate system in the global coordinate systemA bit vector; d is the distance between the original point of the structured light reconstruction coordinate system and the original point of the robot moving coordinate system;
a unit vector of the direction of the ith edge in the global coordinate system;
is a point in space, λiAnd a variable corresponding to the ith edge.
Furthermore, the normal direction of the linear structured light plane of the optical system is perpendicular to the z-axis direction of the robot tool coordinate system, and the motion direction of the robot during scanning and shooting is perpendicular to the linear structured light plane.
Furthermore, the origin of the robot moving coordinate system coincides with the origin of the tool coordinate system at the scanning starting position of the robot, the z-axis direction of the robot moving coordinate system is consistent with the z-axis direction of the tool coordinate system of the robot, the y-axis direction of the robot moving coordinate system is consistent with the moving direction of the robot during scanning and shooting, and the x-axis direction of the robot moving coordinate system meets the requirement of a right-handed system.
Furthermore, the origin of the structured light reconstruction coordinate system is located on the z-axis of the corresponding robot moving coordinate system, the y-axis direction of the structured light reconstruction coordinate system is consistent with the moving direction of the robot during scanning and shooting, and the x-axis direction of the structured light reconstruction coordinate system meets the requirement of a right-handed system.
Compared with the prior art, the method has the following beneficial effects:
the invention designs an automatic calibration method which combines the calibration of a structured light reconstruction coordinate system with the positioning process of an actual trihedral weld structure by utilizing the structural characteristic that three edges in the trihedral weld structure intersect at one point, avoids the calibration by hands and eyes, solves the defects that the prior hand and eye calibration method needs to control a robot to carry out an additional hand and eye calibration flow or needs additional targets even for accurate positioning, has the advantages of simple, convenient and reliable detection method, no need of adding special detection targets, realization of decoupling of an optical system and the robot system, and no need of additional hand and eye calibration flow for the robot positioning system after the optical system is installed.
2, the invention combines the calibration of the structured light reconstruction coordinate system with the positioning process in production, can continuously fine-adjust and correct the reconstruction-movement relation in application, and has the advantage of improving the calibration precision.
The invention has wide application prospect in the field of positioning of welded workpieces, and provides a new idea for automatic calibration of positioning of workpieces with other shapes.
The conception, the specific structure and the technical effects of the present invention will be further described with reference to the accompanying drawings to fully understand the objects, the features and the effects of the present invention.
Drawings
FIG. 1 is a schematic flow chart of a preferred embodiment of the present invention;
FIG. 2 is an image of an optical system scanning a photographing edge according to a preferred embodiment of the present invention;
FIG. 3 is a schematic diagram of a robot moving coordinate system according to a preferred embodiment of the present invention;
FIG. 4 is a schematic diagram of the coordinate transformation of the ridge before and after automatic calibration according to a preferred embodiment of the present invention.
The method comprises the following steps of 1-y-axis of a robot moving coordinate system, 2-z-axis of the robot moving coordinate system, 3-automatic calibration front ridge line, 4-automatic calibration rear ridge line, 5-automatic calibration front center point and 6-automatic calibration rear center point.
Detailed Description
The technical contents of the preferred embodiments of the present invention will be more clearly and easily understood by referring to the drawings attached to the specification. The present invention may be embodied in many different forms of embodiments and the scope of the invention is not limited to the embodiments set forth herein.
In the drawings, structurally identical elements are represented by like reference numerals, and structurally or functionally similar elements are represented by like reference numerals throughout the several views. The size and thickness of each component shown in the drawings are arbitrarily illustrated, and the present invention is not limited to the size and thickness of each component. The thickness of the components may be exaggerated where appropriate in the figures to improve clarity.
The embodiment of the invention discloses an automatic calibration method for locating a trihedral weld joint, which combines the actual measurement of the position parameters of a trihedral structure with the calibration process of a structured light reconstruction coordinate system to realize automatic calibration. First, a set of structured light optical systems is constructed using a line structured light laser and an industrial camera. And completing the calibration of the optical system. And then, scanning and shooting three edges of the trihedral structure by using a robot carrying the optical system according to a preset track respectively to obtain three groups of line structured light images. In the shooting process, information such as the initial position coordinates, the end position coordinates, the tool coordinate system z-axis orientation and the like of the robot end effector during each group of shooting needs to be recorded, so that three robot moving coordinate systems and three structured light reconstruction coordinate systems are constructed. According to the calibration information of the structured light optical system and the principle of a triangulation method, the laser line image coordinates in each image are converted into the coordinates of the line structure light plane and the trihedral surface intersecting line on the line structure light plane. And calculating the motion vector of the linear structured light plane every two times of image shooting according to the initial position and the end position of the robot movement and the image shooting position interval, and calculating the space linear equation of the three edges of the trihedron in the corresponding structured light reconstruction coordinate system respectively according to the motion vector. There is a fixed conversion relationship between the three structured light reconstruction coordinate systems and the three corresponding robot movement coordinate systems, which is called reconstruction-movement relationship. And converting the three edges into a moving coordinate system according to the assumed reconstruction-moving relation, and further converting the three edges into a global coordinate system. And further, a point with the minimum sum of squares of the distances between the point and the three edges in the global coordinate system is obtained, and the reconstruction-movement relation is obtained by using the sum of squares of the distances between the point and the three edges as an objective function and calculating by using an optimization method.
The method specifically comprises the following steps:
step 1, respectively scanning and shooting three edges of a trihedral weld by using a robot with an optical system, respectively establishing linear equations of the three edges in a corresponding robot moving coordinate system and a structured light reconstruction coordinate system aiming at the scanning and shooting processes of the three edges, and expressing a spatial linear equation of the three edges in a global coordinate system in a form containing a reconstruction-movement relation, wherein the reconstruction-movement relation is a conversion relation between the structured light reconstruction coordinate system and the robot moving coordinate system; in the embodiment, an optical system is composed of a red line structured laser emitter and an industrial CCD camera, the optical system is required to carry out optical system parameter calibration before the optical system is used for the first time, and the optical system parameter calibration comprises parameters of the industrial CCD camera and a relative position relation between a plane where line structured light of the red line structured laser emitter is located and the industrial CCD camera; the optical system is fixedly arranged on the robot end effector: the line-structured light plane refers to a plane where line-structured light emitted by a line-structured light laser of the optical system is located; the normal direction of the linear structure light plane of the optical system is vertical to the z-axis direction of the robot tool coordinate system, and the motion direction of the robot during scanning and shooting is vertical to the linear structure light plane; the original point of the robot moving coordinate system is coincided with the original point of the tool coordinate system at the scanning initial position of the robot, the direction of a z-axis 2 of the robot moving coordinate system is consistent with the direction of the z-axis of the robot tool coordinate system, the direction of a y-axis 1 of the robot moving coordinate system is consistent with the moving direction of the robot during scanning and shooting, and the direction of an x-axis of the robot moving coordinate system meets the requirement of a right-hand system; the origin of the structured light reconstruction coordinate system is located on the z-axis 2 of the corresponding robot moving coordinate system, the y-axis direction of the structured light reconstruction coordinate system is consistent with the motion direction of the robot during scanning and shooting, and the x-axis direction of the structured light reconstruction coordinate system meets the requirement of a right-handed system; the step of establishing a linear equation of the three edges in the corresponding structured light reconstruction coordinate system specifically comprises the following substeps:
step 1.1, recording position information of the robot during scanning shooting aiming at three edges, wherein the position information of the robot comprises a starting position coordinate, an ending position coordinate, an image shooting position interval and a coordinate system parameter of an end effector of the robot; the position coordinates of the end effector of the robot refer to the coordinates of the origin of the robot tool coordinate system in the global coordinate system, and the coordinate system parameters of the robot end effector refer to the unit vectors of the z-axis of the robot tool coordinate system in the global coordinate system;
step 1.2, obtaining a line structure light image corresponding to three edges according to the shot image;
step 1.3, converting the laser line image coordinate of the line structure light image into the coordinate of the line structure light plane and the trihedral surface intersecting line on the line structure light plane according to the calibration information of the optical system and the principle of a triangulation method;
step 1.4, calculating the motion vector of the linear structured light plane when the image is shot every two times according to the position information of the robot recorded in the step 1.1, and calculating the space linear equation of three edges of the trihedron in the corresponding structured light reconstruction coordinate system respectively according to the motion vector;
step 2, obtaining the coordinate representation of the point with the minimum sum of squares of the distances from the three edges in the global coordinate system under the representation of the step 1;
in the formula (I), the compound is shown in the specification,
represents the coordinates of the ith edge starting point in the global coordinate system when the structured light reconstruction coordinate system is supposed to coincide with the robot moving coordinate system,
a unit vector representing the z-axis 2 direction of the ith robot movement coordinate system in the global coordinate system; d is the distance between the original point of the structured light reconstruction coordinate system and the original point of the robot moving coordinate system;
is the unit vector of the direction of the ith edge in the global coordinate system;
is a point in space, λiA variable corresponding to the ith edge;
and 5, performing self-optimization of the calibration method, wherein after the self-optimization is to complete the positioning of a group of trihedral weld structures, the reconstruction-movement relationship is finely adjusted and corrected by combining the newly obtained reconstruction-movement relationship of the calibration and the previously obtained reconstruction-movement relationship under the condition of not interfering normal production.
Fig. 1 is a schematic flow chart of the present embodiment. The detected object in this embodiment is a trihedral-structure workpiece, and an optical system composed of a red-line-structure laser transmitter and an industrial CCD camera is used, the scanning speed is 10mm/s, and the scanning and shooting frequency is 10 Hz. Fig. 2 shows an image of one edge of the trihedron obtained when the optical system scans and photographs the trihedron, and the scanned and photographed image of the trihedron with three edges obtained by scanning and photographing the trihedron in sequence.
In a robot end tool coordinate system, a robot moving coordinate system shown in fig. 3 is established, and an origin and a z-axis 2 of the robot moving coordinate system are both the same as the tool coordinate system and can be directly read out through a robot control system; the y-axis 1 of the robot moving coordinate system is the moving direction of the robot, and can be obtained by calculation according to the set starting point and the set end point in the robot program.
And aiming at each edge, extracting edge information in the shot image, and reconstructing a spatial equation of the edge in the structured light reconstruction coordinate system according to the calibration information of the optical system. Assuming that the structured light reconstruction coordinate system coincides with the robot moving coordinate system, the edge lines in the structured light reconstruction coordinate system are directly transformed into the global space to obtain three automatic calibration front edge lines 3 as shown in fig. 4, and it can be seen that the three automatic calibration front edge lines 3 do not intersect at one point because there is an offset between the structured light reconstruction coordinate system and the robot moving coordinate system. But we can still find a point with the smallest sum of squared distances from the three lines, automatically calibrating the front center point 5 as shown in fig. 4. With the solution of the optimization function, the reconstruction-movement relationship can be obtained when the sum of the squares of the distances of the three lines from this point is minimized. The edge lines are converted into a robot moving coordinate system by utilizing the reconstruction-moving relation and then are converted into a global coordinate system to obtain three automatically calibrated edge lines 4 in the figure 4, and the three automatically calibrated edge lines 4 can be seen to intersect at an automatically calibrated central point 6 and have the same position as that of a preset trihedron.
The test result shows that the obtained reconstruction-movement relation well realizes the coordinate conversion from the structured light reconstruction coordinate system to the robot moving coordinate system of the edge line, and the automatic calibration method based on the trihedral prior information successfully solves the problem of the conversion from the optical system reconstruction coordinate to the global coordinate without extra hand-eye calibration work.
The foregoing detailed description of the preferred embodiments of the invention has been presented. It should be understood that numerous modifications and variations could be devised by those skilled in the art in light of the present teachings without departing from the inventive concepts. Therefore, the technical solutions available to those skilled in the art through logic analysis, reasoning and limited experiments based on the prior art according to the concept of the present invention should be within the scope of protection defined by the claims.
Claims (10)
1. An automatic calibration method for positioning a trihedral weld, characterized by comprising the following steps:
step 1, respectively scanning and shooting three edges of a trihedral weld by using a robot with an optical system, respectively establishing linear equations of the three edges in a corresponding robot moving coordinate system and a structured light reconstruction coordinate system aiming at the scanning and shooting processes of the three edges, and expressing a spatial linear equation of the three edges in a global coordinate system in a form including a reconstruction-movement relation, wherein the reconstruction-movement relation is a conversion relation between the structured light reconstruction coordinate system and the robot moving coordinate system;
step 2, obtaining the coordinate representation of the point which is represented by the step 1 and has the minimum square sum of the distances from the three edges in the global coordinate system;
step 3, establishing a target function according to the sum of squares of the distances between the points found in the step 2 and the three edges; the target function takes the reconstruction-movement relation as a variable;
step 4, converting the linear equation of the three edges in the corresponding structured light reconstruction coordinate system into the robot moving coordinate system by using the reconstruction-movement relation when the objective function in the step 3 is minimum, and further converting the linear equation into the global coordinate system;
and 5, performing calibration method self-optimization, wherein after a group of trihedral weld structure is positioned, the reconstruction-movement relationship is finely adjusted and corrected by combining the newly obtained reconstruction-movement relationship of the calibration and the previously obtained reconstruction-movement relationship under the condition of not interfering normal production.
2. The automatic calibration method for trihedral weld seam positioning according to claim 1, wherein the optical system comprises a line structured light laser and a camera.
3. The automatic calibration method for trihedral weld seam positioning according to claim 2, wherein the optical system is subjected to optical system parameter calibration before initial use, and the optical system parameter calibration comprises parameters of the camera, and a relative position relationship between a plane of the line structured light laser and the camera.
4. The automatic calibration method for trihedral weld seam positioning according to claim 3, wherein the step 1 of establishing the linear equations of three edges in the corresponding structured light reconstruction coordinate system comprises the following steps:
step 1.1, recording position information of the robot during scanning shooting of the three edges, wherein the position information of the robot comprises a starting position coordinate, an ending position coordinate, an image shooting position interval and a coordinate system parameter of an end effector of the robot;
step 1.2, obtaining a line structure light image corresponding to three edges according to the shot image;
step 1.3, converting the laser line image coordinate of the line structure light image into the coordinate of the line structure light plane and the surface intersection line of the trihedron on the line structure light plane according to the calibration information of the optical system and the principle of a triangulation method;
step 1.4, calculating the motion vector of the light plane of the line structure every two times of image shooting according to the position information of the robot recorded in the step 1.1, and calculating the space linear equation of the three edges of the trihedron in the corresponding structured light reconstruction coordinate system respectively according to the motion vector.
5. The automatic calibration method for trihedral weld seam positioning according to claim 4, wherein the position coordinates of the robot end effector refer to coordinates of the origin of the robot tool coordinate system in the global coordinate system, and the coordinate system parameters of the robot end effector refer to unit vectors of the z-axis of the robot tool coordinate system in the global coordinate system.
6. The automatic calibration method for trihedral weld seam positioning according to claim 5, wherein the line structure light plane is a plane on which line structure light emitted from the line structure light laser of the optical system is located.
7. The automatic calibration method for trihedral weld seam positioning according to claim 6, characterized in that the expression of the objective function in the step 3 is as follows:
in the formula (I), the compound is shown in the specification,
indicating the coordinates of the ith edge starting point in the global coordinate system, assuming that the structured light reconstruction coordinate system and the robot movement coordinate system coincide,
a unit vector representing the z-axis direction of the ith robot moving coordinate system in the global coordinate system; d is the distance between the original point of the structured light reconstruction coordinate system and the original point of the robot moving coordinate system;
a unit vector of the direction of the ith edge in the global coordinate system;
is a point in space, λiAnd a variable corresponding to the ith edge.
8. The automatic calibration method for trihedral weld seam positioning according to claim 7, characterized in that the normal direction of the line structured light plane of the optical system is perpendicular to the z-axis direction of the robot tool coordinate system, and the moving direction of the robot during scanning and shooting is perpendicular to the line structured light plane.
9. The automatic calibration method for trihedral weld seam positioning according to claim 8, characterized in that the origin of the robot moving coordinate system coincides with the origin of the tool coordinate system of the robot scanning start position, the z-axis direction of the robot moving coordinate system coincides with the z-axis direction of the tool coordinate system of the robot, the y-axis direction of the robot moving coordinate system coincides with the moving direction of the robot during scanning and shooting, and the x-axis direction of the robot moving coordinate system satisfies the right-handed system requirement.
10. The automatic calibration method for trihedral weld seam positioning according to claim 9, wherein the origin of the structured light reconstruction coordinate system is located on the corresponding z-axis of the robot moving coordinate system, the y-axis direction of the structured light reconstruction coordinate system is consistent with the moving direction of the robot during scanning and shooting, and the x-axis direction of the structured light reconstruction coordinate system meets the requirements of a right-handed system.
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