CN110614459B - Intelligent welding plate device and method for end face of steel bundle - Google Patents
Intelligent welding plate device and method for end face of steel bundle Download PDFInfo
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- CN110614459B CN110614459B CN201910787070.9A CN201910787070A CN110614459B CN 110614459 B CN110614459 B CN 110614459B CN 201910787070 A CN201910787070 A CN 201910787070A CN 110614459 B CN110614459 B CN 110614459B
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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
- B23K37/00—Auxiliary devices or processes, not specially adapted to a procedure covered by only one of the preceding main groups
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B25—HAND TOOLS; PORTABLE POWER-DRIVEN TOOLS; MANIPULATORS
- B25J—MANIPULATORS; CHAMBERS PROVIDED WITH MANIPULATION DEVICES
- B25J11/00—Manipulators not otherwise provided for
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B25—HAND TOOLS; PORTABLE POWER-DRIVEN TOOLS; MANIPULATORS
- B25J—MANIPULATORS; CHAMBERS PROVIDED WITH MANIPULATION DEVICES
- B25J9/00—Programme-controlled manipulators
- B25J9/16—Programme controls
- B25J9/1656—Programme controls characterised by programming, planning systems for manipulators
- B25J9/1661—Programme controls characterised by programming, planning systems for manipulators characterised by task planning, object-oriented languages
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B25—HAND TOOLS; PORTABLE POWER-DRIVEN TOOLS; MANIPULATORS
- B25J—MANIPULATORS; CHAMBERS PROVIDED WITH MANIPULATION DEVICES
- B25J9/00—Programme-controlled manipulators
- B25J9/16—Programme controls
- B25J9/1679—Programme controls characterised by the tasks executed
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- G—PHYSICS
- G06—COMPUTING; CALCULATING OR COUNTING
- G06T—IMAGE DATA PROCESSING OR GENERATION, IN GENERAL
- G06T7/00—Image analysis
- G06T7/10—Segmentation; Edge detection
- G06T7/13—Edge detection
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- G—PHYSICS
- G06—COMPUTING; CALCULATING OR COUNTING
- G06T—IMAGE DATA PROCESSING OR GENERATION, IN GENERAL
- G06T7/00—Image analysis
- G06T7/10—Segmentation; Edge detection
- G06T7/194—Segmentation; Edge detection involving foreground-background segmentation
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- G—PHYSICS
- G06—COMPUTING; CALCULATING OR COUNTING
- G06T—IMAGE DATA PROCESSING OR GENERATION, IN GENERAL
- G06T7/00—Image analysis
- G06T7/70—Determining position or orientation of objects or cameras
- G06T7/73—Determining position or orientation of objects or cameras using feature-based methods
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Abstract
An intelligent welding plate device for end faces of steel bundles and a method thereof belong to the field of intelligent equipment application of intelligent factories. The invention solves the problems of high error rate, high labor intensity, high danger of a working area and the like caused by manual completion of steel bundle welding plate operation in a steel plant. The invention carries out image analysis and positions the steel rods in the steel bundle by a machine vision technology, and assists the industrial robot to move to the positioning position by accurate coordinate information to weld the plates by a special head welding plate actuating mechanism. The whole working process meets the rhythm requirement of the production flow, completely replaces the site manual operation post, improves the production efficiency and improves the control level.
Description
Technical Field
The invention belongs to the field of intelligent equipment application of intelligent factories, and particularly relates to an intelligent steel bundle welding plate device, which is an automatic control system based on intelligent application of an industrial robot technology in a metallurgical production process.
Background
The intelligent factory construction characterized by the fusion application of advanced technologies such as internet of things, cloud computing, big data and the like and intelligent equipment becomes a main power for driving iron and steel enterprises to improve the core competitiveness and form an innovative development mechanism. The industrial robot is an important member of intelligent equipment, can effectively improve production efficiency, improve equipment operation stability, reduce intensity of labour and cost of labor.
The control quality ability is improved through diversified perception ability and the self-adaptation of improvement industrial robot, realizes that the robot replaces the manual work, accomplishes the production operation automatically, forms the integration solution platform to steel main industry actual demand, is the important development direction of intelligent factory to reach the security that promotes labor efficiency and promote the operation, guarantee product quality, improve and produce the intelligent level of line, reduce or avoid the final purpose of on-the-spot worker's operation under the poisonous harmful environment of high temperature.
After being bundled and weighed, the rolled steel rods from the rod mill need to be welded with labels containing relevant specification information for feeding into a warehouse or for external sale. At present, the steel bundle welding plate operation of rolling bars in domestic steel and iron works is basically completed manually, the danger of a working area is high, the environment is severe, manual welding guns are adopted to weld plates manually, the labor intensity is high, the welding plate welding machine belongs to repetitive work, and the welding plate welding machine is suitable for being replaced by industrial robots. The automatic welding plate system used in China at present is generally only used for executing the welding plate body process, is not effectively combined with a production main production line and a metering system, has single function and insufficient intelligence, and cannot really realize full automation and unmanned welding plate.
Disclosure of Invention
The invention provides an intelligent welding plate device for steel bundle end faces and a method thereof, which replace manual work to realize automatic input, tracking and updating of label information and complete full automation of the whole operation of label welding, improve production efficiency, improve control level and reduce labor cost.
An intelligent welding plate device for end faces of steel bundles comprises a robot body, a welding plate actuating mechanism, a programmable controller, an image collector, an image analysis and positioning device and a welding plate information tracker; the robot body, the image analysis and positioning device and the welding plate information tracker are all connected with the programmable controller and are coordinately controlled by the programmable controller; the image collector is connected with the image analysis and positioner; the welding plate executing mechanism is connected with the robot body through a machine head flange;
the image collector comprises a camera and a light source; the system is in charge of collecting images and sending the images to an image analysis and positioner;
the image analysis and positioner carries out image processing and image analysis, mainly realizes the identification of the steel bundle without welded plates, identifies and positions the end face of a steel rod of the steel bundle, and carries out the plate detection function on the welded steel bundle;
the image processing is to process the image by combining the actual appearance characteristics of the steel bundle through background subtraction, characteristic extraction and edge detection algorithms for image analysis.
The image analysis is to judge a first bundle of unwelded steel bundles in a visual field through an optimized pattern matching algorithm, position the actual steel bundle position through a particle analysis and appearance matching recognition algorithm, carry out comprehensive analysis by combining brightness and ellipticity, and provide a group of steel bar two-dimensional coordinates with the best comprehensive effect to a programmable controller for robot welding plate positioning; and after a welding plate completion signal sent by the programmable controller is received, acquiring the image again, and judging whether the welding plate is successfully welded or not through a pattern matching algorithm according to the coordinates given before so as to define whether re-welding is required or not by the programmable controller.
The image analysis combines the actual appearance characteristics and the operation rules of the steel bundles and the size and brightness characteristics of the labels, and external constraint conditions are added into an image analysis algorithm, so that the influence of ambient light change and irregular end face shape of the steel bundles on bundle identification and the influence of uneven end face shearing or color depth change of the section of the steel bar caused by different rolling processing methods are avoided.
The welding plate device also comprises a printer, wherein the welding plate information tracker receives information and weighing information of the production line off-line steel bar sent by the metering system, automatically generates label information containing specification and weight after the steel bundle is weighed, and adds the label information into a steel bundle information queue for positioning and tracking, wherein the queue contains the label information of all unwelded steel bundles; and when the first unwelded steel bundle in the calculation queue moves to the visual field of the image acquisition camera, starting the welding plate system to perform image acquisition positioning and welding plate operation, and simultaneously printing a corresponding label by the printer for welding by the robot.
The actual steel bundle position is calculated by taking the coordinates of the end face in the image visual field during the previous welding as a reference, and the target welding plate position and the limit moving position of the next unwelded steel bundle are calculated;
the target position of the welding plate is the distance which needs to be moved to ensure that the next unwelded steel bundle completely enters the visual field of the camera, and the calculation method comprises the following steps:
d is the target position of the welding plate; dm is the coordinate position of the former welding plate at the fixed end in the image visual field; ds is the coordinate position of the former welding plate of the moving end in the visual field of the image; Δ S is the mobile terminal reverse bias; dc is the diameter of the end face of the preset steel bundle;
the limiting movement position is the maximum distance which is allowed to move by taking at least one bundle of welded steel bundles with labels as reference in the image acquisition visual field, so that the problem that the first bundle of unwelded steel bundles cannot be correctly positioned when all the unwelded steel bundles are avoided, and the calculation method comprises the following steps:
Dlis an extreme moving position; s is the horizontal total range of the camera view;
and after the two positions are calculated, comparing the current advancing distance with the advancing distance of the conveying chain in real time, locking the conveying chain and automatically starting the robot welding plate process when the current advancing distance reaches the target position and the conveying chain stops, and forcibly locking the conveying chain and starting the robot welding plate process if the current advancing distance reaches the limit moving target position.
An intelligent welding method for end faces of steel bundles comprises the following steps:
firstly, sorting and bundling finished steel bundles cut to length, conveying the finished steel bundles to a weighing device for weighing, conveying the finished steel bundles to a bundle conveying chain and other plates to be welded, automatically weighing the steel bundles by a welding plate information tracker, acquiring specification and weight information of the steel bundles when the steel bundles are weighed, generating tracking information corresponding to the actual steel bundles, tracking the steel bundles in real time in the conveying process of the bundle conveying chain, and starting a welding plate flow when the steel bundles without welding plates enter the visual field of an image acquisition camera;
step two, judging and giving a signal for starting a welding plate process by a programmable controller, respectively triggering image analysis and a positioner to start image acquisition and positioning, printing the information of the steel bundle label by a printer, and starting a welding plate robot to start a plate taking action;
moving a welding plate executing mechanism to a label printing position by the robot, taking the welding plate by a machine head sucker, simultaneously giving positioning coordinate information by an image analysis and positioner, moving the welding plate executing mechanism to a welding plate preparation position by the robot according to the coordinates, and measuring a more prominent steel bundle by the system through machine head laser ranging to weld the welding plate;
fourthly, after the robot finishes welding the cards, performing a nail taking action, simultaneously acquiring images again by the image collector, analyzing whether the welding of the cards is successful or not by the image analyzer and the positioner, if the welding of the cards is unsuccessful, starting a re-welding function, reprinting the welding of the cards, performing the card taking and welding actions again, giving out a new coordinate position according to the image analyzer and the positioner for welding the cards, if the welding of the cards is not successful after the set number of re-welding times is exceeded, skipping the bundle for welding the next bundle, and correspondingly updating the information and the positioning information of the welding of the cards;
and step five, if the welding plate detection is successful, the system recovers the initial state, the welding plate identification is sent to the metering system for warehousing treatment, and the corresponding steel bundle is hoisted by the overhead traveling crane and warehoused.
The welding plate device is arranged on two sides of a steel bundle bundling and weighing bundling conveying chain, so that welding plates are synchronously welded at two ends of the steel bundle, information of the welding plates is guaranteed to be correct and consistent, and one end of each welding plate can be independently welded according to production requirements.
The two ends of the welding robot are respectively provided with a set of field welding plate devices with basically consistent configuration, the welding robot is uniformly controlled by a set of programmable controller, one end of a general steel bundle can be flush processed by a general steel bundle offline process, the end surface position of the general steel bundle is fixed, the end surface of the general steel bundle at the other end can have several specification length positions according to production requirements, therefore, the system is provided with a transverse moving platform at the side, the transverse moving platform is driven by a servo motor, the field welding plate devices at the end are arranged on the transverse moving platform and are positioned to corresponding positions according to the actual length of the steel bundle, and the consistency of the welding robot and the reference.
The main equipment of the welding plate executing mechanism comprises a welding gun, a sucking disc and a detection device.
The field device comprises a welding machine and an automatic welding nail conveying device.
The system realizes full-automatic unmanned operation from steel bundle weighing to welding plate welding, realizes automatic tracking, automatic positioning and automatic welding of the steel bundle, can automatically judge to perform re-welding or separate bundle welding of the welding plate, ensures that the automatic flow is not interrupted, can meet the rhythm requirement of the production flow in the whole working process, and completely replaces on-site manual operation.
Drawings
The following further describes embodiments of the present invention with reference to the drawings.
Fig. 1 is a system architecture diagram.
FIG. 2 is a top view of the welding tag device in situ
Fig. 3 is a structure view of the fixing end installation.
Fig. 4 is a diagram showing an installation structure of a mobile terminal.
Fig. 5 is a diagram of a configuration of a welding tag actuator.
FIG. 6 is a functional diagram of an image analysis and locator.
101 is a robot body, 102 is a label printer, 103 is an automatic welding nail conveying device, 104 is a transverse moving platform and a servo motor, 105 is an image collector, 201 is a welding nail executing mechanism, 202 is a laser ranging device, and 203 is a welding nail gun head; 204 is a label chuck and 205 is a handpiece label detection device.
Detailed Description
According to the intelligent welding plate device for the end face of the steel bundle, the full-automatic unmanned welding plate function in the production process is realized by combining the industrial robot with the image processing of machine vision.
After steel bundles produced by bars are bundled and weighed, label data including specification, weight and other information are sent to a welding plate information tracker by an original metering system, the welding plate information tracker adds the information into a steel bundle tracking queue, meanwhile, the weighed steel bundles are correspondingly and sequentially conveyed to a bundling conveying chain and other plates to be welded, a programmable controller of the welding plate system receives a conveying chain moving signal of a production line system, the position of the unwelded steel bundle is calculated and tracked in real time, and when the next unwelded steel bundle completely enters the visual field of an image acquisition camera according to the position calculation of the previous welding plate, a welding plate flow is started by the programmable controller.
The welding plate starting comprises triggering the robot body 101, the image collector 105 and the image analysis and positioning device, and the welding plate information printer is started simultaneously.
The robot body 101 firstly performs a tile taking action, the tag is sucked by the tag sucker 204 of the welding tile executing mechanism 201, the head tag detection device 205 confirms that the tag is sucked, if the tag sucking failure is detected, the tag is automatically sucked again, and if the tag sucking failure occurs, the robot body alarms.
The image analysis and positioning device carries out image acquisition through the image acquisition device 105, firstly identifies a first bundle of unwelded steel plate bundles after analysis and processing, then obtains the position information of the weldable steel plate rods in the steel plate bundles, and sends the position coordinates to the robot after being processed by the programmable control system.
The welding information tracker prints out the label of the steel bundle to be welded through the label printer 102 for the robot to obtain.
The robot body 101 takes out the label, confirms that the positioning information is obtained, and then starts the welding process. The robot moves the welding plate executing mechanism 201 to a welding plate preparation position according to the coordinates, and because the positioning coordinates can only give two-dimensional coordinates, the programmable controller selects the coordinates of three to five steel bars, the robot firstly measures the coordinates through the laser ranging device 202, selects the most prominent steel bar to weld the welding plate, and welds the welding nail with the label on the steel bundle through the head welding gun 203, so that the robot is effectively prevented from colliding with the steel bars which are sheared unevenly or not sheared evenly.
After the welding of the welding plate is completed, the robot removes the welding nail from the automatic conveying device 103 to take out the welding nail, and meanwhile, the image analysis and positioning device carries out image acquisition again through the image acquisition device 105 to judge whether the welding of the welding plate is successful or not. If the operation is unsuccessful, the programmable controller starts a re-welding process, selects a group of new coordinates to re-take the cards, and performs a welding process.
If the number of times of re-welding is over the set number of times, the welding plate is not welded successfully, the next bundle is automatically skipped to prepare for welding the welding plate, the welding plate information and the positioning information are correspondingly updated, and post operators can be prompted to manually repair the welding plate in time through sound and image alarm. Thereby ensuring that the entire automated process is not interrupted.
And if the welding plate is detected successfully, the system restores the initial state, and the welding plate tracking module automatically updates the welding plate information and sends the welded plate identifier to the metering system for warehousing processing.
The whole process is automatically realized without manual intervention, and when a problem or an abnormality occurs, the system can perform corresponding processing according to actual conditions, so that the requirement of intelligent application is met.
Claims (5)
1. The utility model provides a tablet device is welded to steel bundle terminal surface intelligence which characterized in that: the device comprises a robot body, a welding plate actuating mechanism, a programmable controller, an image collector, an image analysis and positioning device and a welding plate information tracker; the robot body, the image analysis and positioning device and the welding plate information tracker are all connected with the programmable controller and are coordinately controlled by the programmable controller; the image collector is connected with the image analysis and positioner; the welding plate executing mechanism is connected with the robot body through a machine head flange;
the image collector comprises a camera and a light source; the system is in charge of collecting images and sending the images to an image analysis and positioner;
the image analysis and positioner carries out image processing and image analysis, mainly realizes the identification of the steel bundle without welded plates, identifies and positions the end face of a steel rod of the steel bundle, and carries out the plate detection function on the welded steel bundle;
the image processing is to process the image by combining the actual appearance characteristics of the steel bundle through background subtraction, characteristic extraction and edge detection algorithms for image analysis;
the image analysis is to judge a first bundle of unwelded steel bundles in a visual field through an optimized pattern matching algorithm, position the actual steel bundle position through a particle analysis and appearance matching recognition algorithm, carry out comprehensive analysis by combining brightness and ellipticity, and provide a group of steel bar two-dimensional coordinates with the best comprehensive effect to a programmable controller for robot welding plate positioning; and after a welding plate completion signal sent by the programmable controller is received, acquiring the image again, and judging whether the welding plate is successfully welded or not through a pattern matching algorithm according to the coordinates given before so as to define whether re-welding is required or not by the programmable controller.
2. The tile welding apparatus of claim 1, wherein: the image analysis combines the actual appearance characteristics and the operation rules of the steel bundles and the size and brightness characteristics of the labels, and external constraint conditions are added into an image analysis algorithm, so that the influence of ambient light change and irregular end face shape of the steel bundles on bundle identification and the influence of uneven end face shearing or color depth change of the section of the steel bar caused by different rolling processing methods are avoided.
3. The tile welding apparatus of claim 1, wherein: the device also comprises a printer, wherein the welding plate information tracker receives information and weighing information of the off-line steel bar in the production line sent by the metering system, automatically generates label information containing specification and weight after the steel bundle is weighed, and adds the label information into a steel bundle information queue for positioning and tracking, wherein the queue contains the label information of all unwelded steel bundles; and when the first unwelded steel bundle in the calculation queue moves to the visual field of the image acquisition camera, starting the welding plate system to perform image acquisition positioning and welding plate operation, and simultaneously printing a corresponding label by the printer for welding by the robot.
4. The tile welding apparatus of claim 1, wherein: the actual steel bundle position is calculated by taking the coordinates of the end face in the image visual field during the previous welding as a reference, and the target welding plate position and the limit moving position of the next unwelded steel bundle are calculated;
the target position of the welding plate is the distance which needs to be moved to ensure that the next unwelded steel bundle completely enters the visual field of the camera, and the calculation method comprises the following steps:
d is the target position of the welding plate; dm is the coordinate position of the former welding plate at the fixed end in the image visual field; ds is the coordinate position of the former welding plate of the moving end in the visual field of the image; Δ S is the mobile terminal reverse bias; dc is the diameter of the end face of the preset steel bundle;
the limiting movement position is the maximum distance which is allowed to move by taking at least one bundle of welded steel bundles with labels as reference in the image acquisition visual field, so that the problem that the first bundle of unwelded steel bundles cannot be correctly positioned when all the unwelded steel bundles are avoided, and the calculation method comprises the following steps:
Dlis an extreme moving position; s is the horizontal total range of the camera view;
and after the two positions are calculated, comparing the current advancing distance with the advancing distance of the conveying chain in real time, locking the conveying chain and automatically starting the robot welding plate process when the current advancing distance reaches the target position and the conveying chain stops, and forcibly locking the conveying chain and starting the robot welding plate process if the current advancing distance reaches the limit moving target position.
5. An intelligent welding method for end faces of steel bundles is characterized by comprising the following steps:
firstly, sorting and bundling finished steel bundles cut to length, conveying the finished steel bundles to a weighing device for weighing, conveying the finished steel bundles to a bundle conveying chain and other plates to be welded, automatically weighing the steel bundles by a welding plate information tracker, acquiring specification and weight information of the steel bundles when the steel bundles are weighed, generating tracking information corresponding to the actual steel bundles, tracking the steel bundles in real time in the conveying process of the bundle conveying chain, and starting a welding plate flow when the steel bundles without welding plates enter the visual field of an image acquisition camera;
step two, judging and giving a signal for starting a welding plate process by a programmable controller, respectively triggering image analysis and a positioner to start image acquisition and positioning, printing the information of the steel bundle label by a printer, and starting a welding plate robot to start a plate taking action;
moving a welding plate executing mechanism to a label printing position by the robot, taking the welding plate by a machine head sucker, simultaneously giving positioning coordinate information by an image analysis and positioner, moving the welding plate executing mechanism to a welding plate preparation position by the robot according to the coordinates, and measuring a more prominent steel bundle by the system through machine head laser ranging to weld the welding plate;
fourthly, after the robot finishes welding the cards, performing a nail taking action, simultaneously acquiring images again by the image collector, analyzing whether the welding of the cards is successful or not by the image analyzer and the positioner, if the welding of the cards is unsuccessful, starting a re-welding function, reprinting the welding of the cards, performing the card taking and welding actions again, giving out a new coordinate position according to the image analyzer and the positioner for welding the cards, if the welding of the cards is not successful after the set number of re-welding times is exceeded, skipping the bundle for welding the next bundle, and correspondingly updating the information and the positioning information of the welding of the cards;
and step five, if the welding plate detection is successful, the system recovers the initial state, the welding plate identification is sent to the metering system for warehousing treatment, and the corresponding steel bundle is hoisted by the overhead traveling crane and warehoused.
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Families Citing this family (9)
| Publication number | Priority date | Publication date | Assignee | Title |
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| CN111105463B (en) * | 2019-12-31 | 2024-04-16 | 东北大学 | Label welding positioning method for end faces of bundled bars |
| CN111055039A (en) * | 2019-12-31 | 2020-04-24 | 东北大学 | Bundled bar label welding system based on machine vision |
| CN111482726A (en) * | 2020-05-14 | 2020-08-04 | 广东汇博机器人技术有限公司 | Automatic flexible welding tablet system of robot |
| CN111563911B (en) * | 2020-05-27 | 2020-10-20 | 江苏金恒信息科技股份有限公司 | Automatic label welding method and device based on multiple steel bundles |
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| CN111558791B (en) * | 2020-05-27 | 2020-10-09 | 江苏金恒信息科技股份有限公司 | Method and device for automatically welding label |
| CN111906481A (en) * | 2020-08-24 | 2020-11-10 | 开阐(上海)实业有限公司 | A sign welding set for different specification finished product rods |
| CN113420856B (en) * | 2021-06-29 | 2024-03-26 | 山东莱钢永锋钢铁有限公司 | Remote weighing low-interference and high-precision transmission system |
| CN115504037A (en) * | 2022-10-18 | 2022-12-23 | 山东莱钢永锋钢铁有限公司 | Automatic collection method for rolled steel bars |
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