CN110773840A - Welding deviation measuring method and device and automatic welding system - Google Patents
Welding deviation measuring method and device and automatic welding system Download PDFInfo
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- CN110773840A CN110773840A CN201911103567.0A CN201911103567A CN110773840A CN 110773840 A CN110773840 A CN 110773840A CN 201911103567 A CN201911103567 A CN 201911103567A CN 110773840 A CN110773840 A CN 110773840A
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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
- 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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- 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
- B23K9/00—Arc welding or cutting
- B23K9/12—Automatic feeding or moving of electrodes or work for spot or seam welding or cutting
- B23K9/127—Means for tracking lines during arc welding or cutting
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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
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Abstract
The invention discloses a welding deviation measuring method, a welding deviation measuring device and an automatic welding system, wherein the method comprises the following steps: acquiring a first molten pool image and a second molten pool image, wherein the first molten pool image is a reference molten pool image; respectively extracting welding gun position information and welding seam position information of the first molten pool image and the second molten pool image; and calculating to obtain a welding deviation value according to the welding gun position information and the welding seam position information of the first molten pool image and the second molten pool image. After the welding deviation value is obtained, whether the deviation can meet the deviation requirement of welding seam tracking is judged according to the actual experience of the existing welding seam tracking technology, if the deviation can meet the deviation requirement, the automatic welding based on the welding seam tracking can be carried out according to the position deviation between a welding gun and the welding seam, and the automatic welding method has the advantages of monitoring the molten pool and observing the position of the welding seam in real time, does not have advanced monitoring errors, and simultaneously only needs a common CCD camera to take pictures, thereby saving the cost of automatic welding equipment.
Description
Technical Field
The invention relates to the technical field of intelligent welding, in particular to a welding deviation measuring method and device and an automatic welding system.
Background
In the field construction of petrochemical industry, automatic welding of pipelines has been a hot point of research. The core problem of automatic pipeline welding lies in how to realize accurate tracking and guiding of pipeline welding seam, and then real-time control welding robot's welder orbit to satisfy welding quality's requirement.
The method for researching the weld tracking in the early stage is mainly based on probe contact sensing, electromagnetic sensing, ultrasonic sensing, arc sensing, infrared sensing and the like, and in recent years, the weld visual tracking has become a hot point for research in the intelligent welding industry because the visual sensing has the advantages of wide application range, no contact, high tracking precision and the like. Weld visual tracking techniques can be generally classified into two major categories, active visual sensing and passive visual sensing. The active visual sensing mainly adopts a method of combining a camera with a light source and combining a camera with structured light, and the method adopts an advanced monitoring mode, namely a certain forward-looking distance exists between a visual monitoring position and a welding position. The advanced monitoring has the advantages that the interference of arc light and welding slag splashing in the welding process can be effectively avoided by acquiring the image of the welding seam, the quality of the image of the welding seam is obviously improved, the defects that the shape change of a molten pool and the position of the welding seam cannot be observed in real time, and the advanced error is introduced into a welding seam visual tracking system, so that the welding seam visual tracking precision is not ideal enough. The passive visual sensing is to obtain a welding seam image by utilizing the highlight state of a molten pool or the reflection of arc light in the welding process, the method has the advantages of monitoring the molten pool and observing the position of the welding seam in real time, and no advanced monitoring error exists, but the arc light and welding slag splash very strongly in the welding process, so that the image obtained by the passive visual sensing mode is seriously interfered, and the accurate positioning of the tip position of the welding wire is difficult.
The key point of the real-time welding seam tracking technology is that the position information of the welding seam and the tip end of the welding wire can be obtained at the same time, and the deviation can be measured according to the relative position of the welding seam and the tip end of the welding wire. The common CCD camera has weak arc light resistance, cannot acquire clear images of the common CCD camera and the clear images of the common CCD camera at the same time, and the professional welding camera is expensive, so that the cost of the automatic welding equipment is increased, and the popularization and the application of the automatic welding equipment are not facilitated. After a large number of molten pool images collected by a common CCD camera are researched and analyzed, the welding gun outline in the molten pool images is clear and is easier to distinguish, so that a welding deviation determination method is provided for the characteristic of the welding gun outline, feasibility analysis is carried out on the method, and the method is necessary.
Disclosure of Invention
The invention mainly aims to provide a welding deviation measuring method, a welding deviation measuring device and an automatic welding system, and aims to solve the problem that the deviation measurement according to the relative position of a welding seam and a welding wire tip is difficult to accurately realize.
In order to achieve the above object, the present invention provides a welding deviation measuring method, including the steps of:
acquiring a first molten pool image and a second molten pool image, wherein the first molten pool image is a reference molten pool image;
respectively extracting welding gun position information and welding seam position information of the first molten pool image and the second molten pool image;
and calculating to obtain a welding deviation value according to the welding gun position information and the welding seam position information of the first molten pool image and the second molten pool image.
Optionally, the first weld puddle image and the second weld puddle image are weld puddle images taken by a welding gun at a swing limit position.
Optionally, the welding gun position information is welding gun outline information, and the welding seam position information is welding seam outline information;
the step of extracting the welding gun position information and the weld joint position information of the first molten pool image and the second molten pool image respectively includes:
and respectively extracting welding gun profile information and welding seam profile information of the first molten pool image and the second molten pool image.
Optionally, the step of calculating a welding deviation value according to the welding gun position information and the weld seam position information of the first molten pool image and the second molten pool image includes:
acquiring welding gun center position information and welding seam edge position information in the first molten pool image and the second molten pool image according to welding gun profile information and welding seam profile information of the first molten pool image and the second molten pool image;
calculating and obtaining the distance d between the center of the welding gun and the two edges of the welding seam in the first molten pool image according to the center position information and the edge position information of the welding gun in the first molten pool image and the second molten pool image
0And w
0Calculating and obtaining the distance d between the center of the welding gun and two edges of the welding seam in the second molten pool image as a reference position parameter
iAnd w
iAs measured position parameters;
and calculating to obtain the welding deviation value according to the reference position parameter and the measured position parameter.
Optionally, the step of calculating the welding deviation value according to the reference position parameter and the measured position parameter includes:
calculating to obtain the welding gun position deviation value D ═ D
i-d
0(ii) a And/or the presence of a gas in the gas,
the step of calculating the welding deviation value according to the reference position parameter and the measured position parameter comprises the following steps:
calculating to obtain the sum W of the distances between the center of the welding gun and the two edges of the welding seam in the reference image
0＝ d
0+w
0Calculating and obtaining the sum W of the distances between the center of the welding gun and the two edges of the welding seam in the second molten pool image as the reference oscillation amplitude value of the welding gun
i＝d
i+w
iCalculating to obtain the swing amplitude deviation of the welding gun as the measured swing amplitude value of the welding gunDifference W ═ W
i-W
0。
Optionally, the step of obtaining the welding gun center position information and the welding seam edge position information in the first molten pool image and the second molten pool image according to the welding gun profile information and the welding seam profile information of the first molten pool image and the second molten pool image includes:
sampling edge points of the welding gun profile and the welding seam profile in the first molten pool image and the second molten pool image to obtain a welding gun profile sampling point and a welding seam profile sampling point;
obtaining a curve equation of the welding gun profile by using a curve fitting algorithm on the welding gun profile sampling point, wherein the welding gun central position information comprises the central point position of the curve equation;
and performing linear fitting on the welding seam profile sampling points to obtain a linear equation of the welding seam profile, wherein the welding seam edge position information comprises the linear equation.
Optionally, the step of sampling edge points of the welding gun profile and the welding seam profile in the first molten pool image and the second molten pool image to obtain a welding gun profile sampling point and a welding seam profile sampling point includes:
selecting a target area in each molten pool image, wherein the target area comprises a welding gun outline, drawing a plurality of section lines in the target area, calculating a gray average value which is perpendicular to the section line direction and takes a unit pixel as an interval in the target area, and taking the gray average value as a gray value of a sampling point on the section line;
smoothing the plurality of section lines by using Gaussian filtering;
and (4) deriving the plurality of the section lines subjected to the smoothing treatment in the target area to obtain a derivative extreme value, and selecting a sampling point corresponding to the section line with the derivative extreme value larger than zero as a welding gun contour sampling point.
Optionally, the welding gun profile sampling points are fitted to form an arc, and a curve equation of the welding gun profile is an ellipse equation.
In order to achieve the above object, the present invention also provides a welding variation measuring apparatus including:
the visual acquisition device comprises a camera which is used for facing the molten pool so as to shoot a first molten pool image and a second molten pool image; and the number of the first and second groups,
a controller electrically connected to the vision acquisition device, the controller including a storage medium storing a welding deviation measurement program and a welding control program, wherein the welding deviation measurement program performs the steps of the welding deviation measurement method described above, and the welding control program performs the steps of: and performing deviation rectifying operation of automatic welding according to the welding deviation value.
In addition, to achieve the above object, the present invention further provides an automatic welding system, including:
a welding gun swingably mounted on the welding carriage;
the driving device is arranged on the welding vehicle and used for driving the welding gun to swing;
the visual acquisition device is arranged on the welding vehicle and comprises a camera which faces the molten pool so as to shoot a first molten pool image and a second molten pool image; and the number of the first and second groups,
a control device electrically connected to the drive device and the vision acquisition device, the control device including a processor and a storage medium, the storage storing a welding deviation measurement program and a welding control program, wherein the welding deviation measurement program performs the steps of the welding deviation measurement method as described above, and the welding control program performs the steps of: and performing deviation rectifying operation of automatic welding according to the welding deviation value.
The technical scheme provided by the invention comprises the steps of firstly photographing to obtain at least two molten pool images comprising a first molten pool image and a second molten pool image, then extracting welding gun position information and welding seam position information in the molten pool images, taking the first molten pool image as a reference molten pool image, taking the welding gun position information and the welding seam position information in the reference molten pool image as position references, calculating the deviation between the welding gun position information and the welding seam position information in the second molten pool image and the position references, then judging whether the deviation can meet the deviation requirement of welding seam tracking according to the actual experience of the existing welding seam tracking technology, if so, indicating that automatic welding based on welding seam tracking can be carried out according to the position deviation between a welding gun and a welding seam, and the technical scheme provided by the invention has the advantages of monitoring the molten pool and observing the welding seam position in real time and has no advanced monitoring error, meanwhile, only a common CCD camera is needed for shooting, so that the cost of automatic welding equipment is saved.
Drawings
In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings used in the description of the embodiments or the prior art will be briefly described below, it is obvious that the drawings in the following description are only some embodiments of the present invention, and for those skilled in the art, other drawings can be obtained according to the structures shown in the drawings without creative efforts.
FIG. 1 is a schematic representation of four representative weld puddle images of the weld deflection determination method of the present invention;
FIG. 2 is a schematic structural view of an embodiment of the welding deviation measuring apparatus according to the present invention;
FIG. 3 is a schematic diagram of an embodiment of an automated welding system of the present invention;
FIG. 4 is a schematic flow chart of a welding variation measuring method according to a first embodiment of the present invention;
FIG. 5 is a schematic flow chart of a welding variation measuring method according to a second embodiment of the present invention;
FIG. 6 is a schematic flow chart of a welding deviation measuring method according to a third embodiment of the present invention;
FIG. 7 is a schematic flow chart of a welding deviation measuring method according to a fourth embodiment of the present invention;
FIG. 8 is a schematic illustration of a first weld puddle image of the welding deviation determination method of the present invention;
FIG. 9 is a schematic flow chart of a second weld puddle image of the welding deviation determination method of the present invention;
FIG. 10 is a schematic flow chart of a fifth embodiment of the welding variation measuring method of the present invention;
FIG. 11 is a schematic flow chart of a welding variation measuring method according to a sixth embodiment of the present invention;
FIG. 12 is a schematic view showing data analysis of a welding deviation value according to the welding deviation measuring method of the present invention;
FIG. 13 is a schematic flow chart of a welding deviation measuring method according to a seventh embodiment of the present invention;
FIG. 14 is a schematic flowchart of an eighth embodiment of the welding variation measuring method of the present invention;
FIG. 15 is a diagram showing a distance distribution between a welding torch center and a welding wire in a weld pool image according to the method for verifying the measurement of welding deviation.
The reference numbers illustrate:
| reference numerals | Name (R) | Reference numerals | Name (R) |
| 100 | Welding |
200 | |
| 1 | |
4 | |
| 2 | |
5 | |
| 3 | |
6 | Camera head |
The implementation, functional features and advantages of the objects of the present invention will be further explained with reference to the accompanying drawings.
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 only a part of the embodiments of the present invention, and not all of the embodiments. 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.
It should be noted that, if directional indications (such as up, down, left, right, front, and back … …) are involved in the embodiment of the present invention, the directional indications are only used to explain the relative positional relationship between the components, the movement situation, and the like in a specific posture (as shown in the drawing), and if the specific posture is changed, the directional indications are changed accordingly.
In addition, if there is a description of "first", "second", etc. in an embodiment of the present invention, the description of "first", "second", etc. is for descriptive purposes only and is not to be construed as indicating or implying relative importance or implicitly indicating the number of technical features indicated. Thus, a feature defined as "first" or "second" may explicitly or implicitly include at least one such feature. In addition, the meaning of "and/or" appearing throughout includes three juxtapositions, exemplified by "A and/or B" including either A or B or both A and B. In addition, technical solutions between various embodiments may be combined with each other, but must be realized by a person skilled in the art, and when the technical solutions are contradictory or cannot be realized, such a combination should not be considered to exist, and is not within the protection scope of the present invention.
After research and analysis on a large number of weld pool images acquired by a common CCD camera, the weld joint features are obvious, the welding gun outline is clear, and the position and the motion track of the weld joint are consistent with those of the welding gun, so that a welding deviation measuring method for measuring the deviation amount through the outline of the welding gun and the relative position of the weld joint is required to be provided, and feasibility analysis is carried out on the method.
The main solution of the embodiment of the invention is to provide a welding deviation measuring method, which comprises the following steps:
acquiring a first molten pool image and a second molten pool image, wherein the first molten pool image is a reference molten pool image;
respectively extracting welding gun position information and welding seam position information of the first molten pool image and the second molten pool image;
and calculating to obtain a welding deviation value according to the welding gun position information and the welding seam position information of the first molten pool image and the second molten pool image.
According to the solution provided by the invention, at least two molten pool images comprising a first molten pool image and a second molten pool image are obtained by photographing, welding gun position information and welding seam position information in the molten pool images are extracted, the first molten pool image is taken as a reference molten pool image, the welding gun position information and the welding seam position information in the reference molten pool image are taken as position references, the deviation between the welding gun position information and the welding seam position information in the second molten pool image and the position references is calculated, whether the deviation can meet the deviation requirement of welding seam tracking or not is judged according to the actual experience of the existing welding seam tracking technology, and if the deviation meets the requirement, automatic welding based on welding seam tracking can be carried out according to the position deviation between a welding gun and a welding seam. Referring to fig. 1, the normal image, the dark image, the bright image and the splash image in the molten pool image are typical four molten pool images, and according to the observation of a large number of molten pool images, the welding gun profiles in the four molten pool images are clear and have obvious characteristics.
Based on the welding deviation measuring method provided by the invention, the invention provides a welding deviation measuring device 100, the welding deviation measuring device 100 comprises a visual collection device and a controller (not shown in the attached drawings), the visual collection device comprises a camera 6 facing a molten pool to shoot a first molten pool image and a second molten pool image, the controller is electrically connected with the visual collection device, the controller comprises a storage medium, and a welding deviation measuring program and a welding control program are stored in the storage medium, wherein the welding deviation measuring program executes the steps of the welding deviation measuring method provided by the embodiment of the invention, and the welding control program executes the steps of: and (5) performing deviation rectifying operation of automatic welding according to the welding deviation value.
Specifically, as shown in fig. 2, in the embodiment of the welding deviation measuring apparatus 100, the welding gun 1 is a circular section, so that the shape of the welding gun 1 is regular in the molten pool image, the welding wire 3 is installed in the center of the head of the welding gun 1, the camera 6 faces the welding gun 1 and the welding seam 4 and takes pictures for a plurality of times, the included angle between the camera 6 and the vertical direction is 60 degrees, so that an image with a large visual angle range and less interference between the welding gun 1 and the welding seam 4 can be obtained conveniently, the visual acquisition device sends the position information of the welding gun 1 and the position information of the welding seam 4 to the controller, the controller calculates the welding deviation according to the position information, and the steps of the welding deviation measuring method according to the embodiment of the present invention are completed through the above devices, wherein the welding control program can.
It will be understood by those skilled in the art that the welding deviation determination apparatus 100 shown in fig. 2 may be installed on an apparatus and system for automatic welding to perform deviation determination when actual automatic welding is performed, or may be installed in a laboratory in an arrangement specific to the welding deviation determination method of the embodiment of the present invention.
Those skilled in the art will also appreciate that the configuration of the weld variation determining apparatus 100 shown in FIG. 2 does not constitute a limitation of the weld variation determining apparatus 100, and may include more or fewer components than shown, or some components in combination, or a different arrangement of components.
Referring to fig. 4, a first embodiment of the welding deviation measuring method of the present invention includes:
s100: acquiring a first molten pool image and a second molten pool image, wherein the first molten pool image is a reference molten pool image;
in the step, the camera photographs the welding gun and the molten pool, the welding deviation needs to be obtained through comparison, so at least two images including a first molten pool image and a second molten pool image need to be obtained, wherein the first molten pool image is a reference molten pool image, the information provided in the image is reference information, the photographing time of the first molten pool image is before, the photographing time of the second molten pool image is after, for convenience of observation and comparison, each molten pool image can select an image with obvious and clear characteristics, in order to enhance the accuracy of deviation measurement, after the first molten pool image and the second molten pool image are obtained, a plurality of molten pool images can be additionally photographed, and the number of test samples is increased.
S200: respectively extracting welding gun position information and welding seam position information of the first molten pool image and the second molten pool image;
in the step, a coordinate system can be established in the molten pool image, and then the welding gun position information and the welding seam position information are expressed through a curve equation or a linear equation, and according to the observation of a large number of molten pool images, the outlines of the welding gun and the welding seam in the molten pool image are clear and have obvious characteristics, so that the common CCD camera can be applied to the welding deviation determination method, and the equipment cost is saved.
It should be noted that, in the process of automatic welding, the welding gun continuously swings, so that the welding wire at the head continuously swings at two edges of the welding seam to complete welding, and according to the requirements of the welding process, when the welding gun swings to the extreme position, the welding gun needs to pause to fully penetrate through the welded equipment.
S300: calculating to obtain a welding deviation value according to the welding gun position information and the welding seam position information of the first molten pool image and the second molten pool image;
in this step, the calculation may be performed through a curve equation or a straight line equation in step S200, so that the result is more accurate, and a preferable mode is to perform the calculation using the pixel value as a unit, so as to further improve the accuracy of the result. The calculation result of the welding deviation value is compared with the deviation range in the existing automatic welding method based on the welding seam tracking, and then whether the welding deviation value calculated according to the welding gun position information and the welding seam position information meets the requirement of the welding seam tracking can be judged.
It should be noted that, if the welding deviation value calculated according to the welding gun position information and the weld seam position information meets the requirement, it indicates that it is feasible to extract the welding gun position information from the weld pool image and finally implement the automatic welding method based on the weld seam tracking in real time. The automatic welding method can monitor the molten pool in real time, observe the position of the welding gun in the molten pool, has no advanced monitoring error, and further quickly tracks the welding seam and corrects the deviation of the welding gun in real time.
In the embodiment, at least two molten pool images including a first molten pool image and a second molten pool image are obtained by photographing, welding gun position information and welding seam position information in the molten pool images are extracted, the first molten pool image is used as a reference molten pool image, the welding gun position information and the welding seam position information in the reference molten pool image are used as position references, deviation between the welding gun position information and the welding seam position information in the second molten pool image and the position references is calculated, whether the deviation can meet deviation requirements of welding seam tracking or not is judged according to actual experience of an existing welding seam tracking technology, and if the deviation can meet the deviation requirements, automatic welding based on welding seam tracking can be carried out according to the position deviation between a welding gun and a welding seam.
Further, referring to fig. 5, a second embodiment of the welding deviation measuring method according to the present invention is based on the first embodiment, in which the welding gun position information is welding gun profile information, and the bead position information is bead profile information, and step S200 includes:
s201: and respectively extracting welding gun profile information and welding seam profile information of the first molten pool image and the second molten pool image.
In this step, please refer to fig. 1, it is found through a large number of observations that the welding gun profile and the weld profile in each molten pool image have obvious characteristics, are easy to distinguish, are not easy to be interfered, and are very stable as a test sample, and both are regular images, which is beneficial to the subsequent calculation processing. In the embodiment, the local enhancement and the image closing operation can be performed on the welding gun profile and the welding seam profile in each molten pool image, so that the profile is clearer and the boundary is smoother. In this embodiment, a welding deviation value is calculated and obtained according to the welding gun profile information and the weld bead profile information of the first molten pool image and the second molten pool image.
Further, referring to fig. 6, a third embodiment of the welding deviation measuring method according to the present invention is proposed based on the aforementioned second embodiment, and in this embodiment, step S300 includes:
s310: and acquiring the central position information and the edge position information of the welding gun in the first molten pool image and the second molten pool image according to the welding gun profile information and the welding seam profile information of the first molten pool image and the second molten pool image.
In the step, the welding gun profile is found to be very regular and stable through a large amount of observation of each molten pool image, and the characteristic is obvious.
S320: calculating and obtaining the distance d between the center of the welding gun and the two edges of the welding seam in the first molten pool image according to the center position information and the edge position information of the welding gun in the first molten pool image and the second molten pool image
0And d
iCalculating and obtaining the distance w between the center of the welding gun and two edges of the welding seam in the second molten pool image as a reference position parameter
0And w
iAs measured position parameters;
in the step, the distance between the center of the welding gun and the two edges of the welding seam is used as a position parameter for calculation, and the sum of the distances between the center of the welding gun and the two edges of the welding seam is the swing amplitude of the welding gun. Referring to fig. 8 and 9, fig. 7 is a schematic diagram of a first molten pool image, fig. 8 is a schematic diagram of a second molten pool image, two edges of a welding seam are an upper edge and a lower edge respectively, a cylindrical welding gun is in an elliptic arc shape in the molten pool image due to the view angle of a camera, the welding seam is approximate to a trapezoid in the image, so that the welding seam can be seen as a trapezoid in a short distance, and the distance between the center of the welding gun and the upper edge is d in the first molten pool image and the second molten pool image respectively
0And d
iThe distance between the center and the lower edge of the welding gun is w
0And w
iWith d
0And d
iAs a parameter required for calculation, d
0And d
iThe difference value is the deviation value of the welding gun in the welding process (of course, w can also be used
0And w
iAs a parameter required for calculation). In the automatic welding process, when the welding gun deviates, the moving path of the welding gun deviates from the welding line, and at the moment, the welding gun can be controlled to return to the correct position according to the deviation value of the position of the welding gun, or the swing amplitude of the welding gun is controlled to offset the position deviation, or the two modes are implemented simultaneously, so that the precision of automatic welding is finally improved.
It should be noted that, in the present embodiment, the calculation is performed in units of pixel numbers, so that the calculation is faster and more accurate.
S330: and calculating to obtain the welding deviation value according to the reference position parameter and the measured position parameter.
In the embodiment, the distance between the center of the welding gun and the two edges of the welding seam can be clearly and simply obtained in each molten pool image, so that the swing amplitude of the welding gun and the position deviation of the welding gun can be further obtained, and in the automatic welding process, when the position of the welding gun is deviated, the welding gun can be controlled to return to the correct position according to the deviation value of the position of the welding gun, or the swing amplitude of the welding gun can be controlled to offset the position deviation, or the two modes are simultaneously implemented, so that the precision of automatic welding is finally improved.
Further, referring to fig. 7, a fourth embodiment of the welding deviation measuring method according to the present invention is proposed based on the aforementioned third embodiment, and in this embodiment, step S330 includes:
s331: calculating to obtain the welding gun position deviation value D ═ D
i-d
0。
In the step, the deviation of the position of the welding gun in the second molten pool image relative to the position of the welding gun in the reference image is obtained, and in the automatic welding process, when the position of the welding gun is deviated, the welding gun can be controlled to return to the correct position according to the deviation value of the position of the welding gun, so that the automatic welding is completed.
Further, in this embodiment, in addition to the first molten pool image and the second molten pool image, a plurality of molten pool images satisfying the test requirements are obtained, calculating a welding deviation value in each molten pool image, performing data analysis on the obtained multiple welding deviation values, wherein the abscissa represents different molten pool images, and the ordinate represents corresponding welding deviation values, referring to the upper two data analysis graphs in FIG. 12, which are welding gun position deviation data analysis results, in the welding deviation measuring apparatus 100 that has completed the embodiment of the welding deviation measuring method, the welding torch is in a free movement state, the width of the weld is uniform, the moving path of the welding carriage is not parallel to the weld, and the welding gun gradually deviates, and the welding gun gradually deviates along with the welding vehicle in the same direction, so that the reliability of the welding gun position deviation measurement by the welding deviation measurement method is verified.
Alternatively, referring to fig. 10, a fifth embodiment of the welding variation measuring method according to the present invention is proposed based on the third embodiment, and in this embodiment, step S330 includes:
s332: calculating to obtain the sum W of the distances between the center of the welding gun and the two edges of the welding seam in the reference image
0＝d
0+w
0Calculating and obtaining the sum W of the distances between the center of the welding gun and the two edges of the welding seam in the second molten pool image as the reference oscillation amplitude value of the welding gun
i＝d
i+w
iCalculating the welding gun swing amplitude deviation value W as the measured swing amplitude value of the welding gun
i-W
0。
In the step, the deviation of the welding gun swing amplitude in the second molten pool image to the welding gun swing amplitude in the reference image is obtained, and in the automatic welding process, when the welding gun position is deviated, the swing amplitude of the welding gun can be controlled, so that the limit position of the welding gun can be correctly stopped at the two edges of the welding line, and the automatic welding is further completed.
Further, referring to the data analysis diagram at the bottom in fig. 12, as a result of analyzing the welding gun swing deviation data, in the welding deviation measuring apparatus 100 that completes the embodiment of the welding deviation measuring method, the welding gun is in a free movement state, the width of the weld is uniform, the moving path of the welding vehicle is not parallel to the weld, and gradually shifts, in this embodiment, a plurality of weld pool images are obtained, and the range W of the welding gun swing deviation value can be calculated from the diagram
rIs (W)
min-W
0)≤W
r≤(W
max-W
0) The welding gun swing amplitude deviation value in each molten pool image is substituted and calculated to obtain the range of W which is more than or equal to-0.207 mm
rThe welding deviation measuring method is less than or equal to 0.205mm, the numerical value is small and stable, and the reliability of the welding deviation measuring method for measuring the swing deviation value of the welding gun is verified.
Further, referring to fig. 11, a sixth embodiment of the welding deviation measuring method according to the present invention is proposed based on the third embodiment, in which the measurement of the torch position deviation value and the torch swing deviation value is performed simultaneously, and step S330 includes:
s331: calculating to obtain the welding gun position deviation value D ═ D
i-d
0；
S332: calculating to obtain the center of the welding gun and two edges of the welding line in the reference imageThe sum of the distances W between
0＝d
0+w
0Calculating and obtaining the sum W of the distances between the center of the welding gun and the two edges of the welding seam in the second molten pool image as the reference oscillation amplitude value of the welding gun
i＝d
i+w
iCalculating the welding gun swing amplitude deviation value W as the measured swing amplitude value of the welding gun
i-W
0。
In the embodiment, the welding gun can be controlled to return to the correct position according to the deviation value of the welding gun position, and the swing amplitude of the welding gun is controlled to offset the position deviation, so that the limit positions of the welding gun can be correctly stopped at the two edges of the welding line, and finally, the precision of automatic welding is improved.
Further, referring to fig. 13, a seventh embodiment of the welding deviation measuring method according to the present invention is proposed based on the aforementioned third embodiment, and in this embodiment, step S310 includes:
s311: sampling edge points of the welding gun profile and the welding seam profile in the first molten pool image and the second molten pool image to obtain a welding gun profile sampling point and a welding seam profile sampling point;
s312: obtaining a curve equation of the welding gun profile by using a curve fitting algorithm on the welding gun profile sampling point, wherein the welding gun central position information comprises the central point position of the curve equation;
s313: and performing linear fitting on the welding seam profile sampling points to obtain a linear equation of the welding seam profile, wherein the welding seam edge position information comprises the linear equation.
In this embodiment, because of the influence of the change of arc brightness and the spattering of the welding slag, the position information of the welding seam and the welding gun is interfered in the weld pool image, and in order to eliminate the interference, in this embodiment, edge point sampling is performed on the contour of the welding seam and the welding gun, so that the stability of each weld pool image when being used for extracting the contour characteristics of the welding seam and the welding gun is improved.
Further, according to the welding deviation measuring device 100 of the embodiment of the present invention, the welding gun is in a circular cross section, and the included angle between the camera and the vertical direction is 60 °, so that the welding gun presents an elliptical arc segment in the molten pool image, and a curve fitting algorithm is applied to the welding gun contour sampling point to obtain a curve equation of the welding gun contour as an elliptical equation, where a central point of the elliptical equation is a central point of the welding gun.
Further, referring to fig. 14, an eighth embodiment of the welding variation measuring method according to the present invention is proposed based on the seventh embodiment, and in this embodiment, step S311 includes:
s311 a: selecting a target area in each molten pool image, wherein the target area comprises a welding gun outline, drawing a plurality of section lines in the target area, calculating a gray average value which is perpendicular to the section line direction and takes a unit pixel as an interval in the target area, and taking the gray average value as a gray value of a sampling point on the section line;
s311 b: smoothing the plurality of section lines by using Gaussian filtering;
s311 c: and (4) deriving the plurality of the section lines subjected to the smoothing treatment in the target area to obtain a derivative extreme value, and selecting a sampling point corresponding to the section line with the derivative extreme value larger than zero as a welding gun contour sampling point.
In this embodiment, taking a welding gun profile sampling point as an example, it is obvious that the welding seam profile sampling point can also be implemented through the above steps, and a target area of the welding seam profile sampling point is selected as a part including the welding seam profile, so that the accuracy and the stability of the sampling point are enhanced in this embodiment.
Furthermore, in the welding deviation measuring method, the welding gun contour sampling points and the welding seam contour sampling points are screened through a clustering algorithm, so that interference on the sampling points is further eliminated, and the fitting precision of the welding gun contour and the welding seam contour is improved. The core step of the clustering algorithm is the discrimination of objects of the same type, the quality of discrimination condition design determines the grouping precision, two characteristics of distance and direction in Euclidean geometry are used in the clustering algorithm, and a threshold value is set by combining the distribution rule of each edge sampling point to discriminate whether the two objects are the same subset.
Taking a welding gun contour sampling point as an example, two welding gun edge sampling points A (x) are set
1,y
1)，B(x
2,y
2) When A, B satisfies the condition:
a, B is the same subset. Wherein D
TA, B is the distance threshold between two points, θ
TA, B is the angle threshold between the two points. The clustering algorithm is realized by the following steps:
1. the algorithm starts, and welding gun contour sampling points are read line by line;
2. the number of the first row of sampling points is n, then C is created
1，C
2，…，C
nA subset of cells, denoted as C
i；
3. Reading the second row of sampling points, and calculating and C by using a formula (6) one by one
iIf the condition is satisfied, the attribution relationship of (A) is C
iMembers of the subset, with C
iNone of which satisfies the condition, and then the subset C is re-created
(n+1)By analogy, the new subset is C
(n+2)，C
(n+3)…, also denoted as C
i；
4. Reading sampling points in the ith row and executing the operation in the step 2;
5. and (5) reading sampling points and finishing the algorithm after the calculation is finished.
Further, in the welding variation measuring method according to the embodiment of the present invention, the following verification method is proposed for the welding variation measured value:
acquiring welding gun center position information and welding seam edge position information in the first molten pool image and the second molten pool image according to welding gun profile information and welding seam profile information of the first molten pool image and the second molten pool image; according to the welding gun center position information and the welding wire position information in the first molten pool image and the second molten pool image; calculating and obtaining the distance d between the center of the welding gun and the welding wire according to the position information of the center of the welding gun and the position information of the welding wire
p。
In order to further improve the reliability of verification, in the verification method, 50 molten pool images capable of simultaneously extracting position information of a welding gun and a welding wire are selected, then the distance dp (p is 1,2, 50) between the center of the welding gun and the welding wire in each molten pool image is calculated, referring to fig. 14, the distance dp is a distribution diagram of the distance dp, the range of dp is more than or equal to 0 and less than or equal to 0.2mm in the selected 50 molten pool images, and according to the experience of the automatic welding field, the range meets the deviation range of automatic welding, which indicates that the welding deviation determination method has higher reliability.
Based on the test results of the welding deviation measuring method of the embodiment of the invention, the invention also provides an automatic welding system 200, the automatic welding system 200 comprises a welding gun 1, a driving device 5, a vision collecting device and a control device, wherein the welding gun 1 is arranged on a welding vehicle 2 in a swinging way, the driving device 5 is arranged on the welding vehicle 2, used for driving the welding gun 1 to swing, the vision acquisition device is arranged on the welding vehicle 2 and comprises a camera 6 used for facing the molten pool, so as to obtain a first molten pool image and a second molten pool image by shooting, the control device is electrically connected with the driving device 5 and the vision acquisition device, the control device comprises a processor and a storage medium, the storage device is stored with a welding deviation measuring program and a welding control program, wherein the welding deviation measurement program executes the steps of the welding deviation measurement method as described above, and the welding control program executes the steps of: and (5) performing deviation rectifying operation of automatic welding according to the welding deviation value.
While the automated welding system 200 of the present embodiment is shown in fig. 3 as being arranged and installed based on the weld aberration determination apparatus 100, those skilled in the art will appreciate that the configuration of the automated welding system 200 shown in fig. 3 is not intended to be limiting of the automated welding system 200, and in other embodiments, the automated welding system 200 may include more or fewer components than shown, or some components may be combined, or a different arrangement of components.
The automatic welding system 200 of the embodiment of the invention has the advantages of real-time monitoring of the molten pool and observation of the position of the welding seam, has no advanced monitoring error, and simultaneously only needs a common CCD camera to take a picture, thereby saving the cost of automatic welding equipment.
The above description is only a preferred embodiment of the present invention, and is not intended to limit the scope of the present invention, and all modifications and equivalents of the present invention, which are made by the contents of the present specification and the accompanying drawings, or directly/indirectly applied to other related technical fields, are included in the scope of the present invention.
Claims (10)
1. A welding deviation measuring method is characterized by comprising the following steps:
acquiring a first molten pool image and a second molten pool image, wherein the first molten pool image is a reference molten pool image;
respectively extracting welding gun position information and welding seam position information of the first molten pool image and the second molten pool image;
and calculating to obtain a welding deviation value according to the welding gun position information and the welding seam position information of the first molten pool image and the second molten pool image.
2. The welding deviation measuring method according to claim 1, wherein the first weld puddle image and the second weld puddle image are weld puddle images taken with the welding gun at the oscillation limit position.
3. The welding deviation measuring method according to claim 1, wherein the welding gun position information is welding gun profile information, and the weld position information is weld profile information;
the step of extracting the welding gun position information and the weld joint position information of the first molten pool image and the second molten pool image respectively includes:
and respectively extracting welding gun profile information and welding seam profile information of the first molten pool image and the second molten pool image.
4. The welding deviation measuring method according to claim 3, wherein the step of calculating the welding deviation value based on the gun position information and the bead position information of the first weld puddle image and the second weld puddle image includes:
acquiring welding gun center position information and welding seam edge position information in the first molten pool image and the second molten pool image according to welding gun profile information and welding seam profile information of the first molten pool image and the second molten pool image;
calculating and obtaining the distance d between the center of the welding gun and the two edges of the welding seam in the first molten pool image according to the center position information and the edge position information of the welding gun in the first molten pool image and the second molten pool image
0And w
0Calculating and obtaining the distance d between the center of the welding gun and two edges of the welding seam in the second molten pool image as a reference position parameter
iAnd w
iAs measured position parameters;
and calculating to obtain the welding deviation value according to the reference position parameter and the measured position parameter.
5. The welding deviation determination method of claim 4, wherein said welding deviation value comprises a welding torch position deviation value, and said step of calculating said welding deviation value based on said reference position parameter and said determined position parameter comprises:
calculating to obtain the welding gun position deviation value D ═ D
i-d
0(ii) a And/or the presence of a gas in the gas,
the step of calculating the welding deviation value according to the reference position parameter and the measured position parameter comprises the following steps:
calculating to obtain the sum W of the distances between the center of the welding gun and the two edges of the welding seam in the reference image
0＝d
0+w
0Calculating and obtaining the sum W of the distances between the center of the welding gun and the two edges of the welding seam in the second molten pool image as the reference oscillation amplitude value of the welding gun
i＝d
i+w
iCalculating the welding gun swing amplitude deviation value W as the measured swing amplitude value of the welding gun
i-W
0。
6. The welding deviation measuring method according to claim 4, wherein the step of acquiring the gun center position information and the bead edge position information in the first weld puddle image and the second weld puddle image on the basis of the gun contour information and the bead contour information in the first weld puddle image and the second weld puddle image includes:
sampling edge points of the welding gun profile and the welding seam profile in the first molten pool image and the second molten pool image to obtain a welding gun profile sampling point and a welding seam profile sampling point;
obtaining a curve equation of the welding gun profile by using a curve fitting algorithm on the welding gun profile sampling point, wherein the welding gun central position information comprises the central point position of the curve equation;
and performing linear fitting on the welding seam profile sampling points to obtain a linear equation of the welding seam profile, wherein the welding seam edge position information comprises the linear equation.
7. The welding deviation measuring method according to claim 6, wherein the step of sampling the edge points of the gun profile and the bead profile in the first weld puddle image and the second weld puddle image to obtain a gun profile sampling point and a bead profile sampling point includes:
selecting a target area in each molten pool image, wherein the target area comprises a welding gun outline, drawing a plurality of section lines in the target area, calculating a gray average value which is perpendicular to the section line direction and takes a unit pixel as an interval in the target area, and taking the gray average value as a gray value of a sampling point on the section line;
smoothing the plurality of section lines by using Gaussian filtering;
and (4) deriving the plurality of the section lines subjected to the smoothing treatment in the target area to obtain a derivative extreme value, and selecting a sampling point corresponding to the section line with the derivative extreme value larger than zero as a welding gun contour sampling point.
8. The welding deviation determination method according to claim 6, wherein the welding torch profile sampling points are fitted to an arc, and the curve equation of the welding torch profile is an ellipse equation.
9. A welding deviation measuring device is characterized by comprising:
the visual acquisition device comprises a camera which is used for facing the molten pool so as to shoot a first molten pool image and a second molten pool image; and the number of the first and second groups,
a controller electrically connected to the vision acquisition device, the controller including a storage medium storing a welding deviation measurement program and a welding control program, wherein the welding deviation measurement program performs the steps of the welding deviation measurement method of claims 1-8, and the welding control program performs the steps of: and performing deviation rectifying operation of automatic welding according to the welding deviation value.
10. An automated welding system, comprising:
a welding gun swingably mounted on the welding carriage;
the driving device is arranged on the welding vehicle and used for driving the welding gun to swing;
the visual acquisition device is arranged on the welding vehicle and comprises a camera which faces the molten pool so as to shoot a first molten pool image and a second molten pool image; and the number of the first and second groups,
a control device electrically connected to the drive device and the vision acquisition device, the control device including a processor and a storage medium, the storage storing a welding deviation measurement program and a welding control program, wherein the welding deviation measurement program performs the steps of the welding deviation measurement method of claims 1-8, and the welding control program performs the steps of: and performing deviation rectifying operation of automatic welding according to the welding deviation value.
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