CN111185664A - Monocular vision-based laser cutting follow-up system and method - Google Patents
Monocular vision-based laser cutting follow-up system and method Download PDFInfo
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- CN111185664A CN111185664A CN202010099314.7A CN202010099314A CN111185664A CN 111185664 A CN111185664 A CN 111185664A CN 202010099314 A CN202010099314 A CN 202010099314A CN 111185664 A CN111185664 A CN 111185664A
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- 238000003698 laser cutting Methods 0.000 title claims abstract description 29
- 238000000034 method Methods 0.000 title claims abstract description 27
- 238000005520 cutting process Methods 0.000 claims abstract description 63
- 230000007246 mechanism Effects 0.000 claims abstract description 28
- 238000001514 detection method Methods 0.000 claims abstract description 22
- 230000005540 biological transmission Effects 0.000 claims abstract description 14
- 230000008569 process Effects 0.000 claims description 10
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- 238000006243 chemical reaction Methods 0.000 claims description 2
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- 238000003708 edge detection Methods 0.000 claims 1
- 239000007769 metal material Substances 0.000 abstract description 5
- 230000000694 effects Effects 0.000 abstract description 4
- 239000002184 metal Substances 0.000 abstract description 4
- 229910052755 nonmetal Inorganic materials 0.000 abstract description 4
- 238000005259 measurement Methods 0.000 description 4
- 238000010586 diagram Methods 0.000 description 3
- 238000006073 displacement reaction Methods 0.000 description 2
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- 230000004048 modification Effects 0.000 description 2
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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
- B23K26/02—Positioning or observing the workpiece, e.g. with respect to the point of impact; Aligning, aiming or focusing the laser beam
- B23K26/04—Automatically aligning, aiming or focusing the laser beam, e.g. using the back-scattered light
- B23K26/046—Automatically focusing the laser beam
- B23K26/048—Automatically focusing the laser beam by controlling the distance between laser head and workpiece
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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
- B23K26/36—Removing material
- B23K26/38—Removing material by boring or cutting
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Abstract
The utility model discloses a laser cutting follow-up system and a method based on monocular vision, which comprises a detection module, a terminal, a driving mechanism, a transmission mechanism and a cutting head; the detection module comprises a CCD camera and a laser, the CCD camera is connected with the terminal through an interface module, and the CCD camera collects a light spot image after the light spot is emitted to the processed workpiece through the laser; the driving mechanism comprises a servo motor and a driver, the transmission mechanism comprises a coupler and a linear motion unit, the driver is connected with the terminal through a system bus, the servo motor is connected with the linear motion unit through the coupler, and the linear motion unit drives the cutting head to move up and down. The method is suitable for cutting metal and non-metal materials, solves the problem that the cutting quality is influenced by the uneven and deformed surface of the machined workpiece, and improves the cutting effect and the cutting efficiency.
Description
Technical Field
The disclosure relates to the technical field of laser cutting, in particular to a laser cutting follow-up system and method based on monocular vision.
Background
The statements in this section merely provide background information related to the present disclosure and may not necessarily constitute prior art.
In the laser cutting process, because the surface of the workpiece to be processed fluctuates, the gap between the nozzle of the cutting head and the workpiece can change greatly, and if the height of the surface of the cutting head and the surface of the workpiece are kept unchanged, the cutting quality cannot be ensured. Therefore, the positions of the laser focus of the cutting head and the surface of a processed workpiece need to be detected in real time in the processing process, the cutting head is controlled to synchronously move up and down along with the fluctuation of the surface of the processed workpiece, the working distance of the cutting head is ensured to be basically constant, and the function of a cutting head follow-up system is realized.
At present, a servo system of a laser cutting head is mainly divided into a contact type mode and a non-contact detection mode. However, the inventors found that at least the following problems exist in the prior art: the laser cutting head servo system based on the contact sensor cannot process complex curved surface workpieces, has the problem of contact wear and is low in efficiency. The non-contact detection method based on the capacitance displacement sensor is mainly used for cutting metal materials, has high detection precision and simple structure, and is difficult to acquire signals due to the influence of noise disturbance such as temperature fluctuation, optical flame sputtering, surface foreign matters and the like. Based on the non-contact detection method of the laser displacement sensor, certain measurement accuracy can be kept in continuous measurement, and the method only utilizes part of reflected light energy to reduce the measurement sensitivity.
Disclosure of Invention
In order to solve the problems, the invention provides a laser cutting follow-up system and a laser cutting follow-up method based on monocular vision, the distance between a cutting head and the surface of a processed workpiece is measured based on a monocular vision measuring method, a driving mechanism drives a transmission mechanism to do linear motion, so that the cutting head is driven to do lifting motion, the positions of the cutting head and the surface of the processed workpiece can be quickly adjusted, the laser cutting follow-up system is suitable for cutting metal and non-metal materials, the problem that the surface of the processed workpiece is uneven and deformed to influence the cutting quality is solved, and the cutting effect and the cutting efficiency are improved.
In order to achieve the purpose, the following technical scheme is adopted in the disclosure:
in a first aspect, the present disclosure provides a monocular vision-based laser cutting follow-up system comprising: the device comprises a detection module, a terminal, a driving mechanism, a transmission mechanism and a cutting head;
the detection module comprises a CCD camera and a laser, the CCD camera is connected with the terminal through an interface module, and the CCD camera collects a light spot image after the light spot is emitted to the processed workpiece through the laser;
the driving mechanism comprises a servo motor and a driver, the transmission mechanism comprises a coupler and a linear motion unit, the driver is connected with the terminal through a system bus, the servo motor is connected with the linear motion unit through the coupler, and the linear motion unit drives the cutting head to move up and down.
In a second aspect, the present disclosure provides a monocular vision-based laser cutting follow-up method, comprising:
the method comprises the steps that a CCD camera collects a light spot image after a laser emits light spots to a machined workpiece, and light spot pixel calibration is carried out on the light spot image according to the horizontal distance between the CCD camera and the laser and the initial height between the laser and the machined workpiece, so that a light spot pixel calibration value is obtained;
the terminal receives and processes the spot image acquired in the cutting process, obtains the number of spot pixels according to the determined spot centroid, and obtains the actual height between the laser and the workpiece to be processed according to the number of spot pixels and the calibration value of the spot pixels;
and driving the cutting head to perform lifting motion according to the difference value between the initial height and the actual height of the laser and the processed workpiece.
Compared with the prior art, the beneficial effect of this disclosure is:
the cutting follow-up system can quickly adjust the distance between the cutting head and the surface of a machined workpiece, and is simple in structure, wide in adjusting range, high in response speed and high in detection precision.
The cutting follow-up system disclosed by the invention realizes the position detection of the cutting head and the surface of a processed workpiece by utilizing a monocular vision measurement method, drives the transmission mechanism to do linear motion through the driving mechanism, so as to drive the cutting head to do lifting motion, can quickly adjust the positions of the cutting head and the surface of the processed workpiece, can adapt to the cutting of metal and non-metal materials with different thicknesses, solves the problem that the surface of the processed workpiece is uneven and deformed to influence the cutting quality, and improves the cutting effect and the cutting efficiency.
Drawings
The accompanying drawings, which are included to provide a further understanding of the disclosure, illustrate embodiments of the disclosure and together with the description serve to explain the disclosure and are not to limit the disclosure.
Fig. 1 is a block diagram of a monocular vision-based laser cutting follow-up system provided in embodiment 1 of the present disclosure;
fig. 2 is a structural diagram of a transmission mechanism of a laser cutting follow-up system provided in embodiment 1 of the present disclosure;
fig. 3 is a flowchart of a laser cutting follow-up system provided in embodiment 2 of the present disclosure;
fig. 4 is a schematic diagram of monocular based visual ranging provided in embodiment 2 of the present disclosure;
the automatic cutting machine comprises a platform 1, a processing workpiece 2, a cutting head 3, a transmission mechanism 4, a driving mechanism 5, a detection module 6, a computer terminal 7, a CCD camera 8, a filter 9, a laser 10, a light shield 11, a servo motor 12, a driver 13, an encoder 14, a coupler 15 and a linear motion unit 16.
The specific implementation mode is as follows:
the present disclosure is further described with reference to the following drawings and examples.
It should be noted that the following detailed description is exemplary and is intended to provide further explanation of the disclosure. Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this disclosure belongs.
It is noted that the terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of example embodiments according to the present disclosure. As used herein, the singular forms "a", "an" and "the" are intended to include the plural forms as well, and it should be understood that when the terms "comprises" and/or "comprising" are used in this specification, they specify the presence of stated features, steps, operations, devices, components, and/or combinations thereof, unless the context clearly indicates otherwise.
Example 1
As shown in fig. 1, the present embodiment provides a monocular vision-based laser cutting follow-up system, including: the cutting machine comprises a cutting head 3, a transmission mechanism 4, a driving mechanism 5, a detection module 6 and a computer terminal 7;
the transmission mechanism 4 comprises a coupler 15 and a linear motion unit 16; the driving mechanism 5 comprises a servo motor 12, a driver 13 and an encoder 14 and is used for driving the transmission mechanism 4;
the servo motor 12 is connected with a linear motion unit 16 through a coupling 15, the linear motion unit 16 drives the cutting head 3 to realize lifting motion, and as shown in fig. 2, in the embodiment, the linear motion unit adopts a ball screw motion unit;
the encoder 14 is installed at the tail of the motor and feeds back the current running position of the motor in real time to form a closed-loop control system.
The detection module 6 comprises a CCD camera 8, a filter 9, a laser 10 and a light shield 11, and realizes the position detection function;
in the present embodiment, the CCD camera 8 is equipped with an industrial camera; the laser 10 emits a red dot laser spot with a fixed wavelength to the surface of the processing workpiece 2; the filter 9 is a narrow-band filter with fixed wavelength and is arranged in front of the lens of the CCD camera 8, and light with the wavelength emitted by the laser 10 is reserved to enter, so that light interference in the processing process can be avoided to a certain extent; the light shield 11 is used for avoiding external interference with the light source; in this embodiment, an industrial camera with a lens focal length of 50mm and a resolution of 130 ten thousand pixels, a 650nm red laser and a 650nm narrow-band filter are selected, the detection module of this embodiment adopts a light shield and a filter to avoid an external interference light source, and separates background light from a laser source for detection, thereby effectively ensuring the stability and reliability of the detection light source.
In the embodiment, a sliding block is arranged on one side of a cutting head, the sliding block and the cutting head are at the same height, and a laser and a CCD camera are arranged on the sliding block; the horizontal distance of the laser 10 from the CCD camera 8 is kept constant, and the horizontal distance of the laser 10 from the cutting head 3 is adjusted to be within a range of 1-2 cm before the cutting process.
The computer terminal 7 controls the transmission mechanism to drive the cutting head 3 to move up and down after completing laser spot image CCD acquisition and monocular vision distance measurement processing;
the CCD camera is connected with the terminal through an interface module, and the driver is connected with the terminal through a system bus; in the present embodiment, the driver 13 of the drive mechanism 5 is connected to the computer terminal 7 through a PCI bus, and the CCD camera 8 is connected to the computer terminal 7 through a network port.
Example 2
As shown in fig. 3, the present embodiment provides a monocular vision-based laser cutting follow-up method, including:
(1) the method comprises the steps that a CCD camera collects a light spot image after a laser emits light spots to a machined workpiece, and light spot pixel calibration is carried out on the light spot image according to the horizontal distance between the CCD camera and the laser and the initial height between the laser and the machined workpiece, so that a light spot pixel calibration value is obtained;
(2) after the calibration is finished, starting workpiece cutting machining; the terminal receives and processes the spot image acquired in the cutting process, obtains the number of spot pixels according to the determined spot centroid, and obtains the actual height between the laser and the workpiece to be processed according to the number of spot pixels and the calibration value of the spot pixels;
(3) driving a cutting head to perform lifting motion according to the difference value between the initial height and the actual height of the laser and the processed workpiece;
(4) and (5) repeating the step (2-3) until the workpiece is cut and machined.
The step (1) further comprises system self-checking and initialization, specifically comprising:
(1.1) checking circuits of a driver and a CCD (charge coupled device) camera to ensure normal communication with a computer terminal, adjusting the distance between the cutting head and the surface of a processed workpiece to a set height, adjusting the position of a detection module, and enabling a light spot emitted by a laser to be within 1-2 cm of the cutting head;
(1.2): accurately measuring horizontal distance D between CCD camera and laser, and measuring initial height value H of laser from surface of workpiece to be machined0；
(1.3): initializing a system: configuring an IP address of a CCD camera and an IP address of a computer terminal to ensure that the CCD camera and the computer terminal are in the same network segment;
as shown in fig. 4, based on the monocular visual ranging principle, the process of performing cursor pixel calibration is as follows:
(2.1): collecting a light spot image of a CCD laser, and obtaining the number N of light spot pixels after image processing;
(2.2): measuring an initial height value H of the distance between the surface of the machined workpiece and the laser;
(2.3): calculating the radian value and the radian error of each pixel according to a formula for calculating the calibration value of the spot pixel;
the formula of the spot pixel calibration value is as follows:
θ＝N×Ar+F (2)
in the above formula, D is the horizontal distance between the CCD camera and the laser, H is the initial height between the laser and the workpiece to be processed, Ar is the radian value of each pixel, F is the radian error, N is the number of spot pixels, and θ is the angle;
substituting the values of H and D into the formula (1) to calculate theta; substituting the theta and the N into the formula (2) to obtain an equation set of Ar and F;
(2.4): adjusting the distance between the laser and the surface of the processed workpiece, measuring the accurate value of H for multiple times, and repeating the step (2.3);
(2.5): and (3) solving Ar and F through a plurality of equation sets of the formula (2), and taking the average value of Ar and F as a light spot pixel calibration value.
The actual height calculation process includes:
(3.1): the terminal performs gray level conversion on the light spot image acquired in the cutting process and converts the light spot image into a gray level image;
(3.2): smoothing the gray level image, and detecting the light spot edge by adopting a Canny edge algorithm;
(3.3): determining a light spot profile, and calculating a profile moment;
(3.4): calculating the centroid of the light spot, and obtaining the number of light spot pixels according to the centroid of the light spot;
(3.5): and (3) calculating the actual height value of the laser and the processed workpiece according to the number of the light spot pixels and the calibration value of the light spot pixels by using the formula (1) and the formula (2).
The embodiment utilizes the monocular vision measuring method to realize the position detection of the surfaces of the cutting head and the machined workpiece, can adapt to the cutting of metal and non-metal materials with different thicknesses, well solves the problem that the surface of the machined workpiece is uneven and deformed to influence the cutting quality, improves the cutting effect and the cutting efficiency, is applied to the aspect of laser cutting machining, and has the advantages of higher automation degree, simple operation and easy implementation.
The above is merely a preferred embodiment of the present disclosure and is not intended to limit the present disclosure, which may be variously modified and varied by those skilled in the art. Any modification, equivalent replacement, improvement and the like made within the spirit and principle of the present disclosure should be included in the protection scope of the present disclosure.
Although the present disclosure has been described with reference to specific embodiments, it should be understood that the scope of the present disclosure is not limited thereto, and those skilled in the art will appreciate that various modifications and changes can be made without departing from the spirit and scope of the present disclosure.
Claims (10)
1. A monocular vision based laser cutting follow-up system comprising: the device comprises a detection module, a terminal, a driving mechanism, a transmission mechanism and a cutting head;
the detection module comprises a CCD camera and a laser, the CCD camera is connected with the terminal through an interface module, and the CCD camera collects a light spot image after the light spot is emitted to the processed workpiece through the laser;
the driving mechanism comprises a servo motor and a driver, the transmission mechanism comprises a coupler and a linear motion unit, the driver is connected with the terminal through a system bus, the servo motor is connected with the linear motion unit through the coupler, and the linear motion unit drives the cutting head to move up and down.
2. The monocular vision based laser cutting follow-up system of claim 1, wherein the detection module further comprises a filter and a light shield mounted on the CCD camera; the filter is a narrow-band filter with fixed wavelength, is arranged in front of a CCD camera lens, keeps light with the wavelength emitted by the laser to enter, and the lens hood is used for avoiding the entering of an external interference light source.
3. The monocular vision based laser cutting follow-up system as set forth in claim 1, wherein a slider is arranged on one side of the cutting head, the slider and the cutting head are at the same height, and a laser and a CCD camera are mounted on the slider.
4. A monocular vision based laser cutting follow-up system as in claim 3, wherein the horizontal distance of the laser from the CCD camera remains constant.
5. The monocular vision based laser cutting follow-up system of claim 1, wherein the driving mechanism is connected with the terminal through a PCI bus, and the CCD camera is connected with the terminal through a portal interface.
6. A monocular vision based laser cutting servomechanism as set forth in claim 1, wherein said drive mechanism further comprises an encoder mounted at the rear of the servo motor.
7. The monocular vision based laser cutting follow-up system of claim 1, wherein the laser emits a red dot laser spot of a fixed wavelength to the work piece surface.
8. A monocular vision based laser cutting follow-up method is characterized by comprising the following steps:
the method comprises the steps that a CCD camera collects a light spot image after a laser emits light spots to a machined workpiece, and light spot pixel calibration is carried out on the light spot image according to the horizontal distance between the CCD camera and the laser and the initial height between the laser and the machined workpiece, so that a light spot pixel calibration value is obtained;
the terminal receives and processes the spot image acquired in the cutting process, obtains the number of spot pixels according to the determined spot centroid, and obtains the actual height between the laser and the workpiece to be processed according to the number of spot pixels and the calibration value of the spot pixels;
and driving the cutting head to perform lifting motion according to the difference value between the initial height and the actual height of the laser and the processed workpiece.
9. The monocular vision based laser cutting follow-up method as claimed in claim 8, wherein in the spot pixel calibration, the formula for calculating the spot pixel calibration value is as follows:
θ＝N×Ar+F
d is the horizontal distance between the CCD camera and the laser, H is the initial height between the laser and a processing workpiece, Ar is the radian value of each pixel, F is the radian error, N is the number of light spot pixels, and theta is an angle;
and repeatedly calculating the radian value and the radian error of each pixel by measuring the initial heights of the laser and the processed workpiece for multiple times, and calculating the average value of the radian values to be used as a light spot pixel calibration value.
10. The monocular vision based laser cutting follow-up method of claim 8, wherein the actual height calculating process comprises:
the terminal performs gray level conversion, smoothing processing and light spot edge detection on the light spot image acquired in the cutting process, determines the light spot profile and calculates the profile moment;
and determining the centroid of the light spot, obtaining the number of light spot pixels according to the centroid of the light spot, and calculating the actual height of the laser and the processed workpiece according to the number of the light spot pixels and the calibration value of the light spot pixels.
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| CN111880474A (en) * | 2020-07-21 | 2020-11-03 | 苏州热工研究院有限公司 | Z-axis self-adaptive laser processing system and processing method thereof |
| CN112719629A (en) * | 2020-12-18 | 2021-04-30 | 苏州科韵激光科技有限公司 | Light source follow-up cutting equipment |
| CN114406507A (en) * | 2022-01-04 | 2022-04-29 | 华工法利莱切焊系统工程有限公司 | Device and method for detecting first workpiece of laser cutting machine and electronic equipment |
| CN117644298A (en) * | 2023-12-22 | 2024-03-05 | 哈尔滨灵运景初技术有限公司 | Metal processing manufacturing system |
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