CN111918741A - Gap detection method and system for visual welding system - Google Patents
Gap detection method and system for visual welding system Download PDFInfo
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- CN111918741A CN111918741A CN201880087342.8A CN201880087342A CN111918741A CN 111918741 A CN111918741 A CN 111918741A CN 201880087342 A CN201880087342 A CN 201880087342A CN 111918741 A CN111918741 A CN 111918741A
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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
Abstract
A seam detection method and system for a vision welding system, the method comprising: determining the arrangement relationship of two metal parts (M1, N1) of the area to be welded by a visual detection mode; projecting surface laser light to the two metal parts (M1, N1) when the two metal parts (M1, N1) are spatially arranged in a coplanar manner; gap information between two metal members (M1, N1) is determined according to the projection result of the surface laser. By the method, the gap detection of the welding area can be realized, the function of a 3D vision detection system is realized by adopting a 2D vision system, the technology is improved, and the cost is saved.
Description
The present disclosure relates to the field of gap detection, and more particularly, to a method and a system for detecting a gap in a vision welding system.
In the field of welding, how to detect whether a gap exists between metals to be welded is particularly important, but the current single-camera vision system is difficult to effectively detect the gap existing between three-dimensional metals to be welded, and meanwhile, in the prior art, a space and a 3D vision system are expensive and difficult to realize mass production, so that a 2D vision system is introduced, but a general optical 2D vision system has many problems in metal checking; for example: visual angle, uneven reflection of the metal surface, poor discrimination of similar gray levels of the metal and the surrounding environment, etc.
[ summary of the invention ]
The application provides a gap detection method and system of a visual welding system, and aims to solve the problem that gap detection is difficult or high in cost nowadays.
The technical scheme adopted by the application is as follows: provided is a gap detection method of a visual welding system, comprising the steps of: determining the arrangement relation of two metal parts of a region to be welded in a visual detection mode; when the two metal parts are arranged in a coplanar manner in space, projecting surface laser to the two metal parts; and determining the gap information between the two metal parts according to the projection result of the surface laser.
In order to solve the above technical problem, another technical solution adopted by the present application is: a visual welding system comprises a visual detection system, a welding system and a welding system, wherein the visual detection system is used for determining the arrangement relation of two metal parts of an area to be welded in a visual detection mode; the laser projection device is used for projecting surface lasers to the two metal components which are arranged in a space coplanar mode; the visual detection system further determines gap information between the two metal parts according to the projection result of the surface laser.
In order to solve the above technical problem, another technical solution adopted by the present application is: a computer storage medium storing a program file capable of implementing any of the above methods.
The beneficial effect of this application is: a method and a system for detecting a gap of a visual welding system are provided, wherein the arrangement relation of two metal parts of a region to be welded is determined through a visual detection mode, when the two metal parts are determined to be arranged in a space coplanar mode, surface laser patterns are projected to the two metal parts, and gap information between the two metal parts is determined according to the projection result of the surface laser, so that the gap detection of the two metal parts in the welding region can be realized.
FIG. 1 is a schematic flow chart diagram illustrating a first embodiment of a method for gap detection in a visual welding system according to the present application;
FIG. 2 is a schematic flow chart diagram illustrating a second embodiment of a method for gap detection in a visual welding system according to the present application;
FIG. 3 is a schematic flow chart diagram illustrating a third embodiment of a method for gap detection in a visual welding system according to the present application;
FIG. 4 is a schematic diagram of a specific structure of the embodiment shown in FIG. 3;
FIG. 5 is a schematic flow chart diagram illustrating a fourth embodiment of a method for gap detection in a visual welding system according to the present application;
FIG. 6 is a schematic diagram of a specific embodiment of the embodiment shown in FIG. 5;
FIG. 7 is a schematic diagram of a configuration of an embodiment of the vision welding system of the present application;
FIG. 8 is a schematic structural diagram of an embodiment of a computer storage medium according to the present application.
The technical solutions in the embodiments of the present application will be described clearly and completely with reference to the drawings in the embodiments of the present application, and it is obvious that the described embodiments are only a part of the embodiments of the present application, 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 application.
Referring to fig. 1, fig. 1 is a schematic flowchart illustrating a first embodiment of a gap detection method of a visual welding system according to the present application, wherein the gap detection method includes the following steps:
and S11, determining the arrangement relation of the two metal parts in the welding area through a visual detection mode.
In this embodiment, since different welding methods are adopted for different arranged metal components, two metal components in a welding area are first detected, specifically, image acquisition, image recognition and processing are performed on the two metals in a visual detection manner.
In a specific embodiment, the two metal components are arranged in different spatial planes and coplanar spatial planes respectively.
Referring to fig. 2, fig. 2 is a schematic flow chart of a second embodiment of the gap detection method of the visual welding system of the present application, and is a sub-embodiment of step S11, which specifically includes the following steps:
and S111, acquiring an image of the region to be welded to obtain a visual detection image.
In this embodiment, the detection of the area to be welded is performed by an automated method, and image acquisition is first required, and mainly performed by a machine to acquire images of the entire welding area, so as to obtain visual detection images of two metal parts in the welding area.
And S112, performing image recognition on the visual detection image to recognize two metal parts from the visual detection image.
This application is mainly through accomplishing the gap detection with laser pattern projection metal parts surface, need confirm two metal parts's positional information, including specific coordinate, position arrangement etc. to need discern the visual detection image that contains metal parts, discern metal parts.
And S113, determining the arrangement relation of the two metal parts in the visual detection image.
Different detection modes are adopted for different metal welding modes, namely different detection modes are adopted for different arrangement modes of metals, so that after identification, the position information of the two metal parts is processed, and the position relation of the two metal parts is obtained.
In the above embodiment, the image of the welding area is acquired, the two metal parts in the acquired visual inspection image are identified, and then the arrangement relationship of the two metal parts is determined, so that the visual inspection and identification of the two metals in the welding area are completed, and the detection mode used next is determined through the arrangement mode.
And S12, when the two metal parts are arranged in a coplanar manner, projecting surface laser to the two metal parts.
And after the two metal parts are determined to be arranged in a coplanar manner in space, a projection detection mode is adopted.
The surface laser with a certain width is projected to the two metal parts, and particularly, all or part of the two metal parts can be covered at the same time, and all or part of the joint of the two metal parts can be covered at the same time.
And S13, determining the gap information between the two metal parts according to the projection result of the surface laser.
According to the method, the two metal parts cannot be penetrated by the surface laser, so that the projection of the metal parts is generated on the imaging plate, or the two metal parts are imaged from the projection direction of the surface laser, so that the gap information between the two metal parts is determined.
Referring to fig. 3 and 4, fig. 3 is a schematic flow chart of a third embodiment of a gap detection method of the visual welding system according to the present application, fig. 4 is a specific schematic diagram of the embodiment of fig. 3, and fig. 4 is a cross-sectional view perpendicular to the collection direction for clarity.
In this embodiment, two metal members are used to project surface laser beams capable of simultaneously covering the two metal members, and then when there is no gap at the joint of the two metal members, the brightness of the surface laser beams is compared with the brightness of the surroundings, and finally the gap information between the two metals is determined. The method specifically comprises the following steps:
s131a, image acquisition is performed on the projections of the two metal members on which the surface laser is projected to acquire projection detection images.
When laser projects on two metal parts, because laser can't see through metal part, then can form the projection on setting up the imaging plate on two metal part shady faces, carry out image acquisition to the projection of two metal parts that have the projection laser on imaging plate to obtain projection detection image.
And S132a, performing image recognition on the projection detection image to judge whether a gap exists between the corresponding projections of the two metal parts.
In the present embodiment, the projection area is formed on the image forming plate on the back surface of the metal member by projecting the surface laser onto the two metal members, but there may be a gap at the joint between the two metal members, and the laser penetrates through the luminance area formed on the image forming plate, that is, there is a gap in the projection areas corresponding to the two metal members, so it is necessary to perform image recognition on the projection detection image first to determine whether there is a gap image larger than a preset threshold between the projections of the two metal members.
As shown in fig. 4, the two metal parts M1 and the metal part N1 are arranged in a coplanar manner in space, and a complete laser pattern is projected onto the two metal parts, so that the laser pattern can cover the two metal parts, and since the laser cannot penetrate through the metal parts, a projection image M1 is formed on the imaging plate on the back side of the metal part M1, and a projection image N1 is formed on the imaging plate on the back side of the metal part N1, so that image acquisition is performed on the whole projection area.
S133a, if there is a gap, it is determined that there is a gap between the two metal members.
In a specific embodiment, if two metal parts have no gap, the surface laser cannot penetrate through the metal parts, and the projection images corresponding to the two metal parts form a complete projection area, but if a gap exists between the two metal parts, the surface laser penetrates through the gap partially when being projected on the metal parts, so that when the projection area is identified, the corresponding projection images of the two metals are discontinuous, and a certain brightness gap exists between the projection images.
When the projection area is identified, whether a brightness gap larger than a preset threshold width exists between projections corresponding to the two metal parts is detected, and if so, a gap is determined to exist between the two metal parts.
As shown in fig. 4, when there is no gap between the metal part M1 and the metal part N1, the projected image M1 and the projected image N1 form a complete projection area, and when there is a gap between the metal part M1 and the metal part N1, there is a luminance gap having a width greater than a preset threshold width at the joint of the projected image M1 and the projected image N1.
Referring to fig. 5 and 6, fig. 5 is a schematic flowchart illustrating a fourth embodiment of a gap detection method of a visual welding system according to the present application, and fig. 6 is a specific schematic diagram of the embodiment in fig. 5.
In this embodiment, two metal members are used to project surface laser beams capable of simultaneously covering the two metal members, and then when there is no gap at the joint of the two metal members, the brightness of the surface laser beams is compared with the brightness of the surroundings, and finally, whether there is a gap between the two metals is determined and the information of the gap is calculated. The method specifically comprises the following steps:
s131b, image acquisition is performed on the two metal members on which the surface laser is projected to acquire a gap detection image.
Different from the embodiment, this embodiment passes through on the surface laser projects two metal parts, because metal part has reflection of light phenomenon to surface laser projects and can directly form corresponding surface laser pattern on two metal parts, directly carries out the collection of image to two metal parts, thereby acquires the gap and detects the image.
S132b, carrying out image recognition on the gap detection image to judge whether a brightness abrupt change region exists at the joint of the two metal parts;
the image detection is carried out on the gap detection image, when surface laser is projected on the metal component, due to the reflection phenomenon of the metal component, a corresponding surface laser pattern can be formed on the metal component, if two metal components have gaps, part of the surface laser can penetrate through the gaps, and therefore brightness abrupt change regions can exist between the surface laser patterns corresponding to the two metal components, namely, the brightness is obviously different relative to the periphery, whether the gaps exist between the metal components can be judged, the surface laser pattern needs to be recognized from the gap detection image, and the brightness abrupt change regions with the width larger than the preset threshold width exist at the joints of the surface laser patterns corresponding to the two metal components are judged.
Referring to fig. 6, wherein metal part M2 and metal part N2 are in a coplanar spatial arrangement, a complete laser pattern is projected onto both metal parts such that the laser pattern can bridge both metal parts, i.e., the laser pattern can at least partially cover metal part M2, metal part N2, and the bonding area thereof at the same time, such that laser pattern M2 is formed on metal part M2 and laser pattern N2 is formed on metal part N2.
And S133b, if the brightness abrupt change region exists, judging that a gap exists between the two metal parts.
In a specific embodiment, if two metal parts have no gap, that is, no surface laser passes through, the whole laser pattern area is a complete area, but if there is a gap between two metal parts, when the surface laser is projected on, there is a portion passing through the gap, resulting in a difference in brightness, that is, a lower or higher brightness relative to other areas, where the gap exists when the surface laser pattern is recognized. Therefore, when the area of the surface laser pattern is identified, the gap between the two metal parts is determined when the fact that the brightness abrupt change area larger than the preset threshold value exists at the joint of the surface laser patterns corresponding to the two metal parts is detected.
Referring to fig. 6, when there is no gap between the metal part M2 and the metal part N2, the laser pattern M2 and the laser pattern N2 form a complete laser pattern, and when there is a gap between the metal part M2 and the metal part N2, it can be detected that there is a sudden luminance change region having a width greater than a preset threshold width in the joint region of the laser pattern M2 and the laser pattern N2.
In other embodiments, in order to achieve a better detection effect, an imaging plate may be disposed on a backlight surface of the metal component, and the imaging plate and the metal component have a relatively obvious reflection difference.
In particular embodiments, the following may be the case:
under the detection at the same angle, when the light reflection degrees of the two metal parts are different and are both smaller than that of the imaging plate, the brightness of the brightness mutation area is larger than the surrounding brightness.
When the two metal parts have different light reflection degrees and are both larger than the imaging plate, the brightness of the brightness mutation area is smaller than the surrounding brightness.
When the reflectivities of the two metal parts are the same and are both larger than that of the imaging plate, the brightness of the brightness mutation area is smaller than the surrounding brightness.
When the reflectivities of the two metal parts are the same and are both smaller than that of the imaging plate, the brightness of the brightness abrupt change region is larger than the surrounding brightness.
When the two metal parts have different reflectivities, and one of the two metal parts is larger than the imaging plate and the other metal part is smaller than the imaging plate, the brightness of the whole image is stepped.
In the above embodiment, by projecting the surface laser onto the two metal members, the region of the two metal members where the gap exists transmits light, so that the brightness is different from that of the other region, thereby determining the information of the gap.
Referring to fig. 7, fig. 7 is a schematic structural diagram of an embodiment of a vision welding system according to the present application.
In this embodiment, the vision welding system includes: a vision inspection system 10 and a laser projection device 20.
The visual detection system 10 is configured to perform visual detection on two metal components in a welding region, and after the arrangement manner of the two metal components is obtained, the laser projection device 20 projects surface lasers on the two metal components which are determined to be coplanar in space, and the visual detection system 10 further determines gap information between the two metal components according to the projection result of the surface lasers.
In a specific embodiment, the image sensor 11 first performs image acquisition on a welding area to obtain a visual detection image, then the processor 12 processes the visual detection image acquired by the image sensor 11, identifies two metal components in the visual detection image that need to perform gap detection, further determines a specific arrangement relationship and position information of the two identified metal components, and sends the position and arrangement information to the laser projection device 20.
The laser projection device 20 mainly includes a light source, when the visual inspection system 10 determines the positions and the specific arrangement relationship of the two metal parts, the visual inspection system 10 sends the position information and the arrangement manner of the two metal parts to determine the laser inspection manner, specifically, the light source 21 projects different laser patterns according to the obtained position information and the arrangement information of the two metal parts through the information sent by the processor 12.
Optionally, the arrangement relationship of the two metals transmitted from the vision inspection system 10 is set to be spatially coplanar.
The light source 21 of the laser projection device 20 projects surface laser onto two metal parts, and enables the surface laser to cover the two metal parts simultaneously according to the specific position information of the metal parts.
After the light source 21 projects a preset laser pattern onto the surfaces of the two metal parts, the image sensor 11 is responsible for image acquisition of the projections of the two metal parts on the imaging plate, so as to acquire a projection detection image.
In a specific embodiment, the imaging plate is transparent, and the image sensor 11 is located in a space on a side of the imaging plate facing away from the two metal parts, and if the imaging plate is non-transparent, the image sensor 11 is located in a space between a side of the imaging plate and a side of the metal parts.
The processor 12 performs image recognition on the projection detection image through the acquired projection detection image to judge whether a corresponding light transmission gap with a width larger than a preset threshold width exists between the projections corresponding to the two metal parts; and if the light-transmitting gap exists, judging that a gap exists between the two metal parts.
In other embodiments, after the light source 21 projects the preset laser pattern onto the surfaces of the two metal parts, the image sensor 11 is responsible for performing image acquisition on the surface laser pattern on the two metal parts, so as to obtain the gap detection image.
The processor 12 identifies the surface laser patterns on the two metal parts through the acquired gap detection image, and determines whether a brightness abrupt change region larger than a preset threshold width exists in the identified surface laser patterns, and if the brightness abrupt change region exists, it determines that a gap exists between the two metal parts.
The specific detection method has already been described in the above embodiments, and is not described herein again.
It should be noted that the processor 12 provided in this embodiment is not limited to image processing, and other processing may be performed, such as controlling the projection direction of the light source 20, controlling the collection angle of the image sensor 11, and the like.
Referring to fig. 8, fig. 8 is a schematic structural diagram of an embodiment of a computer storage medium of the present application, and includes a program file 31 capable of implementing all the methods described above, where the program file 31 may be stored in the storage device in the form of a software product, and also records data of various computations, including several instructions for enabling a computer device (which may be a personal computer, a server, or a network device) or a processor (processor) to execute all or part of the steps of the methods of the embodiments of the present application.
The aforementioned storage device includes: various media capable of storing program codes, such as a usb disk, a mobile hard disk, a Read-Only Memory (ROM), a Random Access Memory (RAM), a magnetic disk or an optical disk, or terminal devices, such as a computer, a server, a mobile phone, and a tablet.
In summary, it is easily understood by those skilled in the art that the present application provides a method and a system for detecting a gap of a visual welding system, where a laser pattern of a preset shape is projected onto two metal parts by selecting a corresponding laser detection method through position visual detection and arrangement of the two metal parts in a welding area, and a positional relationship of the laser pattern is calculated according to the collected laser pattern, so as to further calculate the gap between the two metal parts.
The above embodiments are merely examples and are not intended to limit the scope of the present disclosure, and all modifications, equivalents, and flow charts using the contents of the specification and drawings of the present disclosure or those directly or indirectly applied to other related technical fields are intended to be included in the scope of the present disclosure.
Claims (12)
- A method of seam detection for a visual welding system, the method comprising:determining the arrangement relation of two metal parts of a region to be welded in a visual detection mode;when the two metal parts are arranged in a coplanar manner in space, projecting surface laser to the two metal parts;and determining the gap information between the two metal parts according to the projection result of the surface laser.
- The method according to claim 1, wherein the determining the arrangement relationship of the two metal parts of the area to be welded by visual inspection comprises:acquiring an image of the area to be welded to obtain a visual detection image;performing image recognition on the visual inspection image to identify the two metal parts from the visual inspection image;and determining the arrangement relation of the two metal parts in the visual detection image.
- The method of claim 1, wherein the determining gap information between the two metal parts according to the projection result of the surface laser comprises:acquiring images of the projections of the two metal parts projected with the surface laser to acquire projection detection images;carrying out image recognition on the projection detection image to judge whether a gap exists between the projections corresponding to the two metal parts;and if the gap exists, judging that a gap exists between the two metal parts.
- The method of claim 1, wherein the determining gap information between the two metal parts according to the projection result of the surface laser comprises:acquiring images of the two metal parts projected with the surface laser from the surface laser projection direction to obtain a gap detection image;and carrying out image recognition on the gap detection image so as to judge the gap information between the two metal parts.And if a brightness abrupt change region exists at the joint of the two metal parts in the gap detection image, wherein the brightness value of the brightness abrupt change region is different from the brightness value of the two metal parts, judging that a gap exists between the two metal parts.
- A visual welding system, the system comprising:the visual detection system is used for determining the arrangement relation of the two metal parts of the area to be welded in a visual detection mode;the laser projection device is used for projecting surface lasers to the two metal components which are arranged in a space coplanar mode;the visual detection system further determines gap information between the two metal parts according to the projection result of the surface laser.
- The system of claim 5, wherein the visual inspection system comprises:the image sensor is used for carrying out image acquisition on the area to be welded so as to obtain a visual detection image;and the processor is used for carrying out image recognition on the visual detection image so as to recognize the two metal parts from the visual detection image and determine the arrangement relation of the two metal parts in the visual detection image.
- The system of claim 5, wherein the laser projection device comprises:a light source for projecting surface laser to the two metal members, respectively; so that the surface laser can cover both metal parts simultaneously.
- The system of claim 6, wherein the image sensor further comprises image acquisition of projections of the two metal parts on which the surface laser is projected to acquire a projection detection image;
- the system of claim 7, wherein the processor further comprises image recognition of the projected inspection image to determine whether a gap exists between the projections corresponding to the two metal parts; and if the gap exists, determining the gap information between the two metal parts.
- The system of claim 6, wherein the image sensor further comprises image capturing the two metal parts on which the surface laser is projected from a surface laser projection direction to obtain a gap detection image.
- The system of claim 10, wherein the processor further comprises image recognition of the gap detection image to determine whether a sudden brightness change region exists at a junction of two metal parts; and if the brightness abrupt change region exists, wherein the brightness value of the brightness abrupt change region is different from the brightness values of the two metal parts, judging that a gap exists between the two metal parts.
- A computer storage medium storing a program file capable of implementing the method according to any one of claims 1 to 4.
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| PCT/CN2018/103076 WO2020042031A1 (en) | 2018-08-29 | 2018-08-29 | Seam inspection method of vision-based welding system, and system |
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| WO2020042031A1 (en) | 2020-03-05 |
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Application publication date: 20201110 |