CN112562002B - Filtering processing method and device for welding seam tracking point, electronic equipment and storage medium - Google Patents
Filtering processing method and device for welding seam tracking point, electronic equipment and storage medium Download PDFInfo
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Abstract
The invention provides a filtering processing method and device for a welding seam tracking point, electronic equipment and a storage medium, which are used for acquiring initial position data of the real-time welding seam tracking point; judging whether the preliminary position data is valid data or not according to the deviation between the preliminary position data and the position data of the last welding seam tracking point in a preset data container; if the preliminary position data are valid data, writing the preliminary position data into the last position of the data container, and filtering the position data of the welding seam tracking point in the data container; extracting the position data of the last welding seam tracking point in the data container after filtering processing as the final position data of the real-time welding seam tracking point; therefore, the phenomenon that the deviation between the welding seam tracking position and the real welding seam position is overlarge due to shaking can be avoided, and the accuracy and the stability of the automatic welding process are ensured.
Description
Technical Field
The present invention relates to the field of welding technologies, and in particular, to a method and an apparatus for filtering a weld tracking point, an electronic device, and a storage medium.
Background
Welding technology is an important technology. Nowadays, welding technology is widely applied to the manufacturing industries of industrial machines such as buildings, aerospace, automobiles, ships and the like. With the development of industrial technology, the need to avoid personnel working in harsh environments is becoming more and more urgent. Welding operations are often performed in harsh environments, and therefore, there is a great need for automated welding techniques to achieve automated welding.
In automatic welding work, a welding seam is generally required to be tracked in real time, and then a welding gun is guided to perform accurate welding operation along the welding seam. With the development of technology, automation and intelligence of welding tracking have become a necessary trend. The real-time welding seam tracking, detecting and rectifying are the key for realizing the welding automation. At present, in order to realize automatic welding, a welding seam tracking sensor is arranged at the front end of a welding gun, and welding seam tracking control is realized through the sensor and a control structure.
At present, because a vision sensor (such as a laser vision sensor) has a non-contact sensing mode, the sensitivity and the detection precision of weld seam tracking can be effectively improved, and therefore the vision sensor is often used as a weld seam tracking sensor. However, in the actual welding process, there may be jitter of different factors, such as defects and flaws of the workpiece itself, spatters, wire feeding jitter, sudden jitter of the mechanical arm and the sensor, and other system jitter factors, and these jitter may not only affect the welding precision and stability, but may even cause the deviation between the weld tracking position signal output by the real-time tracking system and the actual weld position to be too large to realize weld tracking.
Therefore, a filtering processing method capable of avoiding the excessive deviation of the welding seam tracking position from the real welding seam position caused by the shaking is needed to be found so as to ensure the accuracy and the stability of the automatic welding process.
Disclosure of Invention
In view of the defects of the prior art, an object of the embodiments of the present application is to provide a filtering processing method capable of avoiding a weld tracking point having an excessively large deviation between a weld tracking position and a true weld tracking position due to jitter, so as to ensure accuracy and stability of an automatic welding process.
In a first aspect, an embodiment of the present application provides a method for filtering weld tracking points, which is applied to a real-time weld tracking system, and includes the steps of:
A1. acquiring initial position data of a real-time welding seam tracking point;
A2. judging whether the preliminary position data is valid data or not according to the deviation between the preliminary position data and the position data of the last welding seam tracking point in a preset data container;
A3. if the preliminary position data are valid data, writing the preliminary position data into the last position of the data container, and filtering the position data of the welding seam tracking point in the data container;
A4. and extracting the position data of the last welding seam tracking point in the data container after filtering processing as the final position data of the real-time welding seam tracking point.
In the filtering processing method of the welding seam tracking point, the position data of the welding seam tracking point comprises two coordinate data of a two-dimensional coordinate system, or the position data of the welding seam tracking point comprises three coordinate data of a three-dimensional coordinate system.
In some embodiments, step a2 includes:
calculating distance data between the preliminary position data and the last weld tracking point position data in the data container;
and if the distance data is larger than a preset first deviation threshold value, judging that the preliminary position data is invalid data, otherwise, judging that the preliminary position data is valid data.
In some embodiments, step a2 includes:
respectively calculating difference absolute values between each coordinate of the preliminary position data and each coordinate of the position data of the last welding seam tracking point in the data container;
and if the absolute value of the difference value of at least one coordinate is larger than a preset second deviation threshold value, judging the preliminary position data to be invalid data, otherwise, judging the preliminary position data to be valid data.
In the filtering processing method of the welding seam tracking point, the size of a filtering window of the filtering processing is equal to the size of the data container;
step a3 includes:
after writing the preliminary location data into the last location of the data container, determining whether the data container is full;
and if so, filtering the position data of the welding seam tracking point in the data container.
Further, step a3 includes:
judging whether the data container is full;
if not, directly writing the preliminary position data into the last of the data container;
if so, erasing the position data of the first welding seam tracking point in the data container, and writing the initial position data into the data container.
In the method for filtering the weld joint tracking points, after the step a2, the method further includes:
A5. if the preliminary position data is invalid data, the super-threshold count is accumulated by 1;
A6. judging whether the super threshold count is greater than a preset count threshold;
A7. if so, the data container is emptied and the super-threshold count is zeroed.
In a second aspect, an embodiment of the present application provides a filter processing apparatus for a weld tracking point, which is applied to a real-time weld tracking system, and includes:
the first acquisition module is used for acquiring preliminary position data of the real-time welding seam tracking point;
the first judgment module is used for judging whether the preliminary position data is valid data or not according to the deviation between the preliminary position data and the position data of the last welding seam tracking point in a preset data container;
the first processing module is used for writing the preliminary position data into the last position of the data container when the preliminary position data is valid data, and filtering the position data of the welding seam tracking point in the data container;
and the extraction module is used for extracting the position data of the last welding seam tracking point in the data container after the filtering processing as the final position data of the real-time welding seam tracking point.
In a third aspect, an embodiment of the present application provides an electronic device, which includes a processor and a memory, where the memory stores a computer program, and the processor is configured to execute the steps of the method for filtering a weld tracking point, by calling the computer program stored in the memory.
In a fourth aspect, the present application provides a storage medium, on which a computer program is stored, where the computer program runs the steps of the method for filtering the weld trace point as described above when being executed by a processor.
Has the advantages that:
according to the filtering processing method, the filtering processing device, the electronic equipment and the storage medium for the weld joint tracking points, preliminary position data of the real-time weld joint tracking points are obtained; judging whether the preliminary position data is valid data or not according to the deviation between the preliminary position data and the position data of the last welding seam tracking point in a preset data container; if the preliminary position data are valid data, writing the preliminary position data into the last position of the data container, and filtering the position data of the welding seam tracking point in the data container; extracting the position data of the last welding seam tracking point in the data container after filtering processing as the final position data of the real-time welding seam tracking point; therefore, the phenomenon that the deviation between the welding seam tracking position and the real welding seam position is overlarge due to shaking can be avoided, and the accuracy and the stability of the automatic welding process are ensured.
Drawings
Fig. 1 is a flowchart of a filtering processing method for a weld tracking point according to an embodiment of the present disclosure.
Fig. 2 is a block diagram of a filter processing apparatus for a weld tracking point according to an embodiment of the present disclosure.
Fig. 3 is a schematic structural diagram of an electronic device according to an embodiment of the present application.
Fig. 4 is a Z-axis position distribution diagram of a weld tracking point in an embodiment without using the weld tracking point filtering method provided in the embodiment of the present application.
Fig. 5 is a Z-axis position distribution diagram of a weld tracking point when the filter processing method of the weld tracking point provided by the embodiment of the present application is used in the embodiment.
Detailed Description
The technical solutions in the embodiments of the present application will be clearly and completely described below 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. The components of the embodiments of the present application, generally described and illustrated in the figures herein, can be arranged and designed in a wide variety of different configurations. Thus, the following detailed description of the embodiments of the present application, presented in the accompanying drawings, is not intended to limit the scope of the claimed application, but is merely representative of selected embodiments of the application. All other embodiments, which can be derived by a person skilled in the art from the embodiments of the present application without making any creative effort, shall fall within the protection scope of the present application.
It should be noted that: like reference numbers and letters refer to like items in the following figures, and thus, once an item is defined in one figure, it need not be further defined and explained in subsequent figures. Meanwhile, in the description of the present application, the terms "first", "second", and the like are used only for distinguishing the description, and are not to be construed as indicating or implying relative importance.
Referring to fig. 1, an embodiment of the present application provides a method for filtering a weld tracking point, which is applied to a real-time weld tracking system, and includes the steps of:
A1. acquiring initial position data of a real-time welding seam tracking point;
A2. judging whether the preliminary position data is valid data or not according to the deviation between the preliminary position data and the position data of the last welding seam tracking point in a preset data container (namely the position data of the last welding seam tracking point arranged in the data container);
A3. if the preliminary position data is valid data, writing the preliminary position data into the final position of the data container, and filtering the position data of the welding seam tracking point in the data container;
A4. and extracting the position data of the last welding seam tracking point in the data container after filtering processing as the final position data of the real-time welding seam tracking point.
The real-time welding seam tracking system is characterized in that a welding seam tracking sensor is arranged at the front end of a welding gun and used for acquiring preliminary position data of a real-time welding seam tracking point, wherein the real-time welding seam tracking point is a groove position point which is not welded in front of the welding gun.
Thus, in step A1, preliminary location data for the real-time weld tracking points is obtained by the weld tracking sensors. For example, in some embodiments, the weld tracking sensor is a vision sensor (e.g., a laser 3D camera), then step a1 includes: acquiring original frame data acquired by a weld joint tracking sensor in real time; and analyzing and calculating the original frame data by an image analysis method to obtain the initial position data of the real-time welding seam tracking point.
In practical applications, when welding is just started (or when welding of another welding seam is started), the data container is empty, so that step a2 cannot be executed at this time, and at this time, the preliminary position data obtained in step a1 may be directly determined as valid data, so that, in some embodiments, after step a1, the method further includes:
A8. judging whether a preset data container is empty or not;
A9. if so, judging that the preliminary position data are effective data and taking the preliminary position data as final position data of the real-time welding seam tracking point; otherwise, step a2 is performed.
When welding is just started (or when another section of welding seam is started), the data container is empty, so that the step A2 cannot be executed at the moment, a plurality of pieces of preliminary position data of the real-time welding seam tracking point can be repeatedly obtained, and finally effective preliminary position data can be determined according to the plurality of pieces of preliminary position data, so that the inaccuracy of judgment on the validity of the preliminary position data of the subsequent welding seam tracking point caused by the inaccuracy of the position data of the first welding seam tracking point is avoided; thus, in some embodiments, after step a1, the method further comprises:
A10. judging whether a preset data container is empty or not;
A11. if so, acquiring a plurality of pieces of preliminary position data of the real-time welding seam tracking point, calculating final effective preliminary position data according to all the preliminary position data, judging the final effective preliminary position data to be effective data, and taking the final effective preliminary position data as final position data of the real-time welding seam tracking point; otherwise, step a2 is performed.
The method for calculating the final valid preliminary location data according to all the preliminary location data may be: calculating the average position data of all the preliminary position data as the final effective preliminary position data of the real-time weld tracking point (when the position data includes a plurality of coordinate values, calculating the average value of each coordinate as each coordinate value of the final effective preliminary position data, respectively). Or after the average position data of all the preliminary position data is obtained through calculation, the preliminary position data closest to the average position data is used as the final effective preliminary position data of the real-time weld joint tracking point. When the plurality of initial position data of the real-time welding seam tracking points are obtained, the positions of the welding seam tracking sensors are kept unmoved, so that the initial position data are collected for a plurality of times at the same position, and the initial position data obtained for a plurality of times are all set initial position data corresponding to the same real-time welding seam tracking points.
Generally, if the deviation between the preliminary position data and the position data of the last weld joint tracking point in the data container is too large, usually, the obtained position data of the tracking point is wrong due to system jitter, so that the deviation is too large, therefore, the position data of the weld joint tracking point can be abandoned and the preliminary position data of the weld joint tracking point can be obtained again (namely, the position of the weld joint tracking sensor is kept not moving, and the preliminary position data of the real-time weld joint tracking point is obtained again), thereby avoiding the influence on filtering processing caused by invalid tracking points, greatly improving reliability, and preventing the problem that the welding joint tracking position signal output by the tracking system is too large to deviate from the real weld joint position due to system jitter to cause that correct welding cannot be realized in real time.
In some embodiments, the weld extends only in a horizontal plane, and the position in the height direction does not change (for example, the weldment is a flat plate), in which case the weld tracking sensor may be a 2D sensor (for example, a 2D camera), and thus, the position data of the weld tracking point may include two coordinate data (X-coordinate, Y-coordinate) of a two-dimensional coordinate system (including X-axis and Y-axis that are perpendicular to each other); the weld tracking sensor may also be a 3D sensor (e.g., a 3D camera), and thus, the position data of the weld tracking point may include three coordinate data (X, Y, and Z coordinates) of a three-dimensional coordinate system including X, Y, and Z axes that are perpendicular to each other.
In other embodiments, the position of the weld varies in the height direction (e.g., the weldment is a non-flat workpiece), and in this case, the weld tracking sensor should be a 3D sensor (e.g., a 3D camera), so that the position data of the weld tracking point includes three coordinate data (X, Y, and Z coordinates) of a three-dimensional coordinate system including X, Y, and Z axes that are perpendicular to each other.
In step a2, there are many methods for determining the validity of the real-time seam tracking point.
For example, in some embodiments, step a2 includes:
A201. calculating distance data between the preliminary position data and the position data of the last welding seam tracking point in the data container;
A202. and if the distance data is larger than a preset first deviation threshold value, judging that the preliminary position data is invalid data, otherwise, judging that the preliminary position data is valid data.
That is, in this embodiment, the deviation between the preliminary position data and the last weld-trace point position data in the preset data container means the distance therebetween.
If the position data of the seam tracking point includes only X coordinates and Y coordinates, the distance data may be calculated according to the following formula in step a 201:
where d is distance data, X0 is an X-coordinate value of the preliminary position data, Y0 is a Y-coordinate value of the preliminary position data, X1 is an X-coordinate value of the last weld tracking point position data in the data container, and Y1 is a Y-coordinate value of the last weld tracking point position data in the data container.
If the position data of the seam tracking point includes an X coordinate, a Y coordinate, and a Z coordinate, the distance data may be calculated according to the following formula in step a 201:
where d is the distance data, X0 is the X coordinate value of the preliminary position data, Y0 is the Y coordinate value of the preliminary position data, Z0 is the Z coordinate value of the preliminary position data, X1 is the X coordinate value of the last weld tracking point position data in the data container, Y1 is the Y coordinate value of the last weld tracking point position data in the data container, and Z1 is the Z coordinate value of the last weld tracking point position data in the data container.
Wherein, the first deviation threshold value can be set according to actual needs.
For example, in other embodiments, step a2 includes:
A203. respectively calculating difference absolute values between each coordinate of the preliminary position data and each coordinate of the last welding seam tracking point position data in the data container;
A204. and if the absolute value of the difference value of at least one coordinate is larger than a preset second deviation threshold, judging that the preliminary position data is invalid data, otherwise, judging that the preliminary position data is valid data.
That is, in this embodiment, the deviation between the preliminary position data and the last weld-following point position data in the preset data container includes the absolute value of the difference between each coordinate value of the preliminary position data and each coordinate value of the last weld-following point position data in the data container.
If the position data of the seam tracking point only includes an X coordinate and a Y coordinate, the absolute value of the difference between the X coordinate and the Y coordinate is calculated in step a203, and the absolute value of the difference between the X coordinate and the Y coordinate is calculated as Δ X = | X-X1|, and the absolute value of the difference between the Y coordinate and the Y coordinate is calculated as Δ Y = | Y-Y1|, and the preliminary position data is determined as invalid data as long as at least one of Δ X and Δ Y is greater than a second deviation threshold in step a204. If the position data of the seam tracking point further includes a Z coordinate, the absolute value of the difference Δ Z = | Z-Z1| of the Z coordinate is further calculated in step a203, and the preliminary position data is determined to be invalid data as long as at least one of Δ X, Δ Y, and Δ Z is greater than a second deviation threshold in step a204.
In practical application, one of the two modes can be independently adopted to judge the effectiveness of the real-time weld joint tracking point. The above two methods may be combined to determine, and in this case, step a2 includes: calculating distance data between the preliminary position data and the position data of the last welding seam tracking point in the data container; respectively calculating difference absolute values between each coordinate of the preliminary position data and each coordinate of the last welding seam tracking point position data in the data container; and if the distance data is greater than a preset first deviation threshold or the absolute value of the difference value of at least one coordinate is greater than a preset second deviation threshold, judging that the preliminary position data is invalid data, otherwise, judging that the preliminary position data is valid data. By adopting the mode, compared with a mode which is singly adopted, the filtering processing can be more effectively prevented from being influenced by invalid tracking points.
The data container is a virtual container with a fixed storage space, and can be used for containing position data of N welding seam tracking points at most, wherein N is a preset positive integer.
In the present embodiment, the filter window size of the filtering process in step a3 is equal to the size of the data container, i.e., the filter window size D = N. The specific filtering method can be selected according to actual needs, the size of the filtering window can be set according to actual needs, and after the size of the filtering window of the filtering method is determined, the size of the data container can be set to be the same. For example, the filtering method is mean filtering, the size of the filtering window is 7-10, and correspondingly, the size of the data container is 7-10; but is not limited thereto.
Thus, step a3 includes:
after writing the preliminary position data into the final position of the data container, judging whether the data container is full;
and if so, filtering the position data of the welding seam tracking point in the data container.
Generally, there is a case where the data container is not filled up only at the beginning of welding (or at the beginning of welding of another weld), and at this time, since the amount of position data in the data container is not enough to perform the filtering process, the filtering process is not performed, so that the final position data of the real-time weld tracking point obtained in step a4 is equal to the preliminary position data.
Further, since the size of the data container is fixed, when the data container is filled and data is written into the data container, the previous data needs to be erased for writing, so that step a3 further includes:
judging whether the data container is full;
if not, directly writing the preliminary position data into the last of the data container;
if so, erasing the position data of the first welding seam tracking point in the data container (namely the position data of the welding seam tracking point with the first position in the data container), and writing the initial position data into the end of the data container.
In fact, the specific method of filtering processing can be selected according to actual needs, and a plurality of filtering processing methods with different filtering window lengths can be preset, so that when the data container is not full, the filtering processing method corresponding to the filtering window length can be selected according to the actual amount of the position data of the welding seam tracking point in the data container for filtering processing, and the accuracy of the welding seam tracking position can be further improved. At this time, step a3 includes: and acquiring the quantity of the position data of the welding seam tracking point of the data container, and selecting a filtering processing method with the length of a filtering window equal to the quantity in a plurality of preset filtering processing methods to filter the position data of the welding seam tracking point in the data container.
Sometimes, the weld is actually divided into multiple segments, step jitter actually exists between the segments (that is, there is a jump between the segments in at least one coordinate direction, for example, the height of a weld of a certain segment is greater than that of a weld of a previous segment), and at the alternate position between the segments, there is also a case where the deviation between the preliminary position data and the position data of the last weld tracking point in the data container is too large, but the step jitter inevitably causes the deviation between the preliminary position data of the real-time weld tracking point obtained again for multiple times continuously and the position data of the last weld tracking point in the data container to be too large compared with the case where the deviation is too large due to system jitter; therefore, in some preferred embodiments, after step a2, the method further comprises:
A5. if the preliminary position data is invalid data, the super-threshold count is accumulated by 1;
A6. judging whether the super threshold count is greater than a preset count threshold;
A7. if so, the data container is emptied and the super threshold count is zeroed.
Wherein, the counting threshold value can be set according to actual needs. And once the count exceeding the threshold value is larger than the preset count threshold value, step jitter exists, the real-time welding seam tracking point at the moment is a welding seam tracking point on another section of welding seam, and the initial position data of the real-time welding seam tracking point acquired next time is directly put into the data container after the data container is emptied. Thereby avoiding interruption of the welding process by always regarding valid preliminary position data as invalid data.
It should be noted that, each time the preliminary data is written into the data container, the super-threshold count is set to zero once, so as to avoid the situation that the welding precision is affected due to misjudgment of step jitter as the super-threshold count is accumulated to be greater than the preset count threshold value due to the intermittent occurrence of multiple invalid data caused by system jitter.
It will be appreciated by those skilled in the art that the steps described above are performed cyclically through a complete welding process to traverse the entire welding operation. Therefore, the position data in the data container can be subjected to multiple times of filtering processing within the time period from writing into the data container to erasing, the numerical value of the position data can be changed after each time of filtering processing, and tests show that compared with the processing method of directly filtering the position data of the previously determined weld joint tracking point and the primary position data obtained this time to determine the final position data of the real-time weld joint tracking point, the processing method of filtering the position data of the weld joint tracking point in the data container to determine the final position data of the real-time weld joint tracking point obtains the final position more accurately, and the automatic welding process is more stable.
In one embodiment, the real-time seam tracking system comprises a vision sensor, a 6-axis welding robot, a welding machine, a welding gun and an industrial personal computer, wherein the industrial personal computer executes the filtering processing method of the seam tracking point. Wherein, the vision sensor is the laser 3D camera, and this laser 3D camera can directly obtain the welding seam profile of welding work piece. The bevel of the welding workpiece is of a common bevel type. The effectiveness of the real-time weld tracking point is judged by adopting the steps A203-A204, and the second deviation threshold value is 3 mm. The preset count threshold is 2. The filtering method selected is mean filtering and the size of the filtering window is 9 (the size of the data container is 9). The actual weld is divided into three segments, where step jitter exists between the first and second segments, and between the second and third segments. During welding, the welding gun is made to move along the Y axis of the surface of the workpiece at a fixed speed, the laser 3D camera collects groove data in real time, and outputs final position data of each welding seam tracking point, wherein the output result of the Z coordinate is shown in FIG. 5, compared with the output result of the Z coordinate obtained when the filtering processing method of the welding seam tracking point is not adopted in FIG. 4.
It can be seen from the figure that when the filtering processing method of the welding seam tracking point is not adopted, the filtering effect of the position data of the welding seam tracking point is poor, the position jitter of the welding seam tracking point is obvious, and a plurality of error tracking points output due to system jitter occur, so that the welding gun of the actually required welding area can not be ensured to run stably; in addition, a large number of wrong tracking points occur between the first and second segments and between the second and third segments due to step jitter, which may lead to welding errors. Compared with the prior art, when the filtering processing method of the welding seam tracking point is adopted, the filtering effect of the position data of the welding seam tracking point is good, the position jitter of the welding seam tracking point is not obvious, no error tracking point output due to system jitter occurs, and the welding gun of an actually required welding area can be ensured to stably run; in addition, a large number of error tracking points cannot occur between the first section and the second section and between the second section and the third section due to step jitter, so that welding errors caused by the step jitter are avoided.
According to the method, the initial position data of the real-time welding seam tracking point is obtained; judging whether the preliminary position data is valid data or not according to the deviation between the preliminary position data and the position data of the last welding seam tracking point in a preset data container; if the preliminary position data are valid data, writing the preliminary position data into the last position of the data container, and filtering the position data of the welding seam tracking point in the data container; extracting the position data of the last welding seam tracking point in the data container after filtering processing as the final position data of the real-time welding seam tracking point; therefore, the phenomenon that the deviation between the welding seam tracking position and the real welding seam position is overlarge due to shaking can be avoided, and the accuracy and the stability of the automatic welding process are ensured. Specifically, by means of a pre-constructed effective updating container, the problem that correct welding cannot be realized due to overlarge deviation between a welding seam tracking position signal output by a tracking system and a real welding seam position caused by system jitter can be prevented in real time; the obtained groove position coordinates are filtered, so that the stability and the reliability of data are improved; the method covers real-time judgment, inspection and deviation correction of the welding seam tracking points, avoids the influence on filtering processing caused by obtaining invalid tracking points, and greatly improves the reliability; the method can meet the requirements of a welding seam tracking system, is irrelevant to the adopted filtering types, is compatible with different filtering types, and can carry out filtering of various filtering types according to real-time welding seam tracking point signals.
Referring to fig. 2, an embodiment of the present application further provides a filtering processing device for a weld tracking point, which is applied to a real-time weld tracking system, and includes a first obtaining module 1, a first determining module 2, a first processing module 3, and an extracting module 4;
the first acquisition module 1 acquires initial position data of a real-time welding seam tracking point;
the first judging module 2 is configured to judge whether the preliminary position data is valid data according to a deviation between the preliminary position data and the position data of the last welding seam tracking point in a preset data container;
the first processing module 3 is used for writing the preliminary position data into the final position of the data container when the preliminary position data is valid data, and filtering the position data of the welding seam tracking point in the data container;
and the extraction module 4 is used for extracting the position data of the last welding seam tracking point in the data container after the filtering processing as the final position data of the real-time welding seam tracking point.
The real-time welding seam tracking system is characterized in that a welding seam tracking sensor is arranged at the front end of a welding gun and used for acquiring preliminary position data of a real-time welding seam tracking point, wherein the real-time welding seam tracking point is a groove position point which is not welded in front of the welding gun.
Thus, the first acquisition module 1 acquires the preliminary position data of the real-time weld tracking point through the weld tracking sensor. For example, in some embodiments, the weld tracking sensor is a vision sensor (e.g., a laser 3D camera), and the first acquisition module 1, when acquiring the preliminary location data of the real-time weld tracking point: acquiring original frame data acquired by a weld joint tracking sensor in real time; and analyzing and calculating the original frame data by an image analysis method to obtain the initial position data of the real-time welding seam tracking point.
In practical applications, when welding is just started (or when welding of another section of weld seam is started), the data container is empty, and at this time, the preliminary position data acquired by the first acquisition module 1 can be directly determined as valid data, so that, in some embodiments, the filter processing device for the weld seam tracking point further includes:
the second judgment module is used for judging whether the preset data container is empty or not;
the first execution module is used for judging the preliminary position data as effective data when a data container is empty, and taking the preliminary position data as final position data of the real-time welding seam tracking point;
and, only when the data container is not empty, the first judging module 2 executes: and judging whether the preliminary position data is valid data or not according to the deviation between the preliminary position data and the position data of the last welding seam tracking point in a preset data container.
When welding is just started (or another section of welding seam is started), the data container is empty, at the moment, a plurality of pieces of preliminary position data of the real-time welding seam tracking points can be repeatedly obtained, and finally effective preliminary position data are determined according to the plurality of pieces of preliminary position data, so that the condition that the validity of the preliminary position data of the subsequent welding seam tracking points is judged inaccurately due to the fact that the position data of the first welding seam tracking point is inaccurate is avoided; thus, in some embodiments, the weld tracking point filtering device further includes:
the third judgment module is used for judging whether the preset data container is empty or not;
the second execution module is used for acquiring a plurality of preliminary position data of the real-time welding seam tracking point when a data container is empty, calculating final effective preliminary position data according to all the preliminary position data, judging the final effective preliminary position data to be effective data, and taking the final effective preliminary position data as final position data of the real-time welding seam tracking point;
and, only when the data container is not empty, the first judging module 2 executes: and judging whether the preliminary position data is valid data or not according to the deviation between the preliminary position data and the position data of the last welding seam tracking point in a preset data container.
The method for calculating the final valid preliminary location data according to all the preliminary location data may be: calculating the average position data of all the preliminary position data as the final effective preliminary position data of the real-time weld tracking point (when the position data includes a plurality of coordinate values, calculating the average value of each coordinate as each coordinate value of the final effective preliminary position data, respectively). Or after the average position data of all the preliminary position data is obtained through calculation, the preliminary position data closest to the average position data is used as the final effective preliminary position data of the real-time weld joint tracking point. When the plurality of initial position data of the real-time welding seam tracking points are obtained, the positions of the welding seam tracking sensors are kept unmoved, so that the initial position data are collected for a plurality of times at the same position, and the initial position data obtained for a plurality of times are all set initial position data corresponding to the same real-time welding seam tracking points.
Generally, if the deviation between the preliminary position data and the position data of the last weld tracking point in the data container is too large, usually, the obtained position data of the tracking point is wrong due to system jitter, so that the deviation is too large, therefore, the position data of the weld tracking point can be discarded and the preliminary position data of the weld tracking point can be obtained again (namely, the position of the weld tracking sensor is kept not moving, and the preliminary position data of the real-time weld tracking point is obtained again by the first obtaining module 1), thereby avoiding the influence on filtering processing caused by invalid tracking points, greatly improving reliability, and preventing the problem that correct welding cannot be realized due to too large deviation between a weld tracking position signal output by the tracking system and a real weld position caused by system jitter.
In some embodiments, the weld extends only in a horizontal plane, and the position in the height direction does not change (for example, the weldment is a flat plate), in which case the weld tracking sensor may be a 2D sensor (for example, a 2D camera), and thus, the position data of the weld tracking point may include two coordinate data (X-coordinate, Y-coordinate) of a two-dimensional coordinate system (including X-axis and Y-axis that are perpendicular to each other); the weld tracking sensor may also be a 3D sensor (e.g., a 3D camera), and thus, the position data of the weld tracking point may include three coordinate data (X, Y, and Z coordinates) of a three-dimensional coordinate system including X, Y, and Z axes that are perpendicular to each other.
In other embodiments, the position of the weld varies in the height direction (e.g., the weldment is a non-flat workpiece), and in this case, the weld tracking sensor should be a 3D sensor (e.g., a 3D camera), so that the position data of the weld tracking point includes three coordinate data (X, Y, and Z coordinates) of a three-dimensional coordinate system including X, Y, and Z axes that are perpendicular to each other.
There are many methods for the first determination module 2 to determine the validity of the seam tracking point in real time.
For example, in some embodiments, the first determining module 2 determines whether the preliminary position data is valid data according to the deviation between the preliminary position data and the position data of the last weld trace point in the preset data container,
calculating distance data between the preliminary position data and the position data of the last welding seam tracking point in the data container;
and if the distance data is larger than a preset first deviation threshold value, judging that the preliminary position data is invalid data, otherwise, judging that the preliminary position data is valid data.
For example, in other embodiments, the first determining module 2 determines whether the preliminary position data is valid data according to the deviation between the preliminary position data and the position data of the last weld trace point in the preset data container,
respectively calculating difference absolute values between each coordinate of the preliminary position data and each coordinate of the last welding seam tracking point position data in the data container;
and if the absolute value of the difference value of at least one coordinate is larger than a preset second deviation threshold, judging that the preliminary position data is invalid data, otherwise, judging that the preliminary position data is valid data.
In practical application, one of the two modes can be independently adopted to judge the effectiveness of the real-time weld joint tracking point. Also can combine above-mentioned two kinds of modes to judge, at this moment, first judgement module 2 is when judging preliminary position data is valid data according to the deviation between preliminary position data and the last welding seam tracking point position data in the predetermined data container: calculating distance data between the preliminary position data and the position data of the last welding seam tracking point in the data container; respectively calculating difference absolute values between each coordinate of the preliminary position data and each coordinate of the last welding seam tracking point position data in the data container; and if the distance data is greater than a preset first deviation threshold or the absolute value of the difference value of at least one coordinate is greater than a preset second deviation threshold, judging that the preliminary position data is invalid data, otherwise, judging that the preliminary position data is valid data.
The data container is a virtual container with a fixed storage space, and can be used for containing position data of N welding seam tracking points at most, wherein N is a preset positive integer.
In this embodiment, the size of the filter window of the filtering process of the first processing module 3 is equal to the size of the data container, i.e., the filter window size D = N. The specific filtering method can be selected according to actual needs, the size of the filtering window can be set according to actual needs, and after the size of the filtering window of the filtering method is determined, the size of the data container can be set to be the same. For example, the filtering method is mean filtering, the size of the filtering window is 7-10, and correspondingly, the size of the data container is 7-10; but is not limited thereto.
Therefore, the first processing module 3 is used for writing the preliminary position data into the final position of the data container when the preliminary position data is valid data, and when filtering the position data of the welding seam tracking point in the data container,
after writing the preliminary position data into the final position of the data container, judging whether the data container is full;
and if so, filtering the position data of the welding seam tracking point in the data container.
Furthermore, since the size of the data container is fixed, when the data container is filled with data and then data is written into the data container, the previous data needs to be erased to write the data, so that the first processing module 3 is used for writing the preliminary position data into the final position of the data container when the preliminary position data is valid data, and filtering the position data of the welding seam tracking point in the data container,
judging whether the data container is full;
if not, directly writing the preliminary position data into the last of the data container;
if so, erasing the position data of the first welding seam tracking point in the data container (namely the position data of the welding seam tracking point with the first position in the data container), and writing the initial position data into the end of the data container.
In fact, the specific method of filtering processing can be selected according to actual needs, and a plurality of filtering processing methods with different filtering window lengths can be preset, so that when the data container is not full, the filtering processing method corresponding to the filtering window length can be selected according to the actual amount of the position data of the welding seam tracking point in the data container for filtering processing, and the accuracy of the welding seam tracking position can be further improved. At this time, the first processing module 3 is configured to, when the preliminary position data is valid data, write the preliminary position data into the last position of the data container, and when performing filtering processing on the position data of the weld tracking point in the data container: and acquiring the quantity of the position data of the welding seam tracking point of the data container, and selecting a filtering processing method with the length of a filtering window equal to the quantity in a plurality of preset filtering processing methods to filter the position data of the welding seam tracking point in the data container.
Sometimes, the weld is actually divided into multiple segments, step jitter actually exists between the segments (that is, there is a jump between the segments in at least one coordinate direction, for example, the height of a weld of a certain segment is greater than that of a weld of a previous segment), and at the alternate position between the segments, there is also a case where the deviation between the preliminary position data and the position data of the last weld tracking point in the data container is too large, but the step jitter inevitably causes the deviation between the preliminary position data of the real-time weld tracking point obtained again for multiple times continuously and the position data of the last weld tracking point in the data container to be too large compared with the case where the deviation is too large due to system jitter; therefore, in some preferred embodiments, the weld tracking point filtering device further includes:
an accumulation module for accumulating the super-threshold count by 1 when the preliminary location data is invalid data;
the fourth judging module is used for judging whether the super-threshold count is greater than the preset count threshold;
and the resetting module is used for emptying the data container and zeroing the super-threshold count when the super-threshold count is greater than the preset count threshold.
Wherein, the counting threshold value can be set according to actual needs. And once the count exceeding the threshold value is larger than the preset count threshold value, step jitter exists, the real-time welding seam tracking point at the moment is a welding seam tracking point on another section of welding seam, and the initial position data of the real-time welding seam tracking point acquired next time is directly put into the data container after the data container is emptied. Thereby avoiding interruption of the welding process by always regarding valid preliminary position data as invalid data.
It should be noted that the reset module is further configured to set the super-threshold count to zero once when the preliminary data is written into the data container once; therefore, the situation that the welding precision is influenced due to misjudgment of step jitter caused by the fact that the count of the super threshold value is accumulated to be larger than the preset count threshold value due to the fact that invalid data occur for many times intermittently due to the system jitter is avoided.
According to the method, the filtering processing device of the welding seam tracking point obtains the initial position data of the real-time welding seam tracking point; judging whether the preliminary position data is valid data or not according to the deviation between the preliminary position data and the position data of the last welding seam tracking point in a preset data container; if the preliminary position data are valid data, writing the preliminary position data into the last position of the data container, and filtering the position data of the welding seam tracking point in the data container; extracting the position data of the last welding seam tracking point in the data container after filtering processing as the final position data of the real-time welding seam tracking point; therefore, the phenomenon that the deviation between the welding seam tracking position and the real welding seam position is overlarge due to shaking can be avoided, and the accuracy and the stability of the automatic welding process are ensured.
Referring to fig. 3, an electronic device 100 according to an embodiment of the present application further includes a processor 101 and a memory 102, where the memory 102 stores a computer program, and the processor 101 is configured to execute the steps of the method for filtering the seam tracking point by calling the computer program stored in the memory 102.
The processor 101 is electrically connected to the memory 102. The processor 101 is a control center of the electronic device 100, connects various parts of the entire electronic device using various interfaces and lines, and performs various functions of the electronic device and processes data by running or calling a computer program stored in the memory 102 and calling data stored in the memory 102, thereby performing overall monitoring of the electronic device.
The memory 102 may be used to store computer programs and data. The memory 102 stores computer programs containing instructions executable in the processor. The computer program may constitute various functional modules. The processor 101 executes various functional applications and data processing by calling a computer program stored in the memory 102.
In this embodiment, the processor 101 in the electronic device 100 loads instructions corresponding to one or more processes of the computer program into the memory 102, and the processor 101 runs the computer program stored in the memory 102 according to the following steps, so as to implement various functions: acquiring initial position data of a real-time welding seam tracking point; judging whether the preliminary position data is valid data or not according to the deviation between the preliminary position data and the position data of the last welding seam tracking point in a preset data container; if the preliminary position data are valid data, writing the preliminary position data into the last position of the data container, and filtering the position data of the welding seam tracking point in the data container; and extracting the position data of the last welding seam tracking point in the data container after filtering processing as the final position data of the real-time welding seam tracking point.
According to the method, the electronic equipment acquires the initial position data of the real-time welding seam tracking point; judging whether the preliminary position data is valid data or not according to the deviation between the preliminary position data and the position data of the last welding seam tracking point in a preset data container; if the preliminary position data are valid data, writing the preliminary position data into the last position of the data container, and filtering the position data of the welding seam tracking point in the data container; extracting the position data of the last welding seam tracking point in the data container after filtering processing as the final position data of the real-time welding seam tracking point; therefore, the phenomenon that the deviation between the welding seam tracking position and the real welding seam position is overlarge due to shaking can be avoided, and the accuracy and the stability of the automatic welding process are ensured.
The embodiment of the present application further provides a storage medium, on which a computer program is stored, and the computer program runs the steps of the above-mentioned filtering processing method for a weld tracking point when being executed by a processor, so as to implement the following functions: acquiring initial position data of a real-time welding seam tracking point; judging whether the preliminary position data is valid data or not according to the deviation between the preliminary position data and the position data of the last welding seam tracking point in a preset data container; if the preliminary position data are valid data, writing the preliminary position data into the last position of the data container, and filtering the position data of the welding seam tracking point in the data container; and extracting the position data of the last welding seam tracking point in the data container after filtering processing as the final position data of the real-time welding seam tracking point.
The storage medium may be implemented by any type of volatile or nonvolatile storage device or combination thereof, such as a Static Random Access Memory (SRAM), an Electrically Erasable Programmable Read-Only Memory (EEPROM), an Erasable Programmable Read-Only Memory (EPROM), a Programmable Read-Only Memory (PROM), a Read-Only Memory (ROM), a magnetic Memory, a flash Memory, a magnetic disk, or an optical disk.
In summary, although the present invention has been described with reference to the preferred embodiments, the above-described preferred embodiments are not intended to limit the present invention, and those skilled in the art can make various changes and modifications without departing from the spirit and scope of the present invention, which are substantially the same as the present invention.
Claims (9)
1. A filtering processing method of a welding seam tracking point is applied to a real-time welding seam tracking system and is characterized by comprising the following steps:
A1. acquiring initial position data of a real-time welding seam tracking point;
A2. judging whether the preliminary position data is valid data or not according to the deviation between the preliminary position data and the position data of the last welding seam tracking point in a preset data container;
A3. if the preliminary position data are valid data, writing the preliminary position data into the last position of the data container, and filtering the position data of the welding seam tracking point in the data container;
A4. extracting the position data of the last welding seam tracking point in the data container after filtering processing as the final position data of the real-time welding seam tracking point;
if the preliminary position data are invalid data, acquiring the preliminary position data of the real-time welding seam tracking point again;
after the step a2, the method further includes:
A5. if the preliminary position data is invalid data, the super-threshold count is accumulated by 1;
A6. judging whether the super threshold count is greater than a preset count threshold;
A7. if so, emptying the data container and setting the super-threshold count to zero;
the super-threshold count is set to zero once each time the preliminary data is written to the data container.
2. The weld-tracking-point filter processing method according to claim 1, wherein the position data of the weld tracking point includes two coordinate data of a two-dimensional coordinate system, or the position data of the weld tracking point includes three coordinate data of a three-dimensional coordinate system.
3. The weld joint tracking point filtering processing method according to claim 1, wherein the step A2 comprises the following steps:
calculating distance data between the preliminary position data and the last weld tracking point position data in the data container;
and if the distance data is larger than a preset first deviation threshold value, judging that the preliminary position data is invalid data, otherwise, judging that the preliminary position data is valid data.
4. The weld joint tracking point filtering processing method according to claim 1, wherein the step A2 comprises the following steps:
respectively calculating difference absolute values between each coordinate of the preliminary position data and each coordinate of the position data of the last welding seam tracking point in the data container;
and if the absolute value of the difference value of at least one coordinate is larger than a preset second deviation threshold value, judging the preliminary position data to be invalid data, otherwise, judging the preliminary position data to be valid data.
5. The method for filter processing of weld tracking points according to claim 1, wherein the filter window size of the filter processing is equal to the size of the data container;
step a3 includes:
after writing the preliminary location data into the last location of the data container, determining whether the data container is full;
and if so, filtering the position data of the welding seam tracking point in the data container.
6. The weld joint tracking point filtering processing method according to claim 5, wherein the step A3 comprises the following steps:
judging whether the data container is full;
if not, directly writing the preliminary position data into the last of the data container;
if so, erasing the position data of the first welding seam tracking point in the data container, and writing the initial position data into the data container.
7. The utility model provides a filtering processing device of welding seam tracking point, is applied to real-time welding seam tracking system which characterized in that includes:
the first acquisition module is used for acquiring preliminary position data of the real-time welding seam tracking point;
the first judgment module is used for judging whether the preliminary position data is valid data or not according to the deviation between the preliminary position data and the position data of the last welding seam tracking point in a preset data container;
the first processing module is used for writing the preliminary position data into the last position of the data container when the preliminary position data is valid data, and filtering the position data of the welding seam tracking point in the data container;
the extraction module is used for extracting the position data of the last welding seam tracking point in the data container after the filtering processing as the final position data of the real-time welding seam tracking point;
if the preliminary position data are invalid data, the first acquisition module acquires the preliminary position data of the real-time welding seam tracking point again;
the filtering processing device of the welding seam tracking point further comprises:
an accumulation module for accumulating the super-threshold count by 1 when the preliminary location data is invalid data;
the fourth judging module is used for judging whether the super-threshold count is larger than a preset count threshold;
the reset module is used for emptying the data container and zeroing the super-threshold count when the super-threshold count is greater than a preset count threshold;
the reset module is further configured to zero the super-threshold count once each time the preliminary data is written to the data container.
8. An electronic device, characterized by comprising a processor and a memory, wherein a computer program is stored in the memory, and the processor is configured to execute the steps of the filter processing method of the weld tracking point according to any one of claims 1 to 6 by calling the computer program stored in the memory.
9. A storage medium on which a computer program is stored, which computer program, when being executed by a processor, executes the steps of the method for filter processing of weld tracking points according to any one of claims 1 to 6.
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