CN113160415B - Three-dimensional visual information-based grid structure workpiece weld joint positioning method and system - Google Patents
Three-dimensional visual information-based grid structure workpiece weld joint positioning method and system Download PDFInfo
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Abstract
The invention provides a method and a system for positioning a welding seam of a grid structure workpiece based on three-dimensional visual information, which are used for preprocessing acquired point cloud data; processing the preprocessed point cloud data in a straight line fitting mode to obtain a line segment relative to each reinforcing steel bar, and performing discretization processing; classifying the fitted line segments according to a camera coordinate system, calculating corresponding male plumb lines and corresponding foot plumbs, calculating the size and the central point of a gap of a steel bar intersection point, and planning a welding track according to a calculation result; and (4) iteratively calculating and planning the welding track until the welding seam formed by the intersection of all the steel bars is found and the final welding track is formed.
Description
Technical Field
The invention belongs to the technical field of grid structure workpiece weld joint positioning, and particularly relates to a grid structure workpiece weld joint positioning method and system based on three-dimensional visual information.
Background
The statements in this section merely provide background information related to the present disclosure and may not constitute prior art.
With the rapid development of social economy, infrastructure construction is accelerated, and the number of applications of grid-structured workpieces represented by welded steel meshes is gradually increased. The welding seam of the grid structure workpiece is located at the cross position of the two steel bars, in the manual welding process, the transverse and vertical layers of steel bars need to be fixed in a lap joint mode and then welded, and due to the fact that the contact area of the cross position is small, the influence of human factors is large, and the welding quality is difficult to control.
In addition, the shortage of welding technicians and the increase of labor cost greatly reduce the production efficiency.
Just because of the above-mentioned shortcomings of manual welding, robotic automated welding is beginning to be used in many technical fields, especially precision machining. For welding of a specific structure, the current general method is to use a clamp with certain positioning precision to assist positioning in the welding process, and then perform precise path planning on the robot to ensure the welding quality. The welding process does not directly position the welding seam, depends on a high-precision tool, has high requirements on the tool and high input cost, and is difficult to control.
Disclosure of Invention
The invention provides a method and a system for positioning a welding seam of a grid-structure workpiece based on three-dimensional visual information, aiming at solving the problems.
According to some embodiments, the invention adopts the following technical scheme:
a method for positioning a welding seam of a grid structure workpiece based on three-dimensional visual information comprises the following steps:
preprocessing the acquired point cloud data;
processing the preprocessed point cloud data in a straight line fitting mode to obtain a line segment relative to each reinforcing steel bar, and performing discretization processing;
classifying the fitted line segments according to a camera coordinate system, calculating corresponding common vertical lines and vertical feet, calculating the size and the central point of a gap of a steel bar intersection point, and planning a welding track according to a calculation result;
and (4) iteratively calculating and planning the welding track until the welding seam formed by the intersection of all the steel bars is found and the final welding track is formed.
As an alternative embodiment, the specific process of preprocessing the acquired point cloud data includes: and sequentially carrying out filtering processing and clustering processing on the acquired point cloud data to obtain a point cloud cluster without noise points.
As an alternative embodiment, the preprocessing process includes first performing irrelevant point cloud removal and noise point processing, and then performing filtering processing or point cloud sparse processing.
As an alternative embodiment, after discretization, each steel bar segment is discretized into a point cloud and stored.
As an alternative embodiment, the specific process of calculating the public vertical line includes:
classifying the fitted straight line according to a camera coordinate system, traversing all line segments under the camera coordinate system, judging whether the line segments are in a transverse direction or a longitudinal direction, performing transverse and vertical grouping according to the obtained line segment point cloud, and expressing by using vectors;
selecting a horizontal line segment point cloud and a vertical line segment point cloud from the horizontal and vertical line cloud groups, marking end points of the line segments, and calculating and determining a public vertical line and a foot according to the end point coordinates and the length of the line segments.
As an alternative embodiment, the specific process of calculating the gap size and the gap center point of the intersection of the reinforcing bars includes:
in a camera coordinate system, setting lower steel bars with the distance from an origin along the Z-axis direction larger than a set value and upper steel bars with the distance smaller than a preset value, and judging the up-down relation of crossed horizontal line segments and vertical line segments according to the point cloud space position relation;
and determining the point of the radius of the steel bar represented by the line segment above the offset of the common vertical line segment, and calculating the gap between the steel bars according to the radius of the steel bar above the spatial position and the radius of the steel bar below the spatial position.
As an alternative embodiment, the specific process of planning the welding track includes: and calculating the end points and the central points of the welding track, and judging whether the welding track is a point or a line segment according to the size of the gap of the welding seam.
As a further limitation, the method specifically comprises the following steps: determining the coordinate of a point A obtained by offsetting the distance of the radius of the steel bar of the transverse line segment along the vertical line segment of the gap center point, and the coordinate of a point B obtained by offsetting the distance of the radius of the steel bar of the transverse line segment along the transverse line segment of the gap center point, searching a point G, forming a parallelogram with the two points and the gap center point M, and searching a symmetrical point F of the point about an MA axis, wherein when the welding track type of the intersection point of the steel bars, which is less than the set distance, is a point, the point A is a welding point; and when the type of the welding track with the distance between the intersection points of the steel bars larger than the set distance is a line segment, the line segment GF is the welding track.
A grid structure workpiece weld seam positioning system based on three-dimensional visual information, comprising:
a preprocessing module configured to preprocess the acquired point cloud data;
the fitting module is configured to process the preprocessed point cloud data in a straight line fitting mode to obtain a line segment relative to each reinforcing steel bar, and discretizes the line segment;
the welding track planning module is configured to classify the fitted line segments according to a camera coordinate system, calculate corresponding public vertical lines and vertical feet, calculate the size and the central point of a gap of a steel bar intersection point and plan a welding track according to a calculation result;
and the iterative calculation module is configured to calculate and plan the welding track iteratively until a welding seam formed by crossing all the steel bars is found and a final welding track is formed.
An electronic device comprises a memory, a processor and computer instructions stored in the memory and executed on the processor, wherein the computer instructions are executed by the processor to complete the steps of the method for positioning the weld of the grid-structure workpiece based on the three-dimensional visual information.
A computer readable storage medium for storing computer instructions, which when executed by a processor, perform the steps of the above-mentioned method for positioning a weld of a grid-structured workpiece based on three-dimensional visual information.
Compared with the prior art, the invention has the beneficial effects that:
the invention uses the three-dimensional visual information to position the cross-shaped welding seam position of the grid structure workpiece, thereby avoiding a fussy manual teaching part and improving the welding efficiency;
aiming at the welding of a grid structure workpiece, the invention is used for grids with different sizes in a certain range, does not need to specially manufacture a clamp, and has very high universality;
the method comprises the steps that a three-dimensional camera is used for shooting a welding scene to obtain three-dimensional visual information; preprocessing the obtained initial point cloud through a point cloud filtering algorithm to obtain a workpiece point cloud; and finally, the welding line point cloud is extracted through a grid structure welding line extraction algorithm, so that the workpiece welding line of the grid structure is positioned, the complex teaching work of the traditional automatic welding is avoided, the precision requirement on a workpiece fixture is reduced, and the welding efficiency is improved.
In order to make the aforementioned and other objects, features and advantages of the present invention comprehensible, preferred embodiments accompanied with figures are described in detail below.
Drawings
The accompanying drawings, which are incorporated in and constitute a part of this specification, are included to provide a further understanding of the invention, and are incorporated in and constitute a part of this specification, illustrate exemplary embodiments of the invention and together with the description serve to explain the invention and not to limit the invention.
FIG. 1 is a schematic diagram of a welding principle of a method for positioning a weld of a grid-structured workpiece based on three-dimensional visual information;
FIG. 2 (a) is a two-dimensional front view of a welding track plan of a first case of a grid structure workpiece weld positioning method based on three-dimensional visual information;
FIG. 2 (b) a welding trajectory planning two-dimensional left view of a case one of a grid structure workpiece weld positioning method based on three-dimensional visual information;
FIG. 2 (c) is a welding track planning two-dimensional top view of a case one of a grid structure workpiece weld positioning method based on three-dimensional visual information;
FIG. 3 (a) is a front view of a welding track planning two-dimensional schematic diagram of a second case of a grid structure workpiece weld positioning method based on three-dimensional visual information;
FIG. 3 (b) is a left view of a welding track planning two-dimensional schematic diagram of a second case of a grid structure workpiece weld positioning method based on three-dimensional visual information;
FIG. 3 (c) is a plan view of a welding track planning two-dimensional schematic diagram of a second case of a grid structure workpiece weld positioning method based on three-dimensional visual information;
FIG. 4 is a flowchart of a method for positioning a weld of a workpiece with a grid structure based on three-dimensional visual information.
The specific implementation mode is as follows:
the invention is further described with reference to the following figures and examples.
It is to be understood that the following detailed description is exemplary and is intended to provide further explanation of the invention as claimed. Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs.
It is noted that the terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of exemplary embodiments according to the invention. As used herein, the singular forms "a", "an" and "the" are intended to include the plural forms as well, and it should be understood that when the terms "comprises" and/or "comprising" are used in this specification, they specify the presence of stated features, steps, operations, devices, components, and/or combinations thereof, unless the context clearly indicates otherwise.
The method for positioning the welding seam of the grid structure workpiece based on the three-dimensional visual information comprises the following steps as shown in figure 4:
step S1: point cloud preprocessing;
the point cloud obtained by shooting through the 3D camera has the characteristics of more noise points, high point cloud density and complex scene. A workpiece point cloud without noise points and with sparse point density can be obtained through a series of filtering processing. And (4) clustering the point clouds belonging to the same steel bar into a class by a clustering method.
Step S2: performing point cloud straight line fitting on the reinforcing steel bars;
the point cloud clustered in the step S1 is a point cloud cluster distributed linearly, and a line segment relative to each reinforcing steel bar can be obtained in a linear fitting mode. And then dispersing the line segments into a point cloud for storage.
And step S3: solving a common vertical line;
1) And classifying the fitted straight line according to a camera coordinate system. Under the camera coordinate system, all line segments are traversed if | x k |>|y k If the horizontal direction is determined; if x k |≤|y k And | then, the vertical direction is considered. And performing horizontal and vertical grouping according to the obtained line point cloud. Let the transverse line segment have n pieces, which are marked as a i The longitudinal line segment has m pieces, and is marked as b j The direction vector of the set of transverse segments is noted
The direction vectors of the longitudinal segment groups are noted
2) Selecting a horizontal line segment point cloud and a vertical line segment point cloud from the horizontal and vertical point cloud group, line segment a i Are marked as A, B, and a line segment B j One end point of (a) is marked as C and D. AB length L 1 Length L of CD 2 . The vertical feet from the public vertical line to the horizontal line and the vertical line are respectively set as P and Q. Then the
And
the relationship of (c) is:
3) From the definition of the common vertical line, one can obtain:
solving the system of equations can yield t 1 、t 2 。
4) According to t 1 、t 2 The foot P and the foot Q can be obtained.
And step S4: calculating the size and the central point of the gap of the intersection point of the reinforcing steel bars;
1) In a camera coordinate system, a lower steel bar is arranged far away from the origin along the Z-axis direction, and an upper steel bar is arranged near the origin. Judging the upper and lower relations between AB and CD according to the point cloud space position relation, and obtaining two conditions: let AB be above CD for case one and AB below CD for case two. And solving the welding track of the case two to obtain a reference case one.
2) For case one, AB is above CD,let P 0 Setting Q for the point obtained by offsetting the radius of the steel bar represented by AB by the common vertical line segment PQ 0 For the point where the male vertical line PQ deviates from the radius of the reinforcement CD, P 0 Q 0 Is the gap between the steel bars.
The radius of the steel bar positioned at the upper part in space is R Upper part of The radius of the steel bar at the lower space position is R Lower part Then P is 0 、Q 0 The coordinates can be derived from the following equation:
the gap being a line segment P 0 Q 0 Is the gap center point M is P 0 、Q 0 The midpoint coordinate of (a).
Step S5: welding trajectory planning, as shown in fig. 1;
1)E 1 is formed by M point edges
The distance of the radius of the AB steel bar is deviated in the direction, and the specific coordinates are as follows:
2)F 1 is defined by M points
The direction is deviated from the distance of the radius of the CD reinforcing steel bar.
3) Find a point G 1 And E 1 、M、F 1 Form a parallelogramThe method is specifically realized as follows:
4) Find a point G 2 Is G 1 About axis ME 1 The symmetry point of (2) is specifically realized as:
5) And when the distance between the intersection points of the reinforcing steel bars is less than 3mm, the welding track type is a point. Point E 1 Is a welding spot; when the welding track type of the steel bar intersection points with the distance larger than 3mm is a line segment, the line segment G 1 G 2 Is a welding track. A two-dimensional schematic diagram of the weld trajectory plan for case one is shown in fig. 4.
Step S6: and (5) circulating S3-S5n m times, finding out the welding seams formed by the intersection of all the steel bars and planning the welding tracks.
In some embodiments, in the point cloud preprocessing in step S1, the point cloud needs to be removed and noise is processed before the point cloud is sparse.
In some embodiments, there are many geometric features available for the common perpendicular line of the out-of-plane straight line in step S3, and in view of the efficiency of the calculation, the preferred method is to use the theorem that the cross product of two perpendicular vectors is equal to zero.
In some embodiments, the radius of the upper and lower steel bars is removed when the size of the gap and the center point of the gap are found in step S4, so that the welding spot identification precision is improved.
In some embodiments, in step S5, it is determined whether the welding point or the welding line segment is obtained according to the actual scene requirement according to the 3mm welding gap.
The embodiment provides a method for positioning a welding seam of a grid structure workpiece based on three-dimensional visual information by analyzing the geometric characteristics of the grid structure workpiece and combining a point cloud processing method. The present embodiment mainly includes five stages: the first stage is point cloud pretreatment, wherein point cloud filtering and sparse are carried out by combining a specific welding scene, and then the point clouds belonging to a steel bar are clustered into a group of point clouds, so that the structuralization treatment taking each steel bar as a unit is facilitated; the second stage is to perform straight line fitting on each group of point clouds, fit the unordered point clouds into line segments relative to each reinforcing steel bar, and then discretize the line segments into new ordered point clouds; the third stage is to obtain the common perpendicular lines of two horizontal and vertical cross line segments, classify the point clouds of the line segments, and obtain the common perpendicular lines of the cross parts of the grid structure by using a geometrical relationship; the fourth stage is to calculate the gap and the central point of the welding seam; the fifth stage is welding track planning, firstly, the end points and the central points of the welding track are solved, and then whether the welding track is a point or a line segment is judged according to the size of the welding seam clearance.
As will be appreciated by one skilled in the art, embodiments of the present invention may be provided as a method, system, or computer program product. Accordingly, the present invention may take the form of an entirely hardware embodiment, an entirely software embodiment or an embodiment combining software and hardware aspects. Furthermore, the present invention may take the form of a computer program product embodied on one or more computer-usable storage media (including, but not limited to, disk storage, CD-ROM, optical storage, and the like) having computer-usable program code embodied therein.
The present invention is described with reference to flowchart illustrations and/or block diagrams of methods, apparatus (systems), and computer program products according to embodiments of the invention. It will be understood that each flow and/or block of the flow diagrams and/or block diagrams, and combinations of flows and/or blocks in the flow diagrams and/or block diagrams, can be implemented by computer program instructions. These computer program instructions may be provided to a processor of a general purpose computer, special purpose computer, embedded processor, or other programmable data processing apparatus to produce a machine, such that the instructions, which execute via the processor of the computer or other programmable data processing apparatus, create means for implementing the functions specified in the flowchart flow or flows and/or block diagram block or blocks.
These computer program instructions may also be stored in a computer-readable memory that can direct a computer or other programmable data processing apparatus to function in a particular manner, such that the instructions stored in the computer-readable memory produce an article of manufacture including instruction means which implement the function specified in the flowchart flow or flows and/or block diagram block or blocks.
These computer program instructions may also be loaded onto a computer or other programmable data processing apparatus to cause a series of operational steps to be performed on the computer or other programmable apparatus to produce a computer implemented process such that the instructions which execute on the computer or other programmable apparatus provide steps for implementing the functions specified in the flowchart flow or flows and/or block diagram block or blocks.
The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention, and various modifications and changes may be made by those skilled in the art. Any modification, equivalent replacement, or improvement made within the spirit and principle of the present invention should be included in the protection scope of the present invention.
Although the embodiments of the present invention have been described with reference to the accompanying drawings, it is not intended to limit the scope of the invention, and it should be understood by those skilled in the art that various modifications and variations can be made without inventive changes in the technical solutions of the present invention.
Claims (10)
1. A method for positioning a welding seam of a grid structure workpiece based on three-dimensional visual information is characterized by comprising the following steps: the method comprises the following steps:
preprocessing the acquired point cloud data;
processing the preprocessed point cloud data in a straight line fitting mode to obtain a line segment relative to each reinforcing steel bar, and performing discretization processing;
classifying the fitted line segments according to a camera coordinate system, calculating corresponding male plumb lines and corresponding foot plumbs, calculating the size and the central point of a gap of a steel bar intersection point, and planning a welding track according to a calculation result; the concrete process of calculating the public vertical line comprises the following steps:
classifying the fitted straight line according to a camera coordinate system, traversing all line segments under the camera coordinate system, and if | x k |＞|y k If the horizontal direction is determined; if x k |≤|y k Determining the point cloud as a longitudinal point, grouping the point clouds according to the obtained line segment points, and expressing the point clouds by using vectors;
selecting a horizontal line segment point cloud and a vertical line segment point cloud from the horizontal and vertical line cloud groups, marking end points of the line segments, and calculating and determining a plumb line and a foot according to end point coordinates and the length of the line segments;
and (4) iteratively calculating and planning the welding track until the welding seam formed by the intersection of all the steel bars is found and the final welding track is formed.
2. The method for positioning the welding seam of the grid structure workpiece based on the three-dimensional visual information as claimed in claim 1, characterized in that: the specific process of preprocessing the acquired point cloud data comprises the following steps: and sequentially carrying out filtering processing and clustering processing on the acquired point cloud data to obtain a point cloud cluster without noise points.
3. The method for positioning the welding seam of the grid structure workpiece based on the three-dimensional visual information as claimed in claim 2, characterized in that: in the pretreatment process, irrelevant point cloud removal and noise point treatment are firstly carried out, and then filtering treatment or point cloud sparse treatment is carried out.
4. The method for positioning the welding seam of the grid-structure workpiece based on the three-dimensional visual information as claimed in claim 1, which is characterized in that: after discretization, each steel bar segment is discretized into point cloud for storage.
5. The method for positioning the welding seam of the grid-structure workpiece based on the three-dimensional visual information as claimed in claim 1, which is characterized in that: the concrete process of calculating the gap size and the gap center point of the steel bar crossing point comprises the following steps:
in a camera coordinate system, setting a lower reinforcing steel bar with a distance from an origin along the Z-axis direction larger than a set value and an upper reinforcing steel bar with a distance smaller than a preset value, and judging the up-down relation of crossed horizontal line segments and vertical line segments according to the point cloud space position relation;
and determining the point of the radius of the steel bar represented by the line segment above the offset of the common vertical line segment, and calculating the gap between the steel bars according to the radius of the steel bar above the spatial position and the radius of the steel bar below the spatial position.
6. The method for positioning the welding seam of the grid-structure workpiece based on the three-dimensional visual information as claimed in claim 1, which is characterized in that: the specific process for planning the welding track comprises the following steps: and calculating the end points and the central point of the welding track, and judging whether the welding track is a point or a line segment according to the size of the gap of the welding seam.
7. The method for positioning the welding seam of the grid structure workpiece based on the three-dimensional visual information as claimed in claim 6, characterized in that: the method specifically comprises the following steps: determining the coordinate of a point A obtained by offsetting the distance of the radius of the steel bar of the transverse line segment along the vertical line segment of the gap center point, and the coordinate of a point B obtained by offsetting the distance of the radius of the steel bar of the transverse line segment along the transverse line segment of the gap center point, searching a point G, forming a parallelogram with the two points and the gap center point M, and searching a symmetrical point F of the point about an MA axis, wherein when the welding track type of the intersection point of the steel bars, which is less than the set distance, is a point, the point A is a welding point; and when the type of the welding track with the distance between the intersection points of the steel bars larger than the set distance is a line segment, the line segment GF is the welding track.
8. A grid structure workpiece weld joint positioning system based on three-dimensional visual information is characterized in that: the method comprises the following steps:
a preprocessing module configured to preprocess the acquired point cloud data;
the fitting module is configured to process the preprocessed point cloud data in a straight line fitting mode to obtain a line segment relative to each reinforcing steel bar and perform discretization processing;
the welding track planning module is configured to classify the fitted line segments according to a camera coordinate system, calculate corresponding public vertical lines and vertical feet, calculate the size and the central point of a gap of a steel bar intersection point and plan a welding track according to a calculation result; the concrete process of calculating the public vertical line comprises the following steps:
classifying the fitted straight line according to a camera coordinate system, traversing all line segments under the camera coordinate system, and if | x k |＞|y k If yes, determining the horizontal direction; if | x k |≤|y k Determining the point cloud as a longitudinal point, grouping the point cloud according to the obtained line segment points, and expressing the point cloud by using a vector;
selecting a horizontal line segment point cloud and a vertical line segment point cloud from the horizontal and vertical line cloud groups, marking end points of the line segments, and calculating and determining a plumb line and a foot according to end point coordinates and the length of the line segments;
and the iterative calculation module is configured to calculate and plan the welding track iteratively until a welding seam formed by crossing all the steel bars is found and a final welding track is formed.
9. An electronic device, characterized by: comprising a memory and a processor, and computer instructions stored on the memory and executed on the processor, wherein the computer instructions, when executed by the processor, perform the steps of the method for three-dimensional visual information based grid structure workpiece weld seam positioning according to any one of claims 1-7.
10. A computer-readable storage medium characterized by: for storing computer instructions which, when executed by a processor, perform the steps of a method for three-dimensional visual information based weld seam positioning of a grid-structured workpiece as claimed in any one of claims 1 to 7.
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