CN113504239B - Quality control data analysis method - Google Patents
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Abstract
The invention discloses a data analysis method for quality control of welded part product quality in automobile production, which comprises the steps of collecting a welding seam macroscopic image by a detection camera, detecting a welding seam contour and planning a detection path according to the contour; acquiring a microscopic image of the welding seam along a detection path, calculating the width and the change rate of the width of the welding seam, and detecting holes on the welding seam; the laser ranging sensor measures the distance along the detection path, calculates the roughness of the welding line, detects welding burrs and verifies whether the detection result of the hole is accurate or not; and finally, analyzing and controlling the quality of each detected parameter. The invention overcomes the problems of single detection item and inaccurate detection in the prior art, ensures good control of the quality of the automobile welding parts and ensures the quality of the whole automobile production.
Description
Technical Field
The invention belongs to the technical field of quality control data analysis, and particularly relates to a quality control data analysis method which is used for quality control of welding quality in automobile production.
Background
The welding plays a vital role in vehicle production, and is widely applied to each link in the vehicle production, and the appearance of a welding spot or a welding seam requires shallow and smooth surface indentation and uniform transition without obvious shoulder or local extruded surface bulge; the outer surface has no obvious annular or radial cracks, and also has no molten, burnt or adhered copper alloy, and the welding core has regular and uniform shape, no overproof cracks, shrinkage cavities and other internal defects, no obvious change of the metal structure and mechanical property of a heat affected zone and the like when viewed from the inside.
In the prior art, various weld detection means have appeared, such as a machine vision-based weld detection method, an X-ray-based weld detection method, an ultrasonic-based weld detection method, and an optical-device-based weld detection method. However, the detection means have the defects of complex detection means, insufficient detection precision, harm to human bodies and the like more importantly, the detection means have single detection items, cannot detect weld seams comprehensively, cannot realize good control of welding quality in automobile production, and restricts the development of the automobile industry.
Disclosure of Invention
In order to solve the technical problem, the invention provides a quality control data analysis method for quality control of welded part product quality in automobile production, which comprises the following steps:
s1, a detection camera collects a macroscopic image of a welding seam, detects to obtain a welding seam outline, compares the welding seam outline with a standard welding seam shape, calculates similarity, judges whether the welding seam outline is qualified or not, and plans a detection path according to the detected outline;
s2, acquiring a microscopic image of the welding seam along the detection path, calculating the width and the width change rate of the welding seam according to the microscopic image, and detecting holes on the welding seam;
s3, the laser ranging sensor measures the distance along the detection path, calculates the roughness of the welding line according to the distance measurement value, detects welding burrs and verifies whether the detection result of the hole in the step S2 is accurate or not;
and S4, analyzing all the detected parameters, and managing and controlling the quality of the welding parts according to the analysis result.
Optionally, step S1 specifically includes the following steps:
s1-1: positioning a welded component to be detected on a positioning device matched with the welded component;
s1-2: unifying coordinate systems of the detection camera and the laser ranging sensor, and unifying the coordinate systems of the detection camera and the laser ranging sensor into a world coordinate system;
s1-3: calibrating a detection system to obtain internal parameters of a detection camera and obtain translation matrix parameters and rotation matrix parameters between the detection camera and a laser ranging sensor;
s1-4: a macroscopic image of the entire part to be inspected is acquired while the entire part can be seen in the field of view of the inspection camera.
Optionally, in step S2, after the width direction of the weld occupies two thirds of the width of the field of view, a microscopic image of the weld is acquired along the detection path.
Optionally, in step S2, the controller controls the detection camera to move on the detection path at a fixed speed, and during the movement, the detection camera shoots the weld image at a fixed frequency, where the moving speed is proportional to the shooting frequency, so that two adjacent front and back images are at least partially overlapped.
Optionally, in step S2, after the image of the weld is captured, an image processing algorithm is used to detect whether a hole appears in the weld, calculate the width of the weld, calculate the change rate of the width of the weld, and associate a specific image with a specific position on the path to achieve fault location; when the holes are detected, the median filtering is firstly carried out on the image, then the image is sharpened, and then the histogram threshold segmentation algorithm is adopted for processing to determine whether the holes appear in the welding line.
Optionally, in step S3, when it is detected that the result of the laser ranging is suddenly increased and the increase value exceeds a threshold of one point, it is determined that a hole exists there, the hole acquired by the image is verified, and whether the image detection result is accurate is verified.
Optionally, in step S3, after the laser ranging data of the whole contour is obtained, curve fitting is performed on the distance point cloud data, differential derivation operation is performed on the curve, and when a differential derivation result at a certain position is higher than a certain threshold, it is determined that a relatively sharp burr exists in the weld at the position.
Optionally, in step S4, after the detection of each parameter is completed, each item of data is summarized and grouped, each group of data is drawn into a histogram, a quality distribution state is obtained according to the distribution condition of statistical data, the quality fluctuation is analyzed, and the product quality and the reject ratio are judged and predicted.
The beneficial effects of the invention are:
1. the method can simultaneously detect the welding seam outline, the welding seam width change rate, holes on the welding seam, the welding seam roughness and welding burrs, verify whether the detection result of the holes is accurate or not, overcome the problem of single detection project in the prior art, and comprehensively and accurately detect the welding seam.
2. Meanwhile, macroscopic image detection, microscopic image detection and laser ranging detection are carried out on the welding seam, and the macroscopic image detection, the microscopic image detection and the laser ranging detection are matched with each other and verified with each other, so that the effectiveness and the accuracy of detection are improved.
3. The macroscopic image detection provides a detection path for microscopic image detection and laser ranging detection, fault location can be achieved, and the measurement efficiency can be improved.
4. By carrying out differential derivation operation on the fitting curve of the laser ranging result, whether burrs appear on the welding line or not is detected, cutting, scratching or scratching workers or consumers and the like are avoided, and damage to parts assembled with the welding line can be caused.
5. The hole detection efficiency is high by adopting an image processing mode, the detection speed is high, but false detection may exist, so that the data of laser ranging is adopted to verify the hole detection efficiency, the false judgment is avoided on the basis of ensuring the detection speed, and the accuracy of hole detection can be ensured while the detection efficiency is ensured.
6. The moving speed of the detection camera is in direct proportion to the shooting frequency, so that at least part of two adjacent front and back images are overlapped, the images are clear, and the problems of shaking, blurring, ghosting and the like do not occur.
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FIG. 1 is a flow chart of a quality control data analysis method;
fig. 2 shows a specific flowchart of the quality control data analysis method step S1.
Detailed Description
In order to make the objects, technical solutions and advantages of the embodiments of the present invention clearer, the technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the drawings of the embodiments of the present invention. It is to be understood that the embodiments described are only a few embodiments of the present invention, and not all embodiments. All other embodiments, which can be derived by a person skilled in the art from the description of the embodiments of the invention given above, are within the scope of protection of the invention.
In the description of the present invention, it should be noted that the terms "center", "upper", "lower", "left", "right", "vertical", "horizontal", "inner", "outer", etc. indicate orientations or positional relationships based on the orientations or positional relationships shown in the drawings, only for the purpose of facilitating description of the present invention and simplifying description, but do not indicate or imply that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and thus, should not be construed as limiting the present invention. Furthermore, the terms "first," "second," and "third" are used for descriptive purposes only and are not to be construed as indicating or implying relative importance.
Example 1
After the welding of the automobile parts is completed, positioning devices, such as a positioning seat, a positioning frame, a positioning fixture and the like, which are correspondingly matched with the welded automobile parts are arranged according to the shapes of the welded automobile parts, so that the welded automobile parts can be stably positioned, and the subsequent weld joint detection is facilitated.
Be provided with welding seam detection device directly over positioner, welding seam detection device specifically includes detection camera, laser range finding sensor, detects three-dimensional removal bearing structure of camera, laser range finding sensor two-dimensional removal bearing structure and controller, and the CCD camera that adopts the high accuracy that the detection camera is preferred realizes to subsequent image processing. The detection camera is arranged on the detection camera three-dimensional moving support structure, the detection camera three-dimensional moving support structure can flexibly move in an XYZ three-dimensional space above the automobile part to be detected, and moving position information can be fed back to the controller.
The laser ranging sensor is arranged on the two-dimensional moving support structure of the laser ranging sensor, can move in an XY two-dimensional plane above the automobile part, and feeds back moving position information to the controller.
In the moving process of the detection camera and the laser ranging sensor, the controller can control the motion process and the track of the detection camera and the laser ranging sensor, and the controller also processes and analyzes detection data of the detection camera and the laser ranging sensor to obtain an automobile welding seam detection result.
As shown in fig. 2, when the detection is started, the welded automobile part to be detected is first positioned on the positioning device matched with the welded automobile part, and preferably, the welded automobile part is positioned by a positioning pin or clamped by a clamping device such as a clamp, so that the welded automobile part is stable during the detection, and the stability of the detection is ensured.
For example, after the engine cover assembly is welded, the engine cover assembly positioning seat is used for positioning the engine cover assembly, the engine cover assembly positioning seat comprises a bottom plate, a plurality of positioning blocks are arranged on the bottom plate, the shapes of the positioning blocks are matched with the shapes of corresponding areas of the engine cover, a clamping structure corresponding to the positions of the positioning blocks is further arranged above the engine cover assembly positioning seat, and the engine cover assembly is firmly positioned on the engine cover assembly positioning seat.
Before the detection starts, coordinate systems of the detection camera and the laser ranging sensor are unified, and the coordinate systems of the detection camera and the laser ranging sensor are unified into a world coordinate system so as to facilitate subsequent control, calculation and analysis. Meanwhile, in the image measuring process and machine vision application, in order to determine the correlation between the three-dimensional geometric position of a certain point on the surface of an object in space and the corresponding point in the image, geometric models of camera imaging must be established, and the geometric model parameters are camera parameters so as to facilitate subsequent calculation and analysis.
Preferably, a checkerboard calibration board can be adopted, and a zhangyou calibration algorithm is adopted to calibrate a detection camera of the detection system, so that internal parameters such as distortion of the detection camera are obtained, and translation matrix parameters and rotation matrix parameters of the detection camera and the laser ranging sensor are obtained.
The specific detection steps are as shown in fig. 1, after the preliminary preparation work is completed, the specific detection of the welding seam is started, the controller controls the detection camera to move in the Z-axis direction, namely the vertical direction, until the whole automobile part to be detected can be seen in the field of view, the movement is stopped, then the macroscopic image of the whole part is shot, an image processing algorithm is adopted to obtain the contour of the welding seam, the similarity calculation is carried out on the contour of the welding seam and the ideal contour of the welding seam, and whether the contour of the welding seam is qualified or not is judged.
Preferably, the contour of the welding seam is extracted by adopting an edge detection algorithm, and specifically, sobel operators, roberts operators, laplacian operators, canny operators and other operators can be used for detection.
And after the welding seam profile is obtained, the controller plans to obtain a subsequent detection path according to the welding seam profile obtained in the previous step and the shape and the trend of the welding seam profile. After obtaining the detection path, the controller controls the detection camera to move in the Z-axis direction, i.e. the vertical direction, so that the detection camera can shoot the detailed structure of the weld joint, preferably, when the width direction of the weld joint occupies two thirds of the field of view of the detection camera, the controller stops moving the detection camera in the Z-axis direction, and acquires the microscopic image of the weld joint along the detection path.
Then, the detection camera is moved in the XY plane according to the detection path obtained above, and the controller controls the three-dimensional moving support structure of the detection camera to move the detection camera on the detection path at a fixed speed, and the detection camera shoots the welding seam image at a fixed frequency during the movement. The moving speed is in direct proportion to the shooting frequency, when the moving speed is high, the shooting frequency is high, and when the moving speed is low, the shooting frequency is low, so that at least part of two front and back adjacent images are overlapped, the images are clear, and the problems of shaking, blurring, ghosting and the like are avoided.
After the series of images of the welding seam are shot, an image processing algorithm is adopted to detect whether the welding seam has holes or not, calculate the width of the welding seam, calculate the change rate of the width of the welding seam at the same time, and correlate the specific image with the specific position on the path so as to facilitate subsequent fault location.
When the hole detection is carried out, the median filtering is carried out on the image, then the image is sharpened, and then the histogram threshold segmentation algorithm is adopted for processing to obtain the hole image. If the welding seam is too narrow or too wide or the width of the welding seam changes too fast, the problem of welding quality is solved, so that the width of the welding seam is calculated by adopting the distance of pixels, the change rate of the width of the welding seam is judged according to the tangent of the edge of the welding seam, and the welding quality is judged by synthesizing the parameters.
After the detection is finished, the controller controls the detection camera to exit from the three-dimensional space above the automobile part, then the controller controls the two-dimensional movement supporting structure of the laser ranging sensor to drive the laser ranging sensor to move in the two-dimensional plane, the moving path is the detection path, the distance data of the welding line at the specific position on the detection path is obtained, the roughness of the welding line is calculated according to the distance data, whether burrs exist in the welding line is detected, and the detected hole is verified and verified during image detection.
Specifically, although the hole detection efficiency is high and the detection speed is high by adopting the image processing mode, the hole detection is realized by adopting the image processing mode during the image detection, the shape of the hole may be similar to that of the welding spot, and the welding spot is judged as the hole by mistake, so that the laser ranging data is adopted to verify the hole, and the misjudgment is avoided on the basis of ensuring the detection speed. The specific verification principle and mode are that, at the hole of the welding seam, the distance measurement result obtained by the laser distance measurement sensor has a large contrast with the normal distance measurement result of the welding seam, so when the sudden change of the laser distance measurement result is detected, more specifically, the laser distance measurement result is suddenly increased, and the increased value exceeds the moving threshold value, it is determined that the hole exists at the hole, and the detection result is adopted to verify and verify the hole result detected by the image.
On the basis of obtaining laser ranging data of the whole outline, curve fitting is carried out on the point cloud data of the distance, differential derivation operation is carried out on a curve, when the differential derivation result at a certain position is higher than a certain threshold value, it is judged that sharp burrs exist in a welding seam at the position, injury can be caused to a contacter, such as cut injury, scratch workers or consumers, damage can be caused to parts assembled with the welding seam, detection is carried out on the welding seam through the laser ranging result, subsequent processing is carried out after the detection, and hidden dangers are eliminated.
After the detection of each item is completed, the conditions of the contour, the width change rate, the holes, the roughness and the burrs of the welding line are obtained, the specific position of the welding line can be positioned, the detected holes are verified, each parameter of the welding line is ensured to be accurately detected, and the technical problems that the detection project is single and not accurate enough in the prior art are solved. Through the analysis of the detection data, the good control of the quality of the automobile welding parts is ensured, and the quality of the whole automobile production is ensured.
Specifically, various data are collected and grouped, each group of data is drawn into a histogram, and according to the distribution condition of statistical data, the research on the production process and the quality distribution state of a product, the investigation on engineering capacity, the analysis on control capacity and the like are carried out. And the quality condition of the product can be predicted and monitored, and the quality fluctuation is analyzed. And (3) processing the collected apparent disorder data by using the histogram to reflect the distribution condition of the product quality, and judging and predicting the product quality and the reject ratio. The data features that can be found through the histogram are: the distribution state of the data, the center position of the data, the size of the data discrete degree, and the relationship between the data and the specification. By these data characteristics, information on the quality status of the process can be transmitted more intuitively, the state of quality fluctuation can be found, and by studying the state of quality fluctuation, the status of the process can be grasped, thereby determining where to concentrate the force to perform quality improvement work.
Example 2
This embodiment is a further improvement on the basis of embodiment 1, and common parts of the technical solutions are not described herein again. In order to improve the quality of image acquisition, an annular light source matched with the detection camera is arranged on the three-dimensional moving support structure of the detection camera, the annular light source is an LED light source, and the three-dimensional moving support structure has the advantages of adjustable brightness, low temperature, balance, no flicker and no shadow, and can be added with a polaroid in a special embedded structure.
Example 3
The present embodiment is further improved on the basis of embodiment 1 or embodiment 2, and common parts of the technical solutions are not described herein again. Due to the influence of factors such as the emitting power of the semiconductor laser, the transmitting and receiving distance, etc., the intensity of the optical signal received by the receiving circuit will change greatly, and if proper calibration is not performed, the normal measurement result will be affected. Therefore, the laser ranging sensor is provided with a temperature compensation circuit for reducing the influence of the ambient temperature on the laser ranging.
While the foregoing is directed to the preferred embodiment of the present invention, it will be understood by those skilled in the art that various changes and modifications may be made without departing from the spirit and scope of the invention as defined by the appended claims.
Claims (4)
1. A quality control data analysis method is used for quality control of welded part product quality in automobile production and is characterized by comprising the following steps:
s1, a detection camera collects a macroscopic image of a welding seam, detects to obtain a welding seam outline, compares the welding seam outline with a standard welding seam shape, calculates similarity, judges whether the welding seam outline is qualified or not, and plans a detection path according to the detected outline;
the step S1 specifically includes the following substeps:
s1-1: positioning a welded component to be detected on a positioning device matched with the welded component;
s1-2: unifying coordinate systems of the detection camera and the laser ranging sensor, and unifying the coordinate systems of the detection camera and the laser ranging sensor into a world coordinate system;
s1-3: calibrating the detection system to obtain internal parameters of the detection camera and obtain translation matrix parameters and rotation matrix parameters between the detection camera and the laser ranging sensor;
s1-4: capturing a macroscopic image of the entire part to be inspected while the entire part can be seen within the field of view of the inspection camera;
s2, acquiring a welding seam microscopic image along a detection path, calculating the width and the width change rate of the welding seam according to the microscopic image, and detecting holes on the welding seam; specifically, after an image of a welding seam is shot, an image processing algorithm is adopted to detect whether the welding seam has a hole or not, the width of the welding seam is calculated, the change rate of the width of the welding seam is calculated, and the specific image is associated with the specific position on the path so as to realize fault positioning; when the holes are detected, firstly carrying out median filtering on the image, then sharpening the image, and then adopting a histogram threshold segmentation algorithm to process to determine whether holes appear in the welding line;
s3, the laser ranging sensor measures the distance along the detection path, the roughness of the welding line is calculated according to the distance measurement value, when the result of the laser ranging is suddenly increased and the increased value exceeds a certain threshold value, the existence of the hole is judged, and whether the detection result of the hole in the step S2 is accurate is verified according to the result; after laser ranging data of the whole contour are obtained, curve fitting is carried out on the distance point cloud data, differential derivation operation is carried out on the curve, and when the differential derivation result at a certain position is higher than a certain threshold value, it is judged that sharp burrs exist in the welding seam at the position;
and S4, analyzing all detected parameters, and managing and controlling the quality of the welding part according to the analysis result.
2. The quality control data analysis method according to claim 1, wherein in step S2, after the width direction of the weld occupies two thirds of the width of the field of view, a microscopic image of the weld is acquired along the detection path.
3. The quality control data analysis method according to claim 1 or 2, wherein in step S2, the controller is configured to control the detection camera to move at a fixed speed on the detection path, and during the movement, the detection camera captures the weld image at a fixed frequency, and the moving speed is proportional to the capturing frequency, so that two adjacent front and rear images are at least partially overlapped.
4. The method as claimed in claim 1, wherein in step S4, after the parameter detection is completed, the data are collected and grouped, each group of data is drawn into a histogram, a quality distribution state is obtained according to the distribution of statistical data, and quality fluctuation is analyzed to determine and predict product quality and failure rate.
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| CA2237640A1 (en) * | 1996-08-12 | 1998-02-19 | Centre De Recherche Industrielle Du Quebec | Apparatus and method for detecting surface defects |
| JP2003065985A (en) * | 2001-08-28 | 2003-03-05 | Matsushita Electric Works Ltd | Method for inspecting laser welding part and apparatus therefor |
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