CN114063508A - Robot laser double-beam welding control system and control method - Google Patents
Robot laser double-beam welding control system and control method Download PDFInfo
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- CN114063508A CN114063508A CN202111343141.XA CN202111343141A CN114063508A CN 114063508 A CN114063508 A CN 114063508A CN 202111343141 A CN202111343141 A CN 202111343141A CN 114063508 A CN114063508 A CN 114063508A
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- laser
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- light source
- molten pool
- personal computer
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- G—PHYSICS
- G05—CONTROLLING; REGULATING
- G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
- G05B19/00—Programme-control systems
- G05B19/02—Programme-control systems electric
- G05B19/04—Programme control other than numerical control, i.e. in sequence controllers or logic controllers
- G05B19/042—Programme control other than numerical control, i.e. in sequence controllers or logic controllers using digital processors
- G05B19/0423—Input/output
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K26/00—Working by laser beam, e.g. welding, cutting or boring
- B23K26/20—Bonding
- B23K26/21—Bonding by welding
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K26/00—Working by laser beam, e.g. welding, cutting or boring
- B23K26/70—Auxiliary operations or equipment
- B23K26/702—Auxiliary equipment
-
- G—PHYSICS
- G05—CONTROLLING; REGULATING
- G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
- G05B2219/00—Program-control systems
- G05B2219/20—Pc systems
- G05B2219/24—Pc safety
- G05B2219/24215—Scada supervisory control and data acquisition
Abstract
The embodiment of the invention provides a robot laser double-beam welding control system, which comprises an industrial camera; an illumination source; a focusing mirror; a welding laser source; a second reflector; a molten pool; an industrial personal computer; welding a head; the industrial personal computer is communicated with the controller, so that the controller controls the welding laser source and the motor according to the instruction of the industrial personal computer, and the motor is used for adjusting the position of the focusing mirror; the irradiation light source reflects light to the second reflecting mirror through the first reflecting mirror, the second reflecting mirror reflects laser emitted by the welding laser source and light emitted by the irradiation light source to the focusing mirror coaxially, the focusing mirror focuses the laser to a molten pool, the industrial camera shoots a molten pool picture and sends the molten pool picture to the industrial personal computer, and the industrial personal computer controls the servo motor after analyzing and processing the stability of the molten pool picture, so that the position of the focusing mirror is adjusted, and stable molten pool pictures are obtained.
Description
Technical Field
The invention relates to the technical field of automatic control, in particular to a robot laser double-beam welding control system and a control method.
Background
The common wallboard structural member in aerospace structural members mainly comprises a skin and an internal reinforcing rib. The ribbed panel structure generally uses riveting or resistance spot welding to achieve connection between the skin and the studs. The two traditional connecting methods are high in labor intensity and low in structural strength, and damage can be caused to the integral integrity of the skin.
When the structure of laser welding is adopted, two laser beams can be adopted to weld from two sides of the stud. And the two laser beams are simultaneously welded from two sides of the T-shaped joint to form fillet welds, so that the fusion of the stud and the skin is facilitated, and the back of the skin is not damaged. Generally, the two sides of the T-shaped joint can be heated uniformly by adopting a double-beam welding process, so that deformation can be controlled. In addition, because two beams of laser are welded simultaneously, the heat input can be reduced under the interaction of a molten pool to generate the effect of 1+1 > 2.
The quality of laser welding depends on the stability of a molten pool in the laser welding process, and a high-quality welding seam can be formed only by the stable molten pool, so that the quality of the welding seam can be pre-judged by detecting the stability of the molten pool on line. However, in the high-power laser welding process, the metal base material is instantly vaporized under the action of a high-energy-density laser beam to form a keyhole, the metal vapor is subjected to electron collapse under the radiation of laser to form plasma with extremely high brightness, great difficulty is brought to the shooting and calculation of an image on the surface of a molten pool, meanwhile, the laser welding speed can reach more than 10m/min, and an effective molten pool image is difficult to obtain by adopting a traditional method.
Disclosure of Invention
In order to solve the problem that a stable molten pool image is difficult to obtain in the prior art, the embodiment of the invention provides a robot laser double-beam welding control system and a control method. The specific technical scheme is as follows:
the embodiment of the invention provides a robot laser double-beam welding control system, which comprises:
an industrial camera for taking an image of the molten pool;
a group of irradiation light sources which are coaxially input with the welding laser source through a first reflector with the function of a half-transmitting and half-reflecting mirror;
the irradiation light source transmits the irradiation light source to the focusing mirror through the first reflecting mirror, and provides a light source for the industrial camera;
a welding laser source; a second reflecting mirror for reflecting the welding laser to the focusing mirror;
a molten pool located below the focusing mirror by a preset distance;
the industrial personal computer is used for acquiring a molten pool image shot by the industrial camera, analyzing and processing the image and adjusting the movement speed of the servo motor;
welding a head;
the industrial personal computer is communicated with the controller, so that the controller controls the welding laser source and the motor according to the instruction of the industrial personal computer, and the motor is used for adjusting the position of the focusing mirror;
the irradiation light source reflects light to the second reflecting mirror through the first reflecting mirror, the second reflecting mirror reflects laser emitted by the welding laser source and light emitted by the irradiation light source to the focusing mirror coaxially, the focusing mirror focuses the laser to a molten pool, the industrial camera shoots a molten pool picture and sends the molten pool picture to the industrial personal computer, and the industrial personal computer controls the servo motor after analyzing and processing the stability of the molten pool picture, so that the position of the focusing mirror is adjusted, and stable molten pool pictures are obtained.
Furthermore, a supplementary light source is arranged around a nozzle of the welding head, a protective lens is arranged in front of the supplementary light source, and a cooling water jacket is arranged around the supplementary light source.
Further, the system also comprises a narrow-band filter which is arranged in front of the industrial camera and is used for filtering light; the irradiation light source adopts infrared laser with the wavelength of 830 nm.
Further, the industrial personal computer is respectively connected with the welding laser source, the motor and the PLC through an EtherCAT bus, and the illumination light source and the supplementary light source are connected with the PLC through I/O ports.
The second aspect of the present invention further provides a robot laser dual-beam welding control method, which is applied to any one of the robot laser dual-beam welding control systems described above; the method comprises the following steps:
and acquiring a molten pool image formed on the welding part by the illumination light source and the welding laser source under the focusing mirror shot by the industrial camera through the first reflecting mirror and the second reflecting mirror.
Further, before the acquiring the weld pool image formed on the weldment by the illumination light source and the welding laser source under the second focusing mirror photographed by the industrial camera through the first reflecting mirror and the second reflecting mirror, the method further comprises: and filtering the light beams formed by the irradiation light source and the welding laser source.
Further, the method also comprises the following steps:
when the industrial personal computer judges the brightness gradient value of the adjacent pixel points of each 20 pictures, if the brightness gradient value exceeds a preset brightness gradient threshold value, the industrial personal computer adjusts the position of the second focusing lens through the motor;
when the industrial personal computer judges that the molten pool is in an unstable state through the molten pool image, a signal for adjusting laser parameters is sent to the welding laser source;
and when the image does not meet the preset requirement, sending an instruction to the controller, and adjusting the brightness of the illumination light source or the supplementary light source by the controller.
Drawings
FIG. 1 is a schematic diagram of a preferred construction of a robotic laser dual-beam welding control system of the present invention;
FIG. 2 is a schematic view of a ring light source according to the present invention;
FIG. 3 is a schematic diagram of the connection structure of the control system of the present invention;
fig. 4 is a schematic diagram of the practical application process of the robot laser double-beam welding control system.
Detailed Description
The present invention is described below with reference to the accompanying drawings, but the present invention is not limited thereto.
Referring to fig. 1-3, fig. 1 is a schematic diagram of a preferred structure of a robot laser double-beam welding control system of the present invention, fig. 2 is a schematic diagram of a ring light source structure of the present invention, and fig. 3 is a schematic diagram of a connection structure of the control system of the present invention.
The robot laser double-beam welding control system shown in fig. 1 comprises:
an industrial camera for taking an image of the molten pool;
a group of irradiation light sources which are coaxially input with the welding laser source through a first reflector with the function of a half-transmitting and half-reflecting mirror;
the irradiation light source transmits the irradiation light source to the focusing mirror through the first reflecting mirror, and provides a light source for the industrial camera;
a welding laser source; a second reflecting mirror for reflecting the welding laser to the focusing mirror;
a molten pool located below the focusing mirror by a preset distance;
the industrial personal computer is used for acquiring a molten pool image shot by the industrial camera, analyzing and processing the image and adjusting the movement speed of the servo motor;
welding a head;
the industrial personal computer is communicated with the controller, so that the controller controls the welding laser source and the motor according to the instruction of the industrial personal computer, and the motor is used for adjusting the position of the focusing mirror;
the irradiation light source reflects light to the second reflecting mirror through the first reflecting mirror, the second reflecting mirror reflects laser emitted by the welding laser source and light emitted by the irradiation light source to the focusing mirror coaxially, the focusing mirror focuses the laser to a molten pool, the industrial camera shoots a molten pool picture and sends the molten pool picture to the industrial personal computer, and the industrial personal computer controls the servo motor after analyzing and processing the stability of the molten pool picture, so that the position of the focusing mirror is adjusted, and stable molten pool pictures are obtained.
The industrial camera adopts an infrared camera. The laser source for welding adopts irradiation laser with the wavelength of 830nm, the wavelength of the welding laser is 1064nm, and a narrow-band filter is arranged in front of the industrial camera and used for filtering light with the wavelength of 830 nm. A830 nm narrow-band filter is placed in front of an industrial camera, all light except 830nm is filtered, and interference of plasma and arc light on measurement is avoided.
The industrial camera transmits the acquired pictures to the industrial personal computer through a gigabit network, the picture resolution is 1280X1024, 2000fps, when the welding speed is 10m/min, the picture resolution is 1280X1024, 200fps, the industrial personal computer controls the industrial camera through an I/O port, in order to ensure the clarity of the pictures acquired by the industrial camera, the industrial personal computer judges the brightness gradient value of adjacent pixel points of the pictures once every 20 pictures, if the brightness gradient value exceeds a threshold value, the industrial personal computer sends a motion signal to a servo motor through an EtherCAT bus, the position of a focusing mirror 2 is adjusted, the clarity of the pictures acquired by the industrial camera is ensured, the servo motor and a driver adopt ecmax30 and epos4 of Maxon company, in order to improve the response speed, the servo motor is directly connected to the EtherCAT bus, the laser and the PLC are also connected with the industrial personal computer through the EtherCAT bus, when the molten pool image is judged to be unstable, the signals for adjusting the laser parameters are sent to the laser through the EtherCAT bus, and when the image is over-exposed or insufficient in brightness, the industrial personal computer sends a signal for adjusting the light source brightness to the PLC through the EtherCAT bus.
In order to ensure the stability of a control program, a grouping weighting judgment mode is introduced in the image processing, every ten pictures form a group, after each picture is judged, the whole group of pictures are comprehensively judged, the result with overlarge deviation is eliminated, and the laser parameters are adjusted according to the processed result.
The semi-transparent semi-reflecting mirror, the reflecting mirror and the narrow-band filter are arranged at preset angles for reflecting a preset amount of light to be used for shooting before the industrial camera, and the rest of light is reflected to be used for providing light for a molten pool to be imaged before the focusing mirror.
The illumination light sources are divided into two groups, and one group of coaxial illumination light sources are coaxially input with the welding laser source through the reflector, so that a welding pool can be fully illuminated, and the imaging of the pool is ensured; in order to make up for the defect of small irradiation light source range, another group of supplement light sources are arranged around the nozzle of the laser welding head, the light sources are annularly arranged to uniformly illuminate the whole welding area, and in order to ensure the reliability of the supplement light sources, a cooling water jacket is arranged around the annular light sources, and a protective lens is arranged in front of the annular light sources to ensure that the annular light sources are not damaged by heat radiation and splashes in the welding process.
Because the area of a laser welding molten pool is smaller by about 3mmX5mm, the industrial camera can meet the precision requirement of measurement without great resolution, the real-time processing speed can be greatly improved to be more than 100 frames/second, and the requirement of laser welding can be completely met.
The invention adopts a coaxial light path design, an industrial camera, illumination laser and welding laser are on the same optical axis, infrared laser with the wavelength of 830nm is used as an irradiation light source, a narrow-band filter with the wavelength of 830nm and OD5 is placed in front of the industrial camera, all light except the light with the wavelength of 830nm is attenuated by 100000 times, interference of plasma and arc light on measurement is avoided, in order to ensure clear imaging, the illumination light sources with the wavelength of 830nm are divided into two groups, the first group of coaxial illumination light is coaxially input with the welding laser beam through a semi-transparent half mirror, the welding pool area can be fully illuminated, and the pool imaging is ensured. Referring to fig. 2, in order to make up for the disadvantage of the small range of the first group of illumination light sources, the supplement light sources are arranged around the nozzle of the laser welding head to uniformly illuminate the whole welding area, and are annularly arranged.
Referring to fig. 3, the industrial personal computer is connected with the welding laser source, the motor and the PLC controller through an EtherCAT bus, and the illumination light source and the supplementary light source are connected with the PLC controller through an I/O port. High-power welding laser (1060nm) is focused by the first focusing lens, the industrial camera focuses and images through the second focusing lens, the influence of the change of the welding laser focal position on the imaging of the industrial camera when parts with different thicknesses are welded is avoided, meanwhile, the position of the second focusing lens is adjusted through the servo motor, and the control system can judge whether the camera focal position is accurate or not through comparing the brightness gradient values of adjacent pixel points of a picture and automatically adjust the camera focal position.
As the area of a laser welding molten pool is approximately about 3mmX5mm, the industrial camera with 120M pixels (1280X1024) can meet the precision requirement of measurement, the speed of image acquisition and real-time processing can be greatly improved, the current image acquisition can reach 1000 and 2000fps, the real-time processing can reach more than 500 frames/second, and the requirement of 10M/s laser welding can be completely met.
The embodiment of the invention provides a robot laser double-beam welding control system and a control method, wherein the system comprises: the device comprises an industrial camera, a narrow-band filter plate, a group of irradiation light sources, a welding laser source and a second reflecting mirror, wherein the industrial camera is used for shooting a molten pool image, the narrow-band filter plate is arranged in front of the industrial camera and used for filtering light rays, the group of irradiation light sources is coaxially input with a welding laser beam through the first reflecting mirror, the welding laser source is used for reflecting the welding laser to the second reflecting mirror of a focusing mirror, the industrial camera, the first reflecting mirror and the second reflecting mirror are arranged according to a preset angle, and the focusing mirror and the molten pool are positioned below the second reflecting mirror at a preset distance; the welding robot comprises an industrial personal computer and a welding head, wherein the industrial personal computer is used for acquiring a molten pool image shot by an industrial camera, analyzing and processing the image, adjusting the movement speed of the robot, and is connected with the welding laser source and the robot. The system is characterized in that a narrow-band filter is placed in front of an industrial camera to filter out other light rays except for an irradiation source, so that the interference of plasma and arc light on measurement is avoided; and the annular supplementary light source is arranged around the nozzle of the laser welding head, so that the characteristic of small irradiation range of the welding laser source is compensated, the whole welding area is uniformly illuminated, the reliability of the irradiation light source is ensured, and the problem that the stable molten pool image is difficult to obtain in the prior art is solved.
A second aspect of the invention provides a laser double-beam welding control method, which is applied to the laser double-beam welding control system; the method comprises the following steps:
and acquiring a molten pool image formed on the welding part by the illumination light source and the welding laser source under a focusing mirror shot by the industrial camera through the semi-transparent semi-reflecting mirror and the reflecting mirror.
Further, the method comprises the step of filtering light beams formed by the illumination light source and the welding laser source before a molten pool image formed on a welding part by the illumination light source and the welding laser source is obtained under a focusing mirror shot by the industrial camera through the semi-transparent semi-reflecting mirror and the reflecting mirror.
Although the invention has been described in detail above with reference to a general description and specific examples, it will be apparent to one skilled in the art that modifications or improvements may be made thereto based on the invention. Accordingly, such modifications and improvements are intended to be within the scope of the invention as claimed.
Claims (7)
1. A robot laser double-beam welding control system is characterized by comprising:
an industrial camera for taking an image of the molten pool;
a group of irradiation light sources which are coaxially input with the welding laser source through a first reflector with the function of a half-transmitting and half-reflecting mirror;
the irradiation light source transmits the irradiation light source to the focusing mirror through the first reflecting mirror, and provides a light source for the industrial camera;
a welding laser source; a second reflecting mirror for reflecting the welding laser to the focusing mirror;
a molten pool located below the focusing mirror by a preset distance;
the industrial personal computer is used for acquiring a molten pool image shot by the industrial camera, analyzing and processing the image and adjusting the movement speed of the servo motor;
welding a head;
the industrial personal computer is communicated with the controller, so that the controller controls the welding laser source and the motor according to the instruction of the industrial personal computer, and the motor is used for adjusting the position of the focusing mirror;
the irradiation light source reflects light to the second reflecting mirror through the first reflecting mirror, the second reflecting mirror reflects laser emitted by the welding laser source and light emitted by the irradiation light source to the focusing mirror coaxially, the focusing mirror focuses the laser to a molten pool, the industrial camera shoots a molten pool picture and sends the molten pool picture to the industrial personal computer, and the industrial personal computer controls the servo motor after analyzing and processing the stability of the molten pool picture, so that the position of the focusing mirror is adjusted, and stable molten pool pictures are obtained.
2. The robot laser double-beam welding control system as claimed in claim 1, wherein a supplementary light source is provided around a nozzle of the welding head, a protective lens is provided in front of the supplementary light source, and a cooling water jacket is provided around the supplementary light source.
3. The robotic laser dual beam welding control system as claimed in claim 1, further comprising a narrow band filter placed in front of the industrial camera for filtering light; the irradiation light source adopts infrared laser with the wavelength of 830 nm.
4. The robot laser double-beam welding control system according to claim 1, wherein the industrial personal computer is respectively connected with the welding laser source, the motor and the PLC through an EtherCAT bus, and the illumination light source and the supplementary light source are both connected with the PLC through an I/O port.
5. A robot laser double-beam welding control method, which is applied to the robot laser double-beam welding control system according to any one of claims 1 to 4; the method comprises the following steps:
and acquiring a molten pool image formed on the welding part by the illumination light source and the welding laser source under the focusing mirror shot by the industrial camera through the first reflecting mirror and the second reflecting mirror.
6. The robot laser dual-beam welding control method according to claim 5, further comprising, before acquiring the weld pool image formed on the weldment by the illumination light source and the welding laser source under a second focusing mirror photographed by the industrial camera through the first reflecting mirror and the second reflecting mirror, further comprising: and filtering the light beams formed by the irradiation light source and the welding laser source.
7. The robot laser dual-beam welding control method according to claim 5, further comprising:
when the industrial personal computer judges the brightness gradient value of the adjacent pixel points of each 20 pictures, if the brightness gradient value exceeds a preset brightness gradient threshold value, the industrial personal computer adjusts the position of the second focusing lens through the motor;
when the industrial personal computer judges that the molten pool is in an unstable state through the molten pool image, a signal for adjusting laser parameters is sent to the welding laser source;
and when the image does not meet the preset requirement, sending an instruction to the controller, and adjusting the brightness of the illumination light source or the supplementary light source by the controller.
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| Application Number | Priority Date | Filing Date | Title |
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| CN202111343141.XA CN114063508A (en) | 2021-11-12 | 2021-11-12 | Robot laser double-beam welding control system and control method |
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| CN202111343141.XA CN114063508A (en) | 2021-11-12 | 2021-11-12 | Robot laser double-beam welding control system and control method |
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| CN106825958A (en) * | 2017-03-16 | 2017-06-13 | 深圳市光大激光科技股份有限公司 | Integrated welding is agreed to play and takes the photograph structure and battery core automatic welding detection means and method |
| CN112828466A (en) * | 2021-03-01 | 2021-05-25 | 上海柏楚数控科技有限公司 | Control method, controller and system for monitoring and adjusting laser processing |
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2021
- 2021-11-12 CN CN202111343141.XA patent/CN114063508A/en active Pending
Patent Citations (6)
| Publication number | Priority date | Publication date | Assignee | Title |
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| DE202009014893U1 (en) * | 2009-12-21 | 2011-05-26 | LT Ultra-Precision-Technology GmbH, 88634 | Device for detecting and adjusting the focus of a laser beam in the laser machining of workpieces |
| CN103604813A (en) * | 2013-12-05 | 2014-02-26 | 上海彩石激光科技有限公司 | Molten pool monitoring device for laser processing process |
| CN204075508U (en) * | 2014-08-27 | 2015-01-07 | 深圳市大族激光科技股份有限公司 | A kind of laser Machining head with function for monitoring |
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