CN114083129A - Three-dimensional visual tracking welding robot and control method thereof - Google Patents
Three-dimensional visual tracking welding robot and control method thereof Download PDFInfo
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- CN114083129A CN114083129A CN202111549535.0A CN202111549535A CN114083129A CN 114083129 A CN114083129 A CN 114083129A CN 202111549535 A CN202111549535 A CN 202111549535A CN 114083129 A CN114083129 A CN 114083129A
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- 238000003466 welding Methods 0.000 title claims abstract description 323
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K26/00—Working by laser beam, e.g. welding, cutting or boring
- B23K26/20—Bonding
- B23K26/21—Bonding by welding
- B23K26/24—Seam welding
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K26/00—Working by laser beam, e.g. welding, cutting or boring
- B23K26/02—Positioning or observing the workpiece, e.g. with respect to the point of impact; Aligning, aiming or focusing the laser beam
- B23K26/04—Automatically aligning, aiming or focusing the laser beam, e.g. using the back-scattered light
- B23K26/044—Seam tracking
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K26/00—Working by laser beam, e.g. welding, cutting or boring
- B23K26/08—Devices involving relative movement between laser beam and workpiece
- B23K26/083—Devices involving movement of the workpiece in at least one axial direction
- B23K26/0853—Devices involving movement of the workpiece in at least in two axial directions, e.g. in a plane
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K26/00—Working by laser beam, e.g. welding, cutting or boring
- B23K26/08—Devices involving relative movement between laser beam and workpiece
- B23K26/0869—Devices involving movement of the laser head in at least one axial direction
- B23K26/0876—Devices involving movement of the laser head in at least one axial direction in at least two axial directions
- B23K26/0884—Devices involving movement of the laser head in at least one axial direction in at least two axial directions in at least in three axial directions, e.g. manipulators, robots
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K26/00—Working by laser beam, e.g. welding, cutting or boring
- B23K26/70—Auxiliary operations or equipment
- B23K26/702—Auxiliary equipment
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K37/00—Auxiliary devices or processes, not specially adapted to a procedure covered by only one of the preceding main groups
- B23K37/04—Auxiliary devices or processes, not specially adapted to a procedure covered by only one of the preceding main groups for holding or positioning work
- B23K37/0426—Fixtures for other work
- B23K37/0435—Clamps
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Abstract
The application relates to a three-dimensional visual tracking welding robot and a control method thereof. The welding mechanism comprises a laser welding head and a mounting frame. The visual tracking system comprises a three-dimensional camera, a support frame, a focus module and a welding line module, wherein the three-dimensional camera is used for capturing a material welding line image, the focus module is used for detecting a laser focus, and the welding line module is used for detecting the position of a welding line to be processed of a material, the welding line state in the actual processing process and the quality calibration after the welding line is processed. The application provides a three-dimensional visual tracking welding robot adopts simulation system to set for standard welding seam parameter, generates basic welding seam route and the standard welding seam contrast that simulation system set for according to focus module and welding seam module detected signal, obtains real-time adjustment behind the route deviation, can three-dimensional visual tracking high accuracy last welding to with three-dimensional digital model display, facilitate the use.
Description
Technical Field
The invention relates to the field of welding, in particular to a three-dimensional visual tracking welding robot and a control method thereof.
Background
Welding is a comprehensive processing process combining light, electricity, heat and force, the heat generated in the welding process can cause a welding workpiece to generate larger thermal deformation, so that welding position deviation is generated, and in order to overcome the influence of the deviation, two modes are mainly used at present, and one mode adopts a high-precision clamp for positioning. Another method of weld seam tracking using sensors has been found by comparison to be much more economical than using precision clamps.
The welding seam tracking system is divided into arc sensing, contact sensing, ultrasonic sensing and visual sensing due to the difference of the sensors, wherein the visual sensing is far away from an arc strong light hot area, so that the amount of collected information is large, and people favor the welding seam tracking system. The vision sensor is used for converting optical images into electric signals, namely, converting light intensity information (such as visible light, laser, X-ray, infrared ray, ultraviolet ray or electron bombardment and the like) which is emitted by a person to a photosensitive surface of the sensor and is distributed according to space into electric signals which are output in series according to time sequence, namely, converting the electric signals into video signals.
At present, a vision sensor widely applied in welding is a CCD camera which is divided into a linear array and an area array, wherein the linear array CCD can shoot a one-dimensional image, and the area array CCD can shoot a two-dimensional plane image. The image picked up by the vision sensor is converted into a gray matrix after space sampling and analog-to-digital conversion, and the gray matrix is sent into a computer memory to generate a digital image. When the CCD works, signal congestion occurs when the data size is large, so that the requirement of high-speed reading of high-definition data during welding cannot be met. In addition, one-dimensional and two-dimensional plane images need to be judged and read manually by professionals, so that the welding production management cost is increased, and large-area continuous automatic operation is not facilitated. In addition, in the process of shooting, the existing visual sensor is limited by various conditions and interfered by random factors, image transformation, enhancement or recovery and other preprocessing are often carried out on the visual sensor, a three-dimensional welding seam is converted into an operable one-dimensional and two-dimensional model, so that phenomena such as noise filtration, gray scale correction, distortion and the like are caused, control variable parameters need to be added, and then the three-dimensional welding seam is sent to an execution mechanism to avoid interference, so that tracking control on the welding seam is realized. This results in problems of slow processing speed, false appearance, etc. in the actual operation of the vision sensor. In addition, the existing welding device has a single welding path, and is difficult to realize a complex welding path track.
The invention provides a three-dimensional visual tracking welding robot and a control method thereof, wherein a simulation system is adopted to set standard welding seam parameters, a basic welding seam path is generated according to detection signals of a focus module and a welding seam module and is compared with the standard welding seam set by the simulation system, welding can be carried out in a high-precision state, welding seam deviation and three-dimensional conversion errors existing in the traditional one-dimensional and two-dimensional modes are overcome, and the three-dimensional visual tracking welding robot is displayed by a three-dimensional digital model and is convenient to use.
Disclosure of Invention
The present invention is directed to a three-dimensional vision tracking welding robot and a control method thereof, so as to solve the problems set forth in the background art.
The invention provides the following technical scheme: the utility model provides a three-dimensional visual tracking welding robot, includes frame, workstation, sets up welding mechanism, visual tracking system, simulation system and the control system on the workstation, welding mechanism includes laser welding head and the mounting bracket of installation laser welding head, the mounting bracket is fixed to be set up in workstation one side, the inside movable mounting motor driven pivot A of mounting bracket, laser welding head rear end is fixed on pivot A, and pivot A can drive laser welding head and reciprocate. The workbench is provided with a material area, and materials to be welded are fixed in the material area in advance. The visual tracking system comprises a three-dimensional camera, a support frame for fixing the three-dimensional camera, a focus module and a welding line module, wherein the support frame is L-shaped, the lower end of the support frame is vertically and fixedly arranged on the rack, the upper end of the support frame is fixed at the upper end of the material area as a cantilever, the three-dimensional camera is used for grabbing a material welding line image, the focus module detects a laser focus by adopting a threshold segmentation method, the welding line module detects the actual state of a welding line by adopting a gray projection method, the welding line module is also used for detecting the position of the welding line to be processed of the material and the quality calibration after the welding line is processed, the visual tracking system, the simulation system and the control system are in communication connection with one another, and the workbench, the welding mechanism and the control system are in electric connection with one another. The simulation system can set standard welding seam parameters and generate a standard welding seam path, the control system can generate a basic welding seam path according to detection signals of the focus module and the welding seam module and compare the basic welding seam path with the standard welding seam path set by the simulation system in real time, and automatically adjust the welding path according to a comparison error to fill up the deviation.
Further, the welding mechanism further comprises a guide rail, a vertical support arm is fixedly arranged on the left side of the rack, a horizontal front-back sliding groove is transversely formed in the middle of the support arm, an electric push rod A is horizontally and movably arranged in the sliding groove at one end of the guide rail, the other end of the guide rail is fixedly connected with the mounting frame, and the electric push rod A can drive the guide rail and the mounting frame to move back and forth. The vision tracking system also comprises a rotating frame for mounting the three-dimensional camera, the rotating frame is movably arranged at the lower end of the cantilever of the support frame, a rotating shaft is arranged at the joint, the rotating shaft can enable the rotating frame and the three-dimensional camera to rotate in the vertical direction relative to the support frame, an arc-shaped groove is formed in the spherical body of the rotating frame, a rotating shaft B is arranged in the arc-shaped groove, the three-dimensional camera is mounted in the arc-shaped groove and is movably connected with the rotating frame through the rotating shaft B, the rotating shaft B can drive the three-dimensional camera to rotate forwards and backwards, the control system controls the electric push rod A to move the guide rail, the guide rail drives the mounting frame, the mounting frame drives the laser welding head to move relatively to the identification area and the material area of the three-dimensional camera, and the control system synchronously controls the rotating shaft B and the rotating shaft to drive the three-dimensional camera to synchronously rotate according to the deviation of a welding path in the welding process, thereby obtaining an image of the welding process in real time.
Further, the workstation still includes a plurality of splint, and splint are the vertical setting of cuboid platelike on the workstation, including horizontally face and both sides circular arc limit, the face and the face or face and circular arc limit through different splint press from both sides tight material. The inside cavity of splint forms the passageway and runs through and sets up pivot C, and pivot C upper end exposes splint and sets up the identification point, and the work area of splint is confirmed through the identification point to the three-dimensional camera to confirm the material district. The rotating shaft C can enable the clamping plates to move back and forth along the horizontal direction of the plate surface, the lower end of the rotating shaft C is movably connected with the rotary table, the rotary table is used for driving the clamping plates to rotate, the control system obtains the material and the shape of a welding seam through the three-dimensional camera, and generates a program of a clamping algorithm so as to control the relative motion of different clamping plates to clamp the material, and the clamping plates are matched with a welding track to move in the welding process.
Furthermore, the splint are four, mutually perpendicular, can fix a plurality of same materials simultaneously or once fix a plurality of positions of material, the face and the circular arc limit of splint all cover elastic bulge and pressure sensor, elastic bulge includes hemisphere face and shaft-like, is used for fixing the material of different grade type respectively. The elastic bulge can protect the material and the clamping plate, the material and the clamping plate are prevented from being mutually abraded, and the pressure sensor can feed back whether the clamping plate completely fixes the material. The outer gear is arranged at the upper end of the rotating shaft C, the inner gear ring groove is formed in the upper end of the clamping plate and is meshed with the outer gear of the rotating shaft C, the outer gear of the rotating shaft C rotates in the inner gear ring groove, the clamping plate moves back and forth relative to the rotating shaft C, and therefore the material is fixed at the relative position of the clamping plate and the material.
Further, the fixed ball that changes that sets up of splint lower extreme, the workstation lower extreme sets up hemispherical groove body, changes ball lower extreme movable mounting in hemispherical groove body, change the fixed a plurality of solenoid that set up of ball lower extreme, the center sets up the bearing block, and the side sets up displacement sensor, set up annular groove between displacement sensor and the hemispherical groove body for detect the relative position who changes the ball, hemispherical groove body inner wall sets up a plurality of electro-magnets, electro-magnet and solenoid and control system electric connection. The control system controls the electrification of different electromagnetic coils and the generation of mutual attraction and repulsion force of the electromagnets to enable the rotary ball to freely rotate 180 degrees relatively in the hemispherical groove body, and simultaneously the rotary ball drives the clamping plate to freely rotate 180 degrees relatively to the laser welding head, so that the inclination angle of a welding line is generated, a complex welding line track can be realized, and the relative position of the rotary ball is determined by the feedback control system of the displacement sensor.
Further, hemispherical groove body lower extreme sets up the transportation track, workstation one side sets up electric putter B, the hemispherical groove body of electric putter B one end fixed connection, other end fixed connection frame, electric putter B are used for driving hemispherical groove body and remove in the transportation track, electric putter B and control system electric connection set up the manipulator around the frame, and front end manipulator snatchs between material to the splint, and the material after the rear end gripper snatchs the welding and accomplishes is put into qualified type and unqualified type respectively, and the material of the type of waiting to repair is directly repaired on the workstation, and reclassification is up to dividing into qualified or unqualified type after the completion of repairing to snatch the transportation by rear end gripper.
Further, control system still includes display and alarm, the display is fixed at the frame front end for the PC end, the alarm includes display lamp, bee calling organ and remote calling end, display and alarm communication connection, the alarm is used for feeding back welding anomaly and feeds back to the display, and remote calling end can in time feed back alarm information to maintenance personal and the long-range interface that conveys the display, the display can receive and show welding anomaly image. When the welding parameters are abnormal or the welding path is suddenly changed, the display lamp flickers, the buzzer gives an alarm, the control system automatically stops the welding mechanism, and the abnormal type is sent to the display and the remote calling terminal.
A control method of a three-dimensional visual tracking welding robot comprises the following steps:
A. before the welding process, materials to be welded are fixed through relative movement and rotation of a clamping plate, a rotating shaft C, a rotating disc and a rotating ball, welding seam parameters and various standard welding seam paths are set in advance in a simulation system, then a control system controls a three-dimensional camera to acquire images of welding seams of the materials, a welding seam module converts the acquired images into welding seam images through characteristic capture and compares the welding seam images with the standard welding seam paths set by the simulation system, and the control system obtains a simulated welding seam path and a welding seam welding completion state;
B. the control system controls the guide rail and the mounting rack to enable the laser welding head to perform welding actions according to the simulation path, and meanwhile the clamping plate, the rotating shaft C, the rotating disc and the rotating ball drive materials to move relatively to match with the welding path;
C. in the welding process, a three-dimensional camera acquires an actual image of the welding process of the welding seam in real time, the actual welding seam is compared with a simulated welding seam, a focus module detects a laser focus by adopting a threshold segmentation method, a welding seam module detects the actual state of the welding seam by adopting a gray projection method, a control system forms a three-dimensional space relative coordinate position of the laser focus and the welding seam by using a three-time linear array or a secondary planar array, and the relative position deviation delta H of the welding seam is filled in real time by using the actual position;
D. after welding is completed, the three-dimensional camera acquires the state of a welding seam, the welding seam module carries out finish degree comparison with the welding seam welding completion state set by the simulation system, the welding seam is divided into a qualified type, a to-be-repaired type and an unqualified type, wherein the repair parameters of the to-be-repaired type welding seam are calculated by the simulation system, the welding seam welding step is repeated by the control system to complete repair, and the qualified material and the unqualified material are conveyed to the next process by the mechanical gripper in a classified mode.
Furthermore, the simulation system simulates a welding seam path and the welding seam welding completion state and displays the welding seam path and the welding seam welding completion state on the display in a digital three-dimensional model mode, and the actual welding process of the control system constructs a digital model in a point-to-point mode and displays the digital model on the display in a split screen mode, so that an operator can conveniently observe the welding state of the welding seam.
Furthermore, the relative position deviation of the welding seam is filled by two-section control, a displacement proportion regulation method is adopted when the deviation exceeds H, a fuzzy regulation method is adopted when the deviation does not exceed H, the slow adjustment speed of large deviation and the low adjustment precision of small deviation are prevented,
displacement proportion regulation and control method: the relative position deviation delta H = delta S/COS alpha of the welding seam, wherein delta S is the relative position of the welding seam obtained by the three-dimensional camera in real time, and alpha is the included angle between the three-dimensional camera and the laser welding head;
fuzzy regulation and control method: and the relative position deviation of the welding seam is delta H = K E + (1-K) E1, wherein E is the deviation under the fuzzy algorithm, E1 is the deviation rate under the fuzzy algorithm, and K is a fuzzy related parameter.
Compared with the prior art, the invention has the following beneficial effects:
1. the simulation system is adopted to set standard welding seam parameters, a basic welding seam path is generated according to detection signals of the focus module and the welding seam module and compared with a standard welding seam set by the simulation system, welding seam deviation and three-dimensional conversion errors existing in the traditional one-dimensional and two-dimensional modes are overcome, the deviation value is adjusted in real time, and finally the welding seam is displayed in a three-dimensional digital model, so that the use is convenient, and the precision is high.
2. The control system can synchronize the guide rail and the mounting rack to enable the laser welding head to move relative to the welding line, meanwhile, the turntable is controlled to drive the clamping plate, the clamping plate drives the material to generate the conversion of the welding path, and the clamping plate can rotate freely along with the rotating ball for 180 degrees relatively, so that the complex welding path can be completed.
3. The plurality of clamping plates move relative to each other to pre-position the material with the complex shape, the identification point is arranged to feed the material area back to the three-dimensional camera, the control system controls the rotating frame to enable the three-dimensional camera to cover the material area constantly, and the relative movement of the laser welding head and the welding line can be prevented from being separated from the tracking area of the three-dimensional camera.
4. The relative position deviation of the welding seam is filled through two-section control, so that the welding deviation can be adjusted in time, and the welding deviation is prevented from further expanding.
Drawings
The accompanying drawings, which are included to provide a further understanding of the invention and are incorporated in and constitute a part of this specification, illustrate embodiments of the invention and together with the description serve to explain the principles of the invention and not to limit the invention. In the drawings:
FIG. 1 is a schematic view of a three-dimensional vision tracking welding robot of the present invention;
FIG. 2 is a schematic view of a laser welding head of a three-dimensional vision tracking welding robot according to the present invention;
FIG. 3 is a bottom view of a three-dimensional visual tracking welding robot visual tracking system of the present invention;
FIG. 4 is a half-sectional view of a clamping plate of a three-dimensional vision tracking welding robot of the present invention;
FIG. 5 is a top view of a clamping plate of a three-dimensional vision tracking welding robot of the present invention;
FIG. 6 is a schematic diagram of the arrangement of clamping plates of a three-dimensional vision tracking welding robot according to the present invention;
in the figure: 1. the automatic welding machine comprises a frame, 2, a workbench, 201, a clamping plate, 202, rotating shafts C, 203, identification points, 204, a rotary plate, 205, elastic protrusions, 206, a rotating ball, 207, a hemispherical groove body, 208, a transportation track, 209, an electric push rod B, 3, a laser welding head, 4, a mounting rack, 5, a rotating shaft A, 6, a three-dimensional camera, 601, a rotating rack, 602, a rotating shaft B, 603, an arc-shaped groove, 7, a supporting rack, 701, a rotating shaft, 8, a guide rail, 9 and a supporting arm.
Detailed Description
The technical solution in the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings in the embodiments of the present invention.
Referring to fig. 1-6, the present invention provides the following technical solutions: the invention discloses a three-dimensional visual tracking welding robot which comprises a rack 1, a workbench 2, a welding mechanism arranged on the workbench 2, a visual tracking system, a simulation system and a control system. Welding mechanism includes laser welding head 3, installation laser welding head 3's mounting bracket 4 and fixed mounting bracket 4's guide rail 8, 1 left side of frame is fixed to be set up vertical support arm 9, support arm 9 transversely sets up the horizontally spout of setting all around, the horizontal movable mounting of guide rail 8 left end forms cantilever and left end in the spout and sets up electric putter A, electric putter A can drive guide rail 8 and the 4 back-and-forth movements of mounting bracket, electric putter A is controlled by control system, 8 right-hand members fixed connection mounting bracket 4 of guide rail, 4 inside movable mounting motor drive's of mounting bracket pivot A5, laser welding head 3 rear end is fixed on pivot A5, pivot A5 can drive laser welding head 3 and reciprocate. The worktable 2 is provided with a material area, and the material to be welded is placed in the material area. The visual tracking system comprises a three-dimensional camera 6, a support frame 7 for fixing the three-dimensional camera 6, a focus module and a welding line module, wherein the support frame 7 is L-shaped, the lower end of the support frame 7 is vertically and fixedly arranged on the rack 1, the upper end of the support frame is fixed at the upper end of the material area as a cantilever, the three-dimensional camera 6 is used for grabbing a material welding line image, the focus module detects a laser focus by adopting a threshold segmentation method, the welding line module detects the actual state of a welding line by adopting a gray projection method, the welding line module is also used for detecting the position of the welding line to be processed of the material and the quality calibration after the welding line is processed, and the welding line module divides the welded material into three types of qualified materials, repaired materials and unqualified materials. The visual tracking system, the simulation system and the control system are in communication connection with each other, and the workbench 2, the welding mechanism and the control system are electrically connected. The simulation system can set standard welding seam parameters and generate a standard welding seam path, the control system can generate a basic welding seam path according to detection signals of the focus module and the welding seam module and compare the basic welding seam path with the standard welding seam path set by the simulation system in real time, and automatically adjust the welding path according to a comparison error to fill up the deviation. The simulation system stores welding paths of different welding lines inside, automatically generates a standard welding path of the welding line according to the actual welding line captured by the three-dimensional camera 6, the generated standard welding path is a combination of one or more stored standard welding paths, and controls the relative movement of the welding mechanism and the workbench 2 by the control system to complete welding of the welding line and fill up deviation.
The visual tracking system further comprises a rotating frame 601 for installing the three-dimensional camera 6, the rotating frame 601 is hemispherical, the rotating frame 601 is movably installed at the lower end of a cantilever of the support frame 7, a rotating shaft 701 is arranged at the joint, the rotating shaft 701 can enable the rotating frame 601 and the three-dimensional camera 6 to rotate in the vertical direction relative to the support frame 7, the rotating frame 601 is an arc-shaped groove 603 arranged inside a sphere, a rotating shaft B602 is arranged in the arc-shaped groove 603, the three-dimensional camera 6 is installed in the arc-shaped groove 603 and is movably connected with the rotating frame 601 through the rotating shaft B602, the rotating shaft B602 can drive the three-dimensional camera 6 to rotate back and forth in the arc-shaped groove 603, and meanwhile the rotating shaft 701 can drive the three-dimensional camera 6 to rotate in the vertical direction. The control system controls the electric push rod A to move the guide rail 8, the guide rail 8 drives the mounting frame 4, the mounting frame 4 drives the laser welding head 3 to move relatively to the identification area and the material area of the three-dimensional camera 6, and in the welding process, the relative position of the laser welding head 3 or the material needs to be adjusted in real time according to the deviation of a welding path, so that the control system synchronously controls the rotating shaft B602 and the rotating shaft 701 to drive the three-dimensional camera 6 to rotate synchronously, and images of the welding process are obtained in real time.
The table 2 further comprises four clamping plates 201, which are perpendicular to each other, and which can simultaneously hold a plurality of identical materials or a plurality of positions of one material at a time, and which together form a material area. Splint 201 is the vertical setting of cuboid platelike on workstation 2, including horizontally face and both sides circular arc limit, presss from both sides tight material through the face and the face or face and circular arc limit of different splint 201. The hollow inside of the clamping plate 201 forms a channel in the shape of a groove of an internal gear ring and penetrates through a rotating shaft C202, the upper end of the rotating shaft C202 is exposed out of the clamping plate 201 and is provided with an identification point 203, the contact part of the identification point 203, close to the lower side, with the channel in the shape of the groove of the internal gear ring is an external gear, the groove of the internal gear ring is meshed with the external gear of the rotating shaft C202, the external gear of the rotating shaft C202 rotates in the groove of the internal gear ring, the clamping plate 201 moves back and forth relative to the rotating shaft C202, and therefore the material is fixed at the relative position of the clamping plate 201 and the material. The three-dimensional camera 6 determines the working area of the clamping plate 201 through the recognition point 203, and further determines the material area of the working table 2. The rotating shaft C202 can enable the clamping plate 201 to move front and back or left and right along the horizontal direction of the plate surface, the lower end of the rotating shaft C202 is movably connected with the turntable 204, the turntable 204 is used for driving the clamping plate 201 to rotate relative to the workbench 2, the control system obtains the material and the shape of a welding seam through the three-dimensional camera 6 and generates a program of a clamping algorithm so as to control the relative movement of different clamping plates 201 to clamp the material, and the clamping plate 201 is moved by matching with a welding track in the welding process. The surface and the arc edge of the clamping plate 201 are covered with the elastic bulge 205 and the pressure sensor, and the elastic bulge 205 comprises two rows of hemispherical surfaces and two rows of rod shapes and is used for fixing materials of different types respectively.
The lower end of the clamping plate 201 is fixedly provided with a rotary ball 206, the rotary ball 206 is hemispherical, the upper end is horizontal and is provided with the clamping plate 201, and the lower end is spherical. The lower end of the workbench 2 is provided with a hemispherical groove 207, the lower end of the rotary ball 206 is movably arranged in the hemispherical groove 207, nine groups of electromagnetic coils are arranged at the lower end of the rotary ball 206 at fixed equal intervals, one group of the electromagnetic coils is located at the center of the lower end of the rotary ball 206, the other eight groups of the electromagnetic coils form two steps which are at an included angle of forty-five degrees, and each step is provided with four groups of the electromagnetic coils and forms an included angle of ninety degrees. The center of the rotating ball 206 is provided with a bearing block which can ensure that the rotating ball 206 can not cause the clamping plate 201 to turn on one side due to relative rotation, the side edge of the rotating ball 206 is provided with a displacement sensor, and an annular groove is arranged between the displacement sensor and the hemispherical groove body 207 and used for detecting the relative position of the rotating ball 206. Nine groups of electromagnets are arranged on the inner wall of the hemispherical groove 207 and corresponding to the rotating ball 206, and the electromagnets and the electromagnetic coils are electrically connected with a control system. The control system controls the electrification of different electromagnetic coils and the generation of mutual attraction and repulsion force of the electromagnets to enable the rotating ball 206 to freely rotate 180 degrees relatively in the hemispherical groove 207, meanwhile, the rotating ball 206 can drive the clamping plate 201 and the laser welding head 3 to freely rotate 180 degrees relatively, and the relative position of the rotating ball 206 is determined through the displacement sensor.
The control system also comprises a display and an alarm, wherein the display is a PC end and is fixed at the front end of the frame 1. The alarm comprises a display lamp, a buzzer and a remote calling end, the display is in communication connection with the alarm, the alarm is used for feeding back welding abnormity and feeding back the welding abnormity to the display, the remote calling end can feed back alarm information to maintenance personnel in time and remotely transmit an interface of the display, the maintenance personnel can hold the remote calling end receiver by hand, the remote calling end receiver is a mobile phone end, and the display can receive and display welding abnormity images. When the welding parameters are abnormal or the welding path is suddenly changed, the display lamp flickers, the buzzer gives an alarm, the control system automatically stops the welding mechanism, and the abnormal type is sent to the display and the remote calling terminal.
A control method of a three-dimensional visual tracking welding robot comprises the following steps:
A. before the welding process, materials to be welded are fixed through relative movement and rotation of a clamping plate 201, a rotating shaft C202, a rotating disc 204 and a rotating ball 206, welding seam parameters and various standard welding seam paths are set in the simulation system in advance, then the control system controls a three-dimensional camera 6 to capture images of welding seams of the materials, a welding seam module converts the captured images into welding seam images through characteristic capture and compares the welding seam images with the standard welding seam paths set by the simulation system, and the control system obtains a simulated welding seam path and a welding seam welding completion state;
B. the control system controls the guide rail 8 and the mounting rack 4 to enable the laser welding head 3 to perform welding actions according to a simulation path, and meanwhile the clamping plate 201, the rotating shaft C202, the turntable 204 and the rotating ball 206 drive materials to move relatively to match with the welding path;
C. in the welding process, the three-dimensional camera 6 acquires an actual image of the welding process of the welding seam in real time, compares the actual welding seam with a simulated welding seam, the focus module detects a laser focus by adopting a threshold segmentation method, the welding seam module detects the actual state of the welding seam by adopting a gray projection method, the control system forms the three-dimensional space relative coordinate position of the laser focus and the welding seam by using a three-time linear array or a two-time planar array, and fills up the relative position deviation delta H of the welding seam in real time according to the actual position;
D. after welding is finished, the three-dimensional camera 6 acquires a welding seam state, the welding seam module carries out finish degree comparison with the welding seam welding finish state set by the simulation system, the welding seam is divided into a qualified type, a to-be-repaired type and an unqualified type, wherein the to-be-repaired type welding seam is subjected to repair parameter calculation by the simulation system, the control system controls and executes the repeated welding seam welding step to finish repairing, and the qualified material and the unqualified material are conveyed to the next process by the mechanical gripper in a classified mode;
E. the relative position deviation of the welding seam is filled by two-stage control, a displacement proportion regulation method is adopted when the deviation exceeds H, a fuzzy regulation method is adopted when the deviation does not exceed H,
displacement proportion regulation and control method: the relative position deviation delta H = delta S/COS alpha of the welding seam, wherein delta S is the relative position of the welding seam obtained by the three-dimensional camera 6 in real time, and alpha is the included angle between the three-dimensional camera 6 and the laser welding head 3;
fuzzy regulation and control method: the relative position deviation of the welding seam is delta H = K E + (1-K) E1, wherein E is the deviation under the fuzzy algorithm, E1 is the deviation rate under the fuzzy algorithm, and K is a fuzzy related parameter;
F. the simulation system simulates a welding seam path and a welding seam welding completion state and displays the welding seam path and the welding seam welding completion state on a display in a digital three-dimensional model mode, and the control system constructs a digital model in a point-to-point mode in the actual welding process and displays the digital model on the display in a split screen mode.
It is noted that, in this document, relational terms such as front, back, up, down, and the like may be used solely to distinguish one entity or action from another entity or action without necessarily requiring or implying any actual such relationship or order between such entities or actions. Also, the terms "comprises," "comprising," or any other variation thereof, are intended to cover a non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements does not include only those elements but may include other elements not expressly listed or inherent to such process, method, article, or apparatus.
Finally, it should be noted that: although the present invention has been described in detail with reference to the foregoing embodiments, it will be apparent to those skilled in the art that changes may be made in the embodiments and/or equivalents thereof without departing from the spirit and scope of the invention. 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.
Claims (10)
1. The utility model provides a three-dimensional visual tracking welding robot, includes frame (1), workstation (2), sets up welding mechanism and visual tracking system on workstation (2), its characterized in that: the three-dimensional visual tracking welding robot further comprises a simulation system and a control system, the welding mechanism comprises a laser welding head (3) and an installation frame (4) for installing the laser welding head (3), the installation frame (4) is fixedly arranged on one side of the workbench (2), a motor-driven rotating shaft A (5) is movably installed in the installation frame (4), the rear end of the laser welding head (3) is fixed on the rotating shaft A (5), and the rotating shaft A (5) can drive the laser welding head (3) to move up and down; the worktable (2) is provided with a material area, the vision tracking system comprises a three-dimensional camera (6), a support frame (7) for fixing the three-dimensional camera (6), a focus module and a welding seam module, the support frame (7) is L-shaped, the lower end of the support frame is vertically and fixedly arranged on the rack (1), the upper end of the support frame is horizontally fixed at the upper end of the material area as a cantilever, the three-dimensional camera (6) is used for capturing a welding seam image of the material, the focus module is used for detecting a laser focus, and the welding seam module is used for detecting the position of a welding seam to be processed of the material, the welding seam state in the actual processing process and the quality calibration after the welding seam is processed; the visual tracking system, the simulation system and the control system are in communication connection with each other, and the workbench (2), the welding mechanism and the control system are electrically connected; the simulation system can set standard welding seam parameters and generate a standard welding seam path, and the control system can generate a basic welding seam path according to the detection signals of the focus module and the welding seam module, compare the basic welding seam path with the standard welding seam path set by the simulation system in real time and fill up the deviation.
2. The three-dimensional visual tracking welding robot according to claim 1, characterized in that: the welding mechanism further comprises a guide rail (8), a support arm (9) is fixedly arranged on the left side of the rack (1), the support arm (9) is transversely provided with a sliding groove, one end of the guide rail (8) is horizontally and movably arranged in the sliding groove and provided with an electric push rod A, the other end of the guide rail (8) is fixedly connected with the mounting frame (4), and the electric push rod A can drive the guide rail (8) and the mounting frame (4) to move back and forth; visual tracking system is still including rotating turret (601) of installation three-dimensional camera (6), rotating turret (601) movable mounting is in support frame (7) cantilever department lower extreme to set up axis of rotation (701) in the junction, axis of rotation (701) can make rotating turret (601) and three-dimensional camera (6) support frame (7) relatively rotate, rotating turret (601) are that the spheroid is inside to set up arc recess (603), set up pivot B (602) in arc recess (603), install in arc recess (603) three-dimensional camera (6) rear end to through pivot B (602) and rotating turret (601) swing joint, pivot B (602) can drive three-dimensional camera (6) rotation back and forth.
3. The three-dimensional visual tracking welding robot according to claim 2, characterized in that: workstation (2) still include a plurality of splint (201), splint (201) are the vertical setting of platelike on workstation (2), including horizontally face and both sides circular arc limit, splint (201) inside cavity forms the passageway and runs through and sets up pivot C (202), and splint (201) are exposed and identification point (203) are set up to pivot C (202) upper end, pivot C (202) can make splint (201) along face horizontal direction back-and-forth movement, pivot C (202) lower extreme swing joint carousel (204), and carousel (204) are used for driving splint (201) to rotate, and control system can acquire material and welding seam shape through three-dimensional camera (6), thereby generates the relative motion of the program control different splint (201) of clamping algorithm and presss from both sides tight material.
4. The three-dimensional visual tracking welding robot according to claim 3, characterized in that: the four clamping plates (201) are mutually perpendicular and can be used for simultaneously fixing a plurality of same materials or a plurality of positions of one material at a time, the plate surface and the arc edge are covered with the elastic bulge (205) and the pressure sensor, and the elastic bulge (205) comprises a hemispherical surface and a rod shape and is respectively used for fixing materials of different types; the upper end of the rotating shaft C (202) is provided with an external gear, and the inner part of the upper end of the clamping plate (201) is provided with an internal gear ring groove and is meshed with the external gear of the rotating shaft C (202).
5. The three-dimensional visual tracking welding robot according to claim 3, characterized in that: the lower end of the clamping plate (201) is fixedly provided with a rotating ball (206), the lower end of the workbench (2) is provided with a hemispherical groove body (207), and the lower end of the rotating ball (206) is movably arranged in the hemispherical groove body (207); the rotary ball bearing is characterized in that a plurality of electromagnetic coils are fixedly arranged at the lower end of the rotary ball (206), a bearing block is arranged at the center, a displacement sensor is arranged on the side edge, an annular groove is formed between the displacement sensor and the hemispherical groove body (207) and used for detecting the relative position of the rotary ball (206), a plurality of electromagnets are arranged on the inner wall of the hemispherical groove body (207), and the electromagnets and the electromagnetic coils are electrically connected with a control system.
6. The three-dimensional visual tracking welding robot according to claim 5, characterized in that: hemispherical groove body (207) lower extreme sets up transportation track (208), workstation (2) one side sets up electric putter B (209), and electric putter B (209) hemispherical groove body (207) of one end fixed connection, other end fixed connection frame (1), electric putter B (209) are used for driving hemispherical groove body (207) and control the removal in transportation track (208), electric putter B (209) and control system electric connection set up the manipulator around frame (1), and the manipulator is used for snatching the material.
7. The three-dimensional visual tracking welding robot according to claim 1, characterized in that: control system still includes display and alarm, the display is fixed at frame (1) front end for the PC end, the alarm includes display lamp, bee calling organ and remote calling end, display and alarm communication connection, the alarm is used for feeding back welding abnormity and feeds back to the display, and remote calling end can in time feed back alarm information to maintenance personal and the long-range interface that conveys the display, the display can receive and show welding abnormal image.
8. A control method of a three-dimensional visual tracking welding robot comprises the following steps:
before the welding process, materials to be welded are fixed through relative movement and rotation of a clamping plate (201), a rotating shaft C (202), a rotating disc (204) and a rotating ball (206), welding seam parameters and various standard welding seam paths are set in advance in a simulation system, then a control system controls a three-dimensional camera (6) to collect images of welding seams of the materials, a welding seam module converts the collected images into welding seam images through characteristic grabbing and compares the welding seam images with the standard welding seam paths set by the simulation system, and the control system obtains a simulated welding seam path and a welding seam welding completion state;
the control system controls the guide rail (8) and the mounting rack (4) to enable the laser welding head (3) to perform welding action according to a simulation path, and meanwhile the clamping plate (201), the rotating shaft C (202), the rotating disc (204) and the rotating ball (206) drive materials to move relatively to match the welding path;
in the welding process, a three-dimensional camera (6) acquires an actual image of the welding process of the welding seam in real time, the actual welding seam is compared with a simulated welding seam, a focus module detects a laser focus by adopting a threshold segmentation method, a welding seam module detects the actual state of the welding seam by adopting a gray projection method, a control system forms the three-dimensional space relative coordinate position of the laser focus and the welding seam by a three-time linear array or a two-time planar array, and the relative position deviation delta H of the welding seam is filled in real time according to the actual position;
after welding is finished, the three-dimensional camera (6) acquires the state of a welding seam, the welding seam module carries out finish degree comparison with the welding seam welding finish state set by the simulation system, the welding seam is divided into a qualified type, a to-be-repaired type and an unqualified type, wherein the simulation system calculates repair parameters of the to-be-repaired type welding seam, the control system repeats the welding seam welding step to finish repairing, and the qualified material and the unqualified material are conveyed to the next procedure by the mechanical gripper in a classified mode.
9. The control method of the three-dimensional visual tracking welding robot according to claim 8, characterized in that: the simulation system simulates a welding seam path and a welding seam welding completion state to be displayed on a display in a digital three-dimensional model mode, and the actual welding process of the control system constructs a digital model in a point-to-point mode to be displayed on the display in a split screen mode.
10. The control method of the three-dimensional visual tracking welding robot according to claim 8, characterized in that: the relative position deviation of the welding seam is filled by two-stage control, a displacement proportion regulation method is adopted when the deviation exceeds H, a fuzzy regulation method is adopted when the deviation does not exceed H,
displacement proportion regulation and control method: the relative position deviation delta H = delta S/COS alpha of the welding seam, wherein delta S is the relative position of the welding seam obtained by the three-dimensional camera (6) in real time, and alpha is the included angle between the three-dimensional camera (6) and the laser welding head (3);
fuzzy regulation and control method: and the relative position deviation of the welding seam is delta H = K E + (1-K) E1, wherein E is the deviation under the fuzzy algorithm, E1 is the deviation rate under the fuzzy algorithm, and K is a fuzzy related parameter.
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