CN114083129B - Three-dimensional vision tracking welding robot and control method thereof - Google Patents
Three-dimensional vision tracking welding robot and control method thereof Download PDFInfo
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- CN114083129B CN114083129B CN202111549535.0A CN202111549535A CN114083129B CN 114083129 B CN114083129 B CN 114083129B CN 202111549535 A CN202111549535 A CN 202111549535A CN 114083129 B CN114083129 B CN 114083129B
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- 238000003466 welding Methods 0.000 title claims abstract description 297
- 238000000034 method Methods 0.000 title claims abstract description 63
- 239000000463 material Substances 0.000 claims abstract description 77
- 238000004088 simulation Methods 0.000 claims abstract description 32
- 230000008569 process Effects 0.000 claims abstract description 25
- 230000007246 mechanism Effects 0.000 claims abstract description 17
- 230000000007 visual effect Effects 0.000 claims abstract description 14
- 238000001514 detection method Methods 0.000 claims abstract description 5
- 238000012545 processing Methods 0.000 claims abstract description 5
- 238000006073 displacement reaction Methods 0.000 claims description 14
- 210000005056 cell body Anatomy 0.000 claims description 11
- 230000008439 repair process Effects 0.000 claims description 10
- 230000002159 abnormal effect Effects 0.000 claims description 8
- 238000004891 communication Methods 0.000 claims description 6
- 230000011218 segmentation Effects 0.000 claims description 5
- 238000012423 maintenance Methods 0.000 claims description 4
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- 230000001105 regulatory effect Effects 0.000 description 6
- 230000005856 abnormality Effects 0.000 description 3
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- 238000006243 chemical reaction Methods 0.000 description 2
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Classifications
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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
-
- 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
-
- 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
-
- 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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- Physics & Mathematics (AREA)
- Optics & Photonics (AREA)
- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Plasma & Fusion (AREA)
- Robotics (AREA)
- Laser Beam Processing (AREA)
- Manipulator (AREA)
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 grabbing a welding line image of a material, the focus module is used for detecting a laser focus, and the welding line module is used for detecting the position of the welding line to be processed of the material, the welding line state of the actual processing process and the quality calibration after the welding line is processed. According to the three-dimensional vision tracking welding robot, the simulation system is adopted to set standard welding seam parameters, the basic welding seam path is generated according to the detection signals of the focus module and the welding seam module, and is compared with the standard welding seam set by the simulation system, the path deviation is obtained, then the real-time adjustment is carried out, the three-dimensional vision tracking high-precision continuous welding can be realized, the three-dimensional vision tracking high-precision continuous welding robot is displayed in a three-dimensional digital model, and the three-dimensional vision tracking welding robot is convenient to use.
Description
Technical Field
The invention relates to the field of welding, in particular to a three-dimensional vision tracking welding robot and a control method thereof.
Background
The welding is a comprehensive processing process combining light, electricity, heat and force, and heat generated in the welding process can cause a welding workpiece to generate larger thermal deformation so as to generate welding position deviation. Another approach to 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 because of the difference of the sensors, wherein the visual sensing is favored by people because the visual sensing can be far away from an arc Jiang Guangjiang hot zone and has large information collection quantity. The vision sensor has the function of 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 on a photosensitive surface of the sensor and distributed according to space into electric signals which are serially output according to time sequence, namely converting the electric signals into video signals.
At present, a visual 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 captures one-dimensional images, and the area array CCD can capture two-dimensional plane images. The image shot by the vision sensor is converted into a gray matrix after spatial sampling and analog-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 volume is large, so that the requirement of high-speed reading of high-definition data by welding cannot be met. In addition, the one-dimensional and two-dimensional plane images are required to be manually judged and interpreted by professional staff, so that the welding production management cost is increased, and the large-area continuous automatic operation is not facilitated. In addition, the existing visual sensor is often subjected to pretreatment such as image transformation, enhancement or recovery and the like due to the limitation of various conditions and the interference of random factors in the process of taking, and the three-dimensional weld joint is converted into an operable one-dimensional and two-dimensional model, so that the phenomena of noise filtration, gray scale correction, distortion and the like are caused, the control variable parameters are required to be increased, and then the control variable parameters are transmitted to an executing mechanism, so that the interference is avoided, and the tracking control of the weld joint is realized. This results in problems of slow processing speed, easy distortion, etc. of the vision sensor in actual operation. In addition, in the conventional welding device, the welding path is single, and it is difficult to realize a complicated welding path track.
Therefore, a welding robot with high precision, high processing speed and convenient use is urgently needed, and the invention provides a three-dimensional vision tracking welding robot and a control method thereof.
Disclosure of Invention
The invention aims to provide a three-dimensional vision tracking welding robot and a control method thereof, which are used for solving the problems in the background technology.
The invention provides the following technical scheme: the utility model provides a welding robot is trailed to three-dimensional vision, includes frame, workstation, welding mechanism, vision tracking system, simulation system and the control system of setting on the workstation, welding mechanism includes the laser bonding tool and installs the mounting bracket of laser bonding tool, the mounting bracket is fixed to be set up in workstation one side, the inside movable mounting motor driven pivot A of mounting bracket, the laser bonding tool rear end is fixed on pivot A, pivot A can drive the laser bonding tool and reciprocate. The workbench is provided with a material area, and the material to be welded is 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 a frame, the upper end of the support frame is used as a cantilever to be fixed at the upper end of a material area, the three-dimensional camera is used for grabbing a material welding line image, the focus module detects a laser focus by a threshold segmentation method, the welding line module detects the actual state of a welding line by a gray projection method, the welding line module is further 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 each other, and the workbench, the welding mechanism and the control system are electrically connected. The simulation system can set standard welding seam parameters and generate standard welding seam paths, the control system can generate basic welding seam paths according to detection signals of the focus module and the welding seam modules, compare the basic welding seam paths with the standard welding seam paths set by the simulation system in real time, and automatically adjust welding paths to fill deviations according to comparison errors.
Further, welding mechanism still includes the guide rail, the fixed vertical support arm that sets up in frame left side, transversely set up horizontal fore-and-aft to the spout in the middle of the support arm, guide rail one end horizontal movable mounting just sets up electric putter A in the spout, other end fixed connection mounting bracket, electric putter A can drive guide rail and mounting bracket back-and-forth movement. The visual tracking system further comprises a rotating frame for installing the three-dimensional camera, the rotating frame is movably arranged at the lower end of the cantilever of the supporting 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 supporting 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 movably connected with the rotating frame through the rotating shaft B, the rotating shaft B can drive the three-dimensional camera to rotate back and forth, 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 three-dimensional camera identification area and the material area, and because the relative position of the laser welding head or the material needs to be adjusted in real time according to the deviation of a welding path in the welding process, the control system synchronously controls the rotating shaft B and the rotating shaft to drive the three-dimensional camera to rotate synchronously, and therefore images of the welding process are obtained in real time.
Further, the workbench further comprises a plurality of clamping plates, the clamping plates are vertically arranged on the workbench in a cuboid plate shape and comprise horizontal plate surfaces and two side arc edges, and materials are clamped through the plate surfaces and the plate surfaces or the plate surfaces and the arc edges of the different clamping plates. The inside cavity of splint forms the passageway and runs through and set up pivot C, and pivot C upper end exposes splint and sets up the identification point, and three-dimensional camera passes through the work area of identification point determination splint 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 rotating disc, the rotating disc is used for driving the clamping plates to rotate, the control system obtains the material and the weld joint shape through the three-dimensional camera, a program of a clamping algorithm is generated, the relative movement of different clamping plates is controlled to clamp the material, and the clamping plates are moved in the welding process in cooperation with the welding track.
Further, the clamping plates are four, are mutually perpendicular, can fix a plurality of same materials simultaneously or fix a plurality of positions of a material once, the face and the circular arc edge of the clamping plates are covered with elastic protrusions and pressure sensors, and the elastic protrusions comprise hemispherical surfaces and rod shapes and are respectively used for fixing different types of materials. The elastic bulge can protect the material and the clamping plate, so that the material and the clamping plate are prevented from being worn mutually, and the pressure sensor can feed back whether the clamping plate completely fixes the material. The upper end of the rotating shaft C is provided with an external gear, the inner part of the upper end of the clamping plate is provided with an internal gear ring groove and is meshed with the external gear of the rotating shaft C, and the external gear of the rotating shaft C rotates in the internal gear ring groove to enable the clamping plate to move back and forth relative to the rotating shaft C, so that the relative position of the clamping plate and a material is changed to fix the material.
Further, the splint lower extreme is fixed to be set up the swivel ball, and the workstation lower extreme sets up the hemisphere cell body, swivel ball lower extreme movable mounting in the hemisphere cell body, swivel ball lower extreme is fixed to be set up a plurality of solenoid, and the center sets up the bearing block, and the side sets up displacement sensor, set up annular groove between displacement sensor and the hemisphere cell body for detect the relative position of swivel ball, hemisphere cell body inner wall sets up a plurality of electro-magnet, electro-magnet and solenoid and control system electric connection. The control system controls the energization of different electromagnetic coils and the generation of mutual attraction and repulsion force of the electromagnets, so that the rotating ball rotates freely in the hemispherical groove body at 180 degrees relatively, and meanwhile, the rotating ball drives the clamping plate to rotate freely at 180 degrees relatively to the laser welding head, so that the inclination angle of the welding seam is generated, a complex welding seam track can be realized, and the displacement sensor feedback control system determines the relative position of the rotating ball.
Further, the transportation track is arranged at the lower end of the hemispherical groove body, an electric push rod B is arranged at one side of the workbench, one end of the electric push rod B is fixedly connected with the hemispherical groove body, the other end of the electric push rod B is fixedly connected with the frame, the electric push rod B is used for driving the hemispherical groove body to move left and right in the transportation track, the electric push rod B is electrically connected with the control system, the mechanical arms are arranged around the frame, the front mechanical arms grasp materials between the clamping plates, the materials after the rear mechanical arms grasp welding are respectively put into qualified and unqualified materials, the materials to be repaired are directly repaired on the workbench, the materials are reclassified after repair are finished until the materials are classified into qualified or unqualified materials, and the materials are grasped and transported by the rear mechanical arms.
Further, the control system further comprises a display and an alarm, the display is characterized in that the PC end of the display is fixed at the front end of the frame, 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 abnormal welding and feeding back to the display, the remote calling end can timely feed back alarm information to a maintenance person and remotely transmit an interface of the display, and the display can receive and display abnormal welding images. When the welding parameters are abnormal or the welding path is suddenly changed, the display lamp flashes, the buzzer alarms, and the control system automatically stops the welding mechanism and sends the abnormal type to the display and the remote calling terminal.
A control method of a three-dimensional vision tracking welding robot comprises the following steps:
A. Before the welding process, the materials to be welded are fixed through the relative movement and rotation of the clamping plate, the rotating shaft C, the rotating disc and the rotating ball, welding line parameters and various standard welding line paths are set in advance in the simulation system, then the control system controls the three-dimensional camera to firstly acquire images of welding lines of the materials, the welding line module converts acquired images into welding line images through characteristic grabbing and compares the welding line images with the standard welding line paths set by the simulation system, and the control system obtains simulated welding line paths and welding line welding completion states;
B. the control system controls the guide rail and the mounting frame to enable the laser welding head to weld according to the simulated 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 a welding process of a welding line in real time, compares the actual welding line with a simulated welding line, a focus module detects a laser focus by adopting a threshold segmentation method, a welding line module detects the actual state of the welding line by adopting a gray projection method, a control system forms a three-dimensional space relative coordinate position of the laser focus and the welding line by using a three-dimensional linear array or a secondary area array, and the actual position fills the relative position deviation delta H of the welding line in real time;
D. after welding is finished, the three-dimensional camera acquires a welding seam state, the welding seam module is compared with the welding seam finishing state set by the simulation system in finishing degree, the welding seam is divided into three types of qualified welding seams, to-be-repaired welding seams and unqualified welding seams, the simulation system calculates repair parameters of the to-be-repaired welding seams, the control system repeats welding seam welding steps to finish repair, and qualified and unqualified materials are classified and transported to the next working procedure by the mechanical claws.
Further, the simulation system simulates a welding path and a welding completion state of the welding seam to be displayed 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 an actual welding process to be displayed on the display in a split screen mode, so that an operator can observe the welding state of the welding seam conveniently.
Further, the relative position deviation of the welding seam is filled through two-stage control, the deviation exceeds H by adopting a displacement proportion regulating method, does not exceed H by adopting a fuzzy regulating method, prevents the large deviation from regulating slowly, has low small deviation regulating precision,
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 control method: the relative position deviation delta H=K of the welding line 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 the fuzzy related parameter.
Compared with the prior art, the invention has the following beneficial effects:
1. The simulation system is adopted to set standard weld parameters, a basic weld path is generated according to detection signals of the focus module and the weld module, and compared with the standard weld set by the simulation system, so that the errors of weld deviation and three-dimensional transformation existing in traditional one-dimension and two-dimension are overcome, deviation values are adjusted in real time, and finally the weld is displayed in a three-dimensional digital model, so that the system is convenient to use and high in precision.
2. The control system can synchronize the guide rail and the mounting frame to enable the laser welding head to move relative to the welding seam, meanwhile, the turntable is controlled to drive the clamping plates, the clamping plates drive materials to generate conversion of welding paths, and the clamping plates can rotate 180 degrees relative to the rotating ball freely, so that more complex welding paths can be completed.
3. The multiple clamping plates can perform pre-positioning on materials in complex shapes by moving relative to each other, meanwhile, the identification points are arranged to feed back the material areas to the three-dimensional camera, the control system controls the rotating frame to enable the three-dimensional camera to cover the material areas at the moment, and relative movement of the laser welding head and the welding seam 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-stage control, so that the welding deviation can be timely adjusted, and the welding deviation is prevented from being further enlarged.
Drawings
The accompanying drawings are included to provide a further understanding of the invention and are incorporated in and constitute a part of this specification, illustrate the invention and together with the embodiments of the invention, serve to explain the invention. In the drawings:
FIG. 1 is a schematic illustration 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 of the present invention;
FIG. 3 is a bottom view of a three-dimensional vision tracking welding robot vision tracking system of the present invention;
FIG. 4 is a semi-sectional view of a three-dimensional vision tracking welding robot clamp plate of the present invention;
FIG. 5 is a top view of a three-dimensional vision tracking welding robot clamp plate of the present invention;
FIG. 6 is a schematic view of an arrangement of three-dimensional vision tracking welding robot cleats in accordance with the present invention;
in the figure: 1. the device comprises a rack, 2, a workbench, 201, clamping plates, 202, rotating shafts C,203, identification points, 204, turntables, 205, elastic bulges, 206, rotating balls, 207, hemispherical groove bodies, 208, transportation tracks, 209, electric push rods B,3, laser welding heads, 4, mounting frames, 5, rotating shafts A,6, three-dimensional cameras, 601, rotating frames, 602, rotating shafts B,603, arc-shaped grooves, 7, supporting frames, 701, rotating shafts, 8, guide rails, 9 and supporting arms.
Detailed Description
The technical solutions 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 relates to a three-dimensional vision tracking welding robot which comprises a frame 1, a workbench 2, a welding mechanism arranged on the workbench 2, a vision tracking system, a simulation system and a control system. The welding mechanism comprises a laser welding head 3, a mounting frame 4 for mounting the laser welding head 3 and a guide rail 8 for fixing the mounting frame 4, wherein a vertical supporting arm 9 is fixedly arranged on the left side of the frame 1, a horizontal chute is arranged at the front and rear positions of the supporting arm 9, a cantilever is formed in the chute by horizontal movable mounting of the left end of the guide rail 8, an electric push rod A is arranged at the left end of the guide rail, the electric push rod A can drive the guide rail 8 and the mounting frame 4 to move back and forth, the electric push rod A is controlled by a control system, the right end of the guide rail 8 is fixedly connected with the mounting frame 4, a rotating shaft A5 driven by a motor is movably mounted inside the mounting frame 4, the rear end of the laser welding head 3 is fixed on the rotating shaft A5, and the rotating shaft A5 can drive the laser welding head 3 to move up and down. The work bench 2 is provided with a material zone in which the material to be welded is placed. 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 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 frame 1, the upper end of the support frame is used as a cantilever to be fixed at the upper end of a material area, the three-dimensional camera 6 is used for grabbing a material welding line image, the focus module detects a laser focus by a threshold segmentation method, the welding line module detects the actual state of a welding line by a gray projection method, the welding line module is also used for detecting the position of the welding line to be processed by 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 qualification, repair and disqualification. The visual tracking system, the simulation system and the control system are in communication connection, and the workbench 2 and the welding mechanism are electrically connected with the control system. The simulation system can set standard welding seam parameters and generate standard welding seam paths, the control system can generate basic welding seam paths according to detection signals of the focus module and the welding seam modules, compare the basic welding seam paths with the standard welding seam paths set by the simulation system in real time, and automatically adjust welding paths to fill deviations according to comparison errors. The simulation system stores welding paths of different welding seams, automatically generates standard welding paths of the welding seams according to actual welding seams grabbed by the three-dimensional camera 6, wherein the generated standard welding paths are combinations of one or more stored standard welding paths, and the control system controls the relative movement of a welding mechanism and the workbench 2 to finish welding of the welding seams and fill up deviations.
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 supporting 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 relative to the supporting frame 7 in the vertical direction, an arc-shaped groove 603 is formed in the spherical body of the rotating frame 601, 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 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 in the welding process, 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 the image of the welding process is obtained in real time.
The table 2 further comprises four clamping plates 201, which are mutually perpendicular, and can fix a plurality of identical materials simultaneously or a plurality of positions of one material at a time, and together form a material area. The clamping plates 201 are vertically arranged on the workbench 2 in a cuboid plate shape and comprise horizontal plate surfaces and two side arc edges, and materials are clamped through the plate surfaces and the plate surfaces or the plate surfaces and the arc edges of different clamping plates 201. The inside cavity of splint 201 forms the passageway of internal gear ring recess form and runs through and set up pivot C202, pivot C202 upper end exposes splint 201 and sets up identification point 203, identification point 203 is the external gear near the downside and the passageway contact portion of internal gear ring recess form, internal gear ring recess and with the external gear meshing of pivot C202, through the external gear rotation of pivot C202 in the internal gear ring recess, make splint 201 back and forth movement relative to pivot C202 to the fixed material of change splint 201 and the relative position of material. The three-dimensional camera 6 determines the working area of the clamping plate 201 and thus the material area of the table 2 by means of the identification points 203. The rotating shaft C202 can enable the clamping plate 201 to move forwards and backwards or leftwards and rightwards along the horizontal direction of the plate surface, the lower end of the rotating shaft C202 is movably connected with the rotating disc 204, the rotating disc 204 is used for driving the clamping plate 201 to rotate relative to the workbench 2, the control system obtains materials and welding seam shapes through the three-dimensional camera 6, a program of a clamping algorithm is generated, the materials are clamped by controlling relative movement of different clamping plates 201, and the clamping plates 201 are moved in cooperation with welding tracks in the welding process. The plate surface and the circular arc edge of the clamping plate 201 are covered with an elastic bulge 205 and a pressure sensor, and the elastic bulge 205 comprises two rows of hemispheres and two rows of rods which are respectively used for fixing different types of materials.
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 extreme of workstation 2 sets up hemispherical cell body 207, and swivel ball 206 lower extreme movable mounting is in hemispherical cell body 207, swivel ball 206 lower extreme fixed equidistance interval sets up nine sets of solenoid, and wherein a set of solenoid is located swivel ball 206 lower extreme central point position, and the rest eight sets of solenoid constitutes two sections ladders and is forty-five degree contained angles each other, and every section ladder sets up four sets of solenoid and constitutes ninety degree contained angles each other. The center of ball 206 is provided with a bearing block which can ensure that ball 206 will not turn clamp 201 over due to its relative rotation, the side of ball 206 is provided with a displacement sensor, and an annular groove is provided between the displacement sensor and hemispherical groove 207 for detecting the relative position of ball 206. Nine groups of electromagnets are arranged on the inner wall of the hemispherical groove 207 corresponding to the rotary ball 206, and the electromagnets are electrically connected with the electromagnetic coil and the control system. The control system controls the energization of different electromagnetic coils and the generation of mutual attraction and repulsion force with the electromagnet, so that the rotary ball 206 can freely rotate 180 degrees relatively in the hemispherical groove 207, meanwhile, the rotary 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 rotary ball 206 is determined through the displacement sensor.
The lower extreme of hemispheric cell body 207 sets up the transportation track 208 that runs through workstation 2 horizontally, the workstation 2 left side sets up electric putter B209, electric putter B209 right-hand member fixed connection hemispheric cell body 207, the left end welds as a whole with frame 1, electric putter B209 is used for driving hemispheric cell body 207 and moves about in transportation track 208, electric putter B209 and control system electric connection, set up the manipulator around frame 1, front end manipulator snatchs the material to between splint 201, the rear end gripper snatchs the material after the welding is accomplished and puts into qualified class and disqualification class respectively, the material of waiting to repair the class is direct to repair on workstation 2, reclassify after repairing the completion until dividing into qualified or disqualification class, and snatch the transportation by the rear end gripper. In other embodiments, mechanisms for transporting materials, such as conveyor belts, conveyor rails, etc., may be selectively employed.
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 terminal, wherein the display is in communication connection with the alarm, the alarm is used for feeding back welding abnormality and feeding back the welding abnormality to the display, the remote calling terminal can timely feed back alarm information to a maintenance person and remotely transmit an interface of the display, the maintenance person holds a remote calling terminal receiver, the remote calling terminal receiver is a mobile phone terminal, and the display can receive and display welding abnormality images. When the welding parameters are abnormal or the welding path is suddenly changed, the display lamp flashes, the buzzer alarms, and the control system automatically stops the welding mechanism and sends the abnormal type to the display and the remote calling terminal.
A control method of a three-dimensional vision tracking welding robot comprises the following steps:
A. Before the welding process, the materials to be welded are fixed through the relative movement and rotation of the clamping plate 201, the rotating shaft C202, the rotating disc 204 and the rotating ball 206, welding line parameters and various standard welding line paths are set in advance in the simulation system, then the control system controls the three-dimensional camera 6 to acquire images of welding lines of the materials, the welding line module converts acquired images into welding line images through characteristic grabbing and compares the welding line images with the standard welding line paths set by the simulation system, and the control system obtains simulated welding line paths and welding line welding completion states;
B. The control system controls the guide rail 8 and the mounting frame 4 to enable the laser welding head 3 to weld according to the simulated path, and meanwhile, the clamping plate 201, the rotating shaft C202, the rotating disc 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 the 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 a three-dimensional space relative coordinate position of the laser focus and the welding seam by using a three-dimensional linear array or a secondary area array, and the actual position fills the relative position deviation delta H of the welding seam in real time;
D. After welding is finished, the three-dimensional camera 6 acquires a welding seam state, the welding seam module and the welding seam welding finishing state set by the simulation system are compared in finishing degree, the welding seam is divided into three types of qualified welding seams, to-be-repaired welding seams and unqualified welding seams, the simulation system calculates repair parameters of the to-be-repaired welding seams, the control system controls the execution of repeated welding seam welding steps to finish repair, and qualified and unqualified welding materials are classified and transported to the next working procedure by the mechanical claws;
E. The relative position deviation of the welding seam is filled through two-section control, the deviation exceeds H by adopting a displacement proportion regulating method, does not exceed H by adopting a fuzzy regulating method,
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 control method: the relative position deviation delta H=K of the welding line E+ (1-K) E1, wherein E is the deviation under a 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 path and a welding completion state of the welding to be displayed 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 an actual welding process to be displayed on the display in a split screen mode.
It is noted that in this document, relational terms such as front, back, upper, lower, and the like are 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. Moreover, 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: the foregoing description is only a preferred embodiment of the present invention, and the present invention is not limited thereto, but it is to be understood that modifications and equivalents of some of the technical features described in the foregoing embodiments may be made by those skilled in the art, although the present invention has been described in detail with reference to the foregoing embodiments. Any modification, equivalent replacement, improvement, etc. made within the spirit and principle of the present invention should be included in the protection scope of the present invention.
Claims (6)
1. The utility model provides a welding robot is trailed to three-dimensional vision, includes frame (1), workstation (2), sets up welding mechanism and vision tracking system on workstation (2), its characterized in that: the three-dimensional vision tracking welding robot further comprises a simulation system and a control system, the welding mechanism comprises a laser welding head (3) and a mounting frame (4) for mounting the laser welding head (3), the mounting frame (4) is fixedly arranged on one side of the workbench (2), a rotating shaft A (5) driven by a motor is movably mounted in the mounting 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 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 is vertically and fixedly arranged on a frame (1), the upper end of the support frame is horizontally used as a cantilever to be fixed at the upper end of the material area, the three-dimensional camera (6) is used for grabbing a welding line image of the material, 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 the material, the welding line state of an actual processing process 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 each other, and the workbench (2) and the welding mechanism are electrically connected with the control system; the simulation system can set standard welding seam parameters and generate standard welding seam paths, and the control system can generate basic welding seam paths according to detection signals of the focus module and the welding seam module, compare the basic welding seam paths with the standard welding seam paths set by the simulation system in real time and fill the deviation;
The welding mechanism further comprises a guide rail (8), a support arm (9) is fixedly arranged on the left side of the frame (1), a chute is transversely arranged on the support arm (9), one end of the guide rail (8) is horizontally movably arranged in the chute and is provided with an electric push rod A, the other end of the guide rail 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 forwards and backwards; the vision tracking system further comprises a rotating frame (601) for installing the three-dimensional camera (6), 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 relative to the support frame (7), an arc-shaped groove (603) is formed in the inner portion of a sphere of the rotating frame (601), a rotating shaft B (602) is arranged in the arc-shaped groove (603), the rear end of 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 B (602), and the rotating shaft B (602) can drive the three-dimensional camera (6) to rotate back and forth;
The workbench (2) further comprises a plurality of clamping plates (201), the clamping plates (201) are vertically arranged on the workbench (2) in a plate shape and comprise horizontal plate surfaces and two side arc edges, a channel is formed in the clamping plates (201) in a hollow mode, a rotating shaft C (202) is arranged in a penetrating mode, the upper ends of the rotating shafts C (202) are exposed out of the clamping plates (201) and are provided with identification points (203), the rotating shafts C (202) can enable the clamping plates (201) to move forwards and backwards along the plate surfaces in the horizontal direction, the lower ends of the rotating shafts C (202) are movably connected with a rotary table (204), the rotary table (204) is used for driving the clamping plates (201) to rotate, and a control system can acquire materials and weld joint shapes through a three-dimensional camera (6) and generate a program of a clamping algorithm so as to control relative movement of different clamping plates (201) to clamp the materials;
The clamping plates (201) are four, are mutually perpendicular, can simultaneously fix a plurality of same materials or fix a plurality of positions of one material at a time, the plate surface and the circular arc edge are covered with elastic protrusions (205) and pressure sensors, and the elastic protrusions (205) comprise hemispherical surfaces and rod shapes and are respectively used for fixing different types of materials; an external gear is arranged at the upper end of the rotating shaft C (202), and an internal gear ring groove is arranged in the upper end of the clamping plate (201) and meshed with the external gear of the rotating shaft C (202);
The lower end of the clamping plate (201) is fixedly provided with a rotary ball (206), the lower end of the workbench (2) is provided with a hemispherical groove body (207), and the lower end of the rotary ball (206) is movably arranged in the hemispherical groove body (207); the rotary ball (206) lower extreme is fixed to be set up a plurality of solenoid, and the center sets up the bearing block, and the side sets up displacement sensor, set up annular groove between displacement sensor and the hemispherical cell body (207) for detect the relative position of rotary ball (206), hemispherical cell body (207) inner wall sets up a plurality of electro-magnets, electro-magnet and solenoid and control system electric connection.
2. The three-dimensional vision tracking welding robot of claim 1, wherein: the semi-spherical trough body (207) lower extreme sets up transportation track (208), workstation (2) one side sets up electric putter B (209), and electric putter B (209) one end fixed connection semi-spherical trough body (207), other end fixed connection frame (1), electric putter B (209) are used for driving semi-spherical trough body (207) and control the removal in transportation track (208), electric putter B (209) and control system electric connection, and frame (1) set up the manipulator around, and the manipulator is used for snatching the material.
3. The three-dimensional vision tracking welding robot of claim 1, wherein: the control system further comprises a display and an alarm, the display is characterized in that the PC end of the display 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 abnormal welding and feeding back to the display, the remote calling end can timely feed back alarm information to a maintenance person and remotely transmit an interface of the display, and the display can receive and display abnormal welding images.
4. A control method of the three-dimensional vision tracking welding robot according to any one of claims 1 to 3:
Before the welding process, the materials to be welded are fixed through the relative movement and rotation of a clamping plate (201), a rotating shaft C (202), a rotating disc (204) and a rotating ball (206), welding line parameters and various standard welding line paths are set in advance in a simulation system, then a control system controls a three-dimensional camera (6) to firstly acquire images of welding lines of the materials, a welding line module converts acquired images into welding line images through characteristic grabbing and compares the welding line images with the standard welding line paths set by the simulation system, and the control system obtains a simulated welding line path and a welding line welding completion state;
The control system controls the guide rail (8) and the mounting frame (4) to enable the laser welding head (3) to weld according to the simulated 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 with the welding path;
In the welding process, a three-dimensional camera (6) acquires an actual image of a welding process of a welding line in real time, compares the actual welding line with a simulated welding line, a focus module detects a laser focus by adopting a threshold segmentation method, a welding line module detects the actual state of the welding line by adopting a gray projection method, a control system forms a three-dimensional space relative coordinate position of the laser focus and the welding line by using a three-dimensional linear array or a secondary area array, and the relative position deviation delta H of the welding line is filled in real time by the actual position;
After welding is finished, the three-dimensional camera (6) acquires the welding seam state, the welding seam module compares the finishing degree with the welding seam finishing state set by the simulation system, the welding seam is divided into three types of qualified welding seams, to-be-repaired welding seams and unqualified welding seams, the simulation system calculates repair parameters of the to-be-repaired welding seams, the control system repeats the welding seam welding steps to finish repair, and qualified and unqualified materials are classified and transported to the next working procedure by the mechanical claws.
5. The control method of the three-dimensional vision tracking welding robot according to claim 4, wherein: the simulation system simulates a welding path and a welding completion state of the welding to be displayed 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 an actual welding process to be displayed on the display in a split screen mode.
6. The control method of the three-dimensional vision tracking welding robot according to claim 4, wherein: the relative position deviation of the welding seam is filled through two-section control, the deviation exceeds H by adopting a displacement proportion regulation method, and does not exceed H by adopting a fuzzy regulation method,
Displacement proportion regulation and control method: the relative position deviation delta H=delta S/COS alpha of the welding seam, wherein delta S is that the three-dimensional camera (6) acquires the relative position of the welding seam in real time, and alpha is the included angle between the three-dimensional camera (6) and the laser welding head (3);
Fuzzy control method: the relative position deviation delta H=K of the welding line 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 the fuzzy related parameter.
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| CN114841959B (en) * | 2022-05-05 | 2023-04-04 | 广州东焊智能装备有限公司 | Automatic welding method and system based on computer vision |
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| KR20080070132A (en) * | 2007-01-25 | 2008-07-30 | 김석조 | Apparatus for weld seam tracking |
| KR102223887B1 (en) * | 2019-08-29 | 2021-03-05 | (주)유일 | Semiautomatic welding device for manufacture of pipe |
| CN111633364A (en) * | 2020-06-10 | 2020-09-08 | 江苏瑞伯特智能科技股份有限公司 | Single-side welding and double-side forming welding robot |
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| CN101456182A (en) * | 2007-12-12 | 2009-06-17 | 中国科学院自动化研究所 | Intelligent robot welding device using large-scale workpiece |
| CN105458462A (en) * | 2015-12-22 | 2016-04-06 | 河北工业大学 | Variable gap trapezoidal welding line multi-parameter synchronous visual inspection tracking method |
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