CN114383559A - Method and system for collecting weld groove morphology - Google Patents
Method and system for collecting weld groove morphology Download PDFInfo
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- CN114383559A CN114383559A CN202210036976.9A CN202210036976A CN114383559A CN 114383559 A CN114383559 A CN 114383559A CN 202210036976 A CN202210036976 A CN 202210036976A CN 114383559 A CN114383559 A CN 114383559A
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- G01—MEASURING; TESTING
- G01B—MEASURING LENGTH, THICKNESS OR SIMILAR LINEAR DIMENSIONS; MEASURING ANGLES; MEASURING AREAS; MEASURING IRREGULARITIES OF SURFACES OR CONTOURS
- G01B21/00—Measuring arrangements or details thereof, where the measuring technique is not covered by the other groups of this subclass, unspecified or not relevant
- G01B21/20—Measuring arrangements or details thereof, where the measuring technique is not covered by the other groups of this subclass, unspecified or not relevant for measuring contours or curvatures, e.g. determining profile
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Abstract
The invention discloses a method and a system for acquiring the appearance of a weld groove, which comprises the following steps: the distance measuring sensor is driven to do constant-speed translation motion along the top plane of the workpiece, and the direction of the constant-speed translation motion is perpendicular to the welding path of the workpiece, so that the distance measuring sensor can acquire a distance value between the surface of the workpiece and a probe of the distance measuring sensor in the constant-speed translation motion process in real time; and processing the distance value data acquired by the distance measuring sensor to obtain the weld groove appearance of the workpiece. By adopting the acquisition method, the distance value between the surface of the workpiece and the probe of the distance measuring sensor in the constant-speed translation motion process is acquired in real time through the distance measuring sensor, and then the distance value data is processed, so that the welding seam groove appearance of the workpiece can be obtained, the intervention of manual measurement is avoided, the welding seam groove appearance can be quickly, conveniently and accurately acquired, and the intelligent degree of thick plate welding is improved.
Description
Technical Field
The invention relates to the technical field of welding, in particular to a method and a system for acquiring the appearance of a weld groove.
Background
In the welding of large steel structure workpieces, the proportion of thick plate welding is higher. For thick plate welding, beveling is generally needed to carry out multilayer multi-pass welding, and the welding quantity is large. The existing common manual welding production mode has the problems of low welding production rate, high labor intensity of personnel, poor quality stability and the like. An intelligent and automatic welding mode is an effective method for solving the problem and is also a development trend of thick plate welding. The industrial robot is mature in application in the field of arc welding and is the first choice of thick plate automatic welding equipment.
Due to the machining precision and the assembly precision of a workpiece, the size and the position of a welding seam groove have certain errors in the automatic welding of the thick plate. At present, for welding seam grooves of different types and sizes, due to poor machining precision, during automatic welding, groove size measurement needs to be carried out manually, and subsequent welding path planning and welding parameter calling are corrected manually. The shape of the weld break is rapidly obtained, a pilot effect can be achieved for path planning and welding parameter calling in subsequent automatic thick plate welding, and meanwhile a foundation is laid for intelligent application of thick plate welding.
A large-scale thick plate steel component has many products as customized products, and when the intelligent welding is promoted for single-piece products or small-batch products, a method capable of quickly, conveniently and accurately acquiring weld groove characteristic points and weld groove sizes, namely the weld groove appearance, is needed to reduce workpiece errors and manual measurement intervention and improve the intelligent degree of thick plate welding.
Disclosure of Invention
The invention aims to provide a method and a system for acquiring the appearance of a weld groove so as to improve the intelligent degree of thick plate welding.
In order to achieve the purpose, the invention provides a method for acquiring the appearance of a weld groove, which comprises the following steps:
the distance measuring sensor is driven to do constant-speed translation motion along the top plane of the workpiece, and the direction of the constant-speed translation motion is perpendicular to the welding path of the workpiece, so that the distance measuring sensor can acquire a distance value between the surface of the workpiece and a probe of the distance measuring sensor in the constant-speed translation motion process in real time;
and processing the distance value data acquired by the distance measuring sensor to obtain the weld groove appearance of the workpiece.
Preferably, the distance value data collected by the distance measuring sensor is processed according to the following steps:
establishing a continuous point set, and constructing the acquisition order of the ranging sensors and the distance values acquired by the ranging sensors in the corresponding order into the continuous point set: (x)i，yi) (i ═ 1, 2, … n), where xiFor the acquisition order of the distance measuring sensors, yiA distance value collected for a ranging sensor;
calculating the distance value y corresponding to two adjacent points in the continuous point setaAnd ybDifference processing is carried out to obtain the difference delta y which is yb-yaIf delta y is greater than a first preset threshold, the rear point y is considered to bebCalculating all the catastrophe points for the catastrophe points, wherein the first preset threshold is larger than the maximum error allowed by the measurement of the ranging sensor;
denoising the mutation points to screen out a feature point set;
and carrying out data processing on the characteristic point set to obtain the appearance of the weld groove.
Preferably, the denoising processing is performed on the mutation point, and specifically includes:
and if the obtained difference value delta y corresponding to the mutation point is larger than a second preset threshold value, removing the mutation point, wherein the second preset threshold value is larger than the first preset threshold value.
Preferably, the denoising processing is performed on the mutation point, and further includes:
and carrying out variance processing on the distance values of a plurality of points before and after the mutation point, and removing the mutation point if the variance value is smaller than a third preset threshold value.
Preferably, the data processing is performed on the feature point set, and specifically includes:
and (4) performing segmentation treatment, namely performing curve fitting on each segment of feature point set by adopting a least square method to obtain a fitting equation of the appearance of the weld groove.
Preferably, the data processing is performed on the feature point set, and further includes:
and calculating the groove depth and the groove width size of the welding seam groove according to the lowest point and the highest point in the characteristic points.
Preferably, the shape of the weld groove is a groove with a single inclined side.
Preferably, the shape of the weld groove is a double-side inclined groove.
Compared with the introduction content of the background technology, the acquisition method of the weld groove morphology comprises the following steps: the distance measuring sensor is driven to do constant-speed translation motion along the top plane of the workpiece, and the direction of the constant-speed translation motion is perpendicular to the welding path of the workpiece, so that the distance measuring sensor can acquire a distance value between the surface of the workpiece and a probe of the distance measuring sensor in the constant-speed translation motion process in real time; and processing the distance value data acquired by the distance measuring sensor to obtain the weld groove appearance of the workpiece. By adopting the acquisition method, the distance value between the surface of the workpiece and the probe of the distance measuring sensor in the constant-speed translation motion process is acquired in real time through the distance measuring sensor, and then the distance value data is processed, so that the welding seam groove appearance of the workpiece can be obtained, the intervention of manual measurement is avoided, the welding seam groove appearance can be quickly, conveniently and accurately acquired, and the intelligent degree of thick plate welding is improved.
In addition, the invention also provides an acquisition system for the weld groove morphology, which comprises:
the distance measuring sensor is used for acquiring a distance value between the surface of the workpiece and a probe of the distance measuring sensor;
the driving mechanism is used for driving the distance measuring sensor to do constant-speed translation motion along the top plane of the workpiece, and the direction of the constant-speed translation motion is perpendicular to the welding path of the workpiece;
and the processor is used for processing the distance value data acquired by the distance measuring sensor so as to obtain the weld groove appearance of the workpiece.
Preferably, the drive mechanism and the processor are both integrated on the welding robot.
Drawings
Fig. 1 is a schematic structural diagram of a distance measuring sensor provided in an embodiment of the present invention, which performs a translational motion on a top plane of a workpiece with a double-sided inclined groove;
FIG. 2 is a schematic structural diagram of a distance measuring sensor provided in an embodiment of the present invention performing a translational motion on a top plane of a workpiece with a single-side inclined groove;
fig. 3 is a schematic diagram of obtaining a groove size according to a characteristic point provided in an embodiment of the present invention.
In the context of figures 1-3,
distance measuring sensor 1, work piece 2, welder 3.
Detailed Description
The core of the invention is to provide a method and a system for acquiring the appearance of a weld groove so as to improve the intelligent degree of thick plate welding.
In order to make those skilled in the art better understand the technical solutions provided by the present invention, the technical solutions in the embodiments of the present application will be clearly and completely described below with reference to the drawings in the embodiments of the present application, and it is obvious that the described embodiments are only a part of the embodiments of the present application, and not all embodiments. All other embodiments, which can be derived by a person skilled in the art from the embodiments given herein without making any creative effort, shall fall within the protection scope of the present application.
As shown in fig. 1 to 3, an embodiment of the present invention provides a method for acquiring a weld groove profile, where the method includes: the distance measuring sensor 1 is driven to do constant-speed translation motion along the top plane of the workpiece 2, and the direction of the constant-speed translation motion is perpendicular to the welding path of the workpiece 2, so that the distance measuring sensor 1 can acquire a distance value between the surface of the workpiece 2 and a probe of the distance measuring sensor 1 in the constant-speed translation motion process in real time; and processing the distance value data acquired by the distance measuring sensor 1 to obtain the weld groove appearance of the workpiece 2.
By adopting the acquisition method, the distance value between the surface of the workpiece and the probe of the distance measuring sensor in the constant-speed translation motion process is acquired in real time through the distance measuring sensor, and then the distance value data is processed, so that the welding seam groove appearance of the workpiece can be obtained, the intervention of manual measurement is avoided, the welding seam groove appearance can be quickly, conveniently and accurately acquired, and the intelligent degree of thick plate welding is improved.
It should be noted that the distance measuring sensor may be a laser distance measuring sensor, or other distance measuring sensors commonly used by those skilled in the art, and is not limited in this respect. Wherein, the distance measuring sensor 1 is generally installed on the welding gun 3 of the welding robot, and it should be understood by those skilled in the art that the distance measuring sensor 1 can also be installed at other positions of the welding robot as long as the purpose of collecting can be achieved, for example, the distance measuring sensor 1 is installed on the end flange of the welding robot.
It should be noted that the distance measuring sensor 1 performs a constant-speed translation motion along the top plane of the workpiece 2, specifically, a constant-speed translation motion parallel or approximately parallel to the top plane of the workpiece 2.
In some specific embodiments, the distance value data collected by the distance measuring sensor 1 may be processed according to the following steps:
step S1: establishing a continuous point set, and constructing the acquisition sequence of the distance measuring sensor 1 and the distance values acquired by the distance measuring sensor 1 in the corresponding sequence into the continuous point set: (x)i，yi) (i ═ 1, 2, … n), where xiFor the acquisition sequence of the distance measuring sensor 1, yiA distance value collected for the distance measuring sensor 1;
step S2: calculating the distance value y corresponding to two adjacent points in the continuous point setaAnd ybDifference processing is carried out to obtain the difference delta y which is yb-yaIf delta y is greater than a first preset threshold, the rear point y is considered to bebCalculating all the mutation points for the mutation points, wherein the first preset threshold value is larger than the distance measurement sensorThe maximum error allowed by the measurement of the device 1 is larger than the accuracy of the distance measuring sensor and the surface roughness of the workpiece;
step S3: denoising the mutation points to screen out a feature point set;
step S4: and carrying out data processing on the characteristic point set to obtain the appearance of the weld groove.
In a further embodiment, denoising the mutation point may specifically include:
and if the difference value delta y corresponding to the calculated mutation point is larger than a second preset threshold value, removing the mutation point, wherein the second preset threshold value is larger than the first preset threshold value, and when the difference value delta y corresponding to the mutation point is larger than the second preset threshold value, indicating that the mutation point is obviously separated from the surface of the workpiece, and the mutation point is a noise point and should be removed. It should be noted that the noise point here mainly refers to an abnormal mutation point which is obviously separated from the surface of the workpiece and is not in accordance with the conventional method.
In a further embodiment, denoising the mutation point may further include:
and carrying out variance processing on the distance values of a plurality of points before and after the mutation point, and removing the mutation point if the variance value is smaller than a third preset threshold value. Specifically, assume that the distance values of several points before and after the mutation point are a set of data y1，y2，…ynMeasuring the fluctuation of the data by the variance of the data, each data and the average
Are respectively the square of
The variance calculation formula is as follows:
if the variance value of the data of a plurality of points before and after the catastrophe point is smaller than a third preset threshold value, the catastrophe point is obviously separated from the discontinuity of the adjacent measurement points, and therefore the catastrophe point is considered as a noise point and needs to be removed. It should be noted that the noise points removed here mainly refer to the abrupt points caused by the micro-pits or micro-bumps on the surface of the workpiece, which are not easily observed by naked eyes, and the abrupt points caused by the spatters and particles caused by the common production environment. The third preset threshold may be specifically defined as a maximum error allowed by the measurement of the ranging sensor. The algorithm is different from a one-dimensional and two-dimensional derivation method after data curve fitting, so that the algorithm complexity is reduced, and the stability is better.
And obtaining the characteristic points of the welding groove sampling data after difference and variance processing.
In a further embodiment, the data processing on the feature point set may specifically include:
the continuous point set acquired by the sensor can be processed in a segmented mode according to the characteristic points, and curve fitting is carried out on the continuous points of each segment by adopting a least square method, so that the appearance of the groove can be obtained. The least square method is a mathematical optimization technology, is simple in calculation by minimizing the square sum of errors and finding the optimal function matching of data, and is a curve fitting method commonly used in engineering practice.
Let the approximation function be: s (x) ═ a0+a1x+a2x2The fitting function is y ═ f (x), and a known point (x) is seti，yi) (i ═ 1, 2, … n), where xiFor the scanning sampling order of the distance measuring sensor, yiFor the scanned distance value of the distance measuring sensor, three coefficients for determining a polynomial are required, and the following function values are minimized.
The formula is found as follows:
to minimize the function value, the higher mathematical knowledge includes:
then the normal equation or normal equation is obtained as:
solving the system of equations to obtain a0，a1，a2And obtaining a fitting equation. The method has the advantages that the collected data are processed in a segmented mode through the characteristic point data, each segment of data is subjected to curve fitting respectively, the groove morphology is obtained, the curve fitting calculated amount is reduced, and the fitting accuracy is improved.
In some specific embodiments, the data processing on the feature point set may further include:
and calculating the groove depth and the groove width size of the welding seam groove according to the lowest point and the highest point in the characteristic points. Specifically, as shown in fig. 3, the difference between the characteristic points 1 and 3 is the groove width L, and the difference between the characteristic points 1 and 2 is the groove depth H.
It should be noted that the shape of the weld groove may specifically be a groove inclined on one side, such as a V-shaped groove inclined on one side, as shown in fig. 2, or may also be a curve with a changing slope, that is, a U-shaped groove on one side. Of course, the slope may be a double-sided inclined groove, for example, a double-sided inclined V-shaped groove, as shown in fig. 1, or a curve with a double-sided slope change, that is, a double-sided U-shaped groove. In the practical application process, the method can be obtained through curve fitting. It will be understood, of course, that if there are other shaped grooves, then the program optimization fitting can be performed to obtain the corresponding fitting equation.
In addition, the invention also provides an acquisition system for the weld groove morphology, which specifically comprises:
the distance measuring sensor 1 is used for acquiring a distance value between the surface of the workpiece 2 and a probe of the distance measuring sensor;
the driving mechanism is used for driving the distance measuring sensor 1 to do constant-speed translation motion along the top plane of the workpiece 2, and the direction of the constant-speed translation motion is perpendicular to the welding path of the workpiece 2;
and the processor is used for processing the distance value data acquired by the distance measuring sensor 1 to obtain the weld groove appearance of the workpiece 2.
Since the acquisition system and the acquisition method belong to a general inventive concept, and both have the same core concept, and the acquisition method has the technical effects, the acquisition system should also have corresponding technical effects, which are not described herein again.
In some specific embodiments, the system for acquiring the weld groove profile may specifically integrate both the driving mechanism and the processor on the welding robot. Therefore, after the appearance of the welding seam groove is obtained, the data such as the size and the appearance of the welding seam groove are given to the variable values of the robot body controller in a parameter mode, and then the data such as the multilayer multi-path planning and the technological parameters of the thick plate welding are called according to the variable values. Because the distance measuring sensor (such as a laser distance measuring sensor) is communicated with the robot, the collected data is stored and calculated by the robot body controller, third-party software development and application are avoided, and development difficulty is reduced. Meanwhile, industrial common equipment, namely an industrial robot and a laser ranging sensor, is adopted, so that equipment redundancy is avoided, cost is saved, and the stability and the universality of the equipment are improved.
Specifically, after the characteristic points of the weld groove are obtained, the arc starting position of the weld groove is obtained by performing data processing on the characteristic points. The characteristic points of the groove are edge mutation and blunt edge mutation of the plate, and the groove is divided into two program algorithms with or without a blunt edge for reducing the program complexity and improving the program stability. And (3) scanning a lower characteristic point 2 of the groove shape by the ranging sensor as an arc starting position, and correcting the position by using higher characteristic points 1 and 3 due to the influence of the group on the gap. And carrying out interpolation calculation according to the sampling sequence of the ranging sensor corresponding to the arcing position, namely the stepping sequence of the robot, and the starting position and the ending position of the robot in the scanning whole process of the ranging sensor to obtain the coordinate value of the arcing position of the robot. Thereby realizing the automatic calculation of the arcing position. The method provides an application method for identifying the arc striking position of the robot for welding the thick plate, provides a basis for parameter calling for automatic welding of the thick plate, and provides an application basis for intelligent welding of the thick plate.
The method and the system for acquiring the weld groove morphology provided by the invention are described in detail above. It should be noted that, in the present specification, the embodiments are all described in a progressive manner, each embodiment focuses on differences from other embodiments, and the same and similar parts among the embodiments may be referred to each other.
It is also noted that, in this document, terms such as "comprises," "comprising," or any other variation thereof, are intended to cover a non-exclusive inclusion, such that an 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 article or apparatus. Without further limitation, an element defined by the phrase "comprising an … …" does not exclude the presence of other like elements in an article or device that comprises the element.
The principles and embodiments of the present invention are explained herein using specific examples, which are presented only to assist in understanding the core concepts of the present invention. It should be noted that, for those skilled in the art, it is possible to make various improvements and modifications to the present invention without departing from the principle of the present invention, and those improvements and modifications also fall within the scope of the claims of the present invention.
Claims (10)
1. The method for acquiring the weld groove morphology is characterized by comprising the following steps:
the distance measuring method comprises the steps that a distance measuring sensor (1) is driven to do constant-speed translation motion along the top plane of a workpiece (2), and the direction of the constant-speed translation motion is perpendicular to the welding path of the workpiece (2), so that the distance measuring sensor (1) can acquire a distance value between the surface of the workpiece (2) and a probe of the distance measuring sensor (1) in the process of the constant-speed translation motion in real time;
and processing the distance value data acquired by the distance measuring sensor (1) to obtain the weld groove appearance of the workpiece (2).
2. The method for acquiring the weld groove morphology according to claim 1, characterized in that the distance value data acquired by the distance measuring sensor (1) is processed according to the following steps:
establishing a continuous point set, and constructing the acquisition sequence of the distance measuring sensor (1) and the distance values acquired by the distance measuring sensor (1) in the corresponding sequence into the continuous point set: (x)i，yi) (i ═ 1, 2, … n), where xiFor the acquisition sequence of the distance measuring sensor (1), yiA distance value collected for the distance measuring sensor (1);
calculating the distance value y corresponding to two adjacent points in the continuous point setaAnd ybDifference processing is carried out to obtain the difference delta y which is yb-yaIf delta y is greater than a first preset threshold, the rear point y is considered to bebCalculating all the catastrophe points for the catastrophe points, wherein the first preset threshold is larger than the maximum error allowed by the measurement of the distance measuring sensor (1);
denoising the mutation points to screen out a feature point set;
and carrying out data processing on the characteristic point set to obtain the appearance of the weld groove.
3. The method for acquiring the weld groove morphology according to claim 2, wherein the denoising treatment is performed on the abrupt change point, and specifically comprises:
and if the obtained difference value delta y corresponding to the mutation point is larger than a second preset threshold value, removing the mutation point, wherein the second preset threshold value is larger than the first preset threshold value.
4. The method for acquiring the weld groove morphology as claimed in claim 3, wherein the denoising of the discontinuity point further comprises:
and carrying out variance processing on the distance values of a plurality of points before and after the mutation point, and removing the mutation point if the variance value is smaller than a third preset threshold value.
5. The method for acquiring the weld groove morphology according to claim 2, wherein the data processing is performed on the feature point set, and specifically comprises the following steps:
and (4) performing segmentation treatment, namely performing curve fitting on each segment of feature point set by adopting a least square method to obtain a fitting equation of the appearance of the weld groove.
6. The method for acquiring the weld groove morphology according to claim 5, wherein the data processing is performed on the feature point set, and further comprising:
and calculating the groove depth and the groove width size of the welding seam groove according to the lowest point and the highest point in the characteristic points.
7. The method for acquiring the weld groove morphology according to any one of claims 1 to 6, wherein the weld groove morphology is a single-side inclined groove.
8. The method for acquiring the weld groove morphology according to any one of claims 1 to 6, wherein the weld groove morphology is a double-sided inclined groove.
9. The welding seam groove appearance acquisition system is characterized by comprising:
the distance measuring sensor (1) is used for acquiring a distance value between the surface of the workpiece (2) and a probe of the distance measuring sensor;
the driving mechanism is used for driving the distance measuring sensor (1) to do constant-speed translation motion along the top plane of the workpiece (2), and the direction of the constant-speed translation motion is perpendicular to the welding path of the workpiece (2);
and the processor is used for processing the distance value data acquired by the distance measuring sensor (1) so as to obtain the weld groove appearance of the workpiece (2).
10. The weld groove topography acquisition system of claim 9, wherein the drive mechanism and the processor are integrated on a welding robot.
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| Publication number | Priority date | Publication date | Assignee | Title |
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| CN102699534A (en) * | 2012-06-26 | 2012-10-03 | 哈尔滨工业大学 | Scanning type laser vision sensing-based narrow-gap deep-groove automatic laser multilayer welding method for thick plate |
| WO2019041984A1 (en) * | 2017-08-31 | 2019-03-07 | 中建钢构有限公司 | Welding method and device capable of variable-amplitude oscillation and welding robot |
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- 2022-01-13 CN CN202210036976.9A patent/CN114383559A/en active Pending
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| Publication number | Priority date | Publication date | Assignee | Title |
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| CN102699534A (en) * | 2012-06-26 | 2012-10-03 | 哈尔滨工业大学 | Scanning type laser vision sensing-based narrow-gap deep-groove automatic laser multilayer welding method for thick plate |
| WO2019041984A1 (en) * | 2017-08-31 | 2019-03-07 | 中建钢构有限公司 | Welding method and device capable of variable-amplitude oscillation and welding robot |
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