CN114459344A - Welding wire monitoring system, method and medium based on laser vision - Google Patents
Welding wire monitoring system, method and medium based on laser vision Download PDFInfo
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- CN114459344A CN114459344A CN202111496088.7A CN202111496088A CN114459344A CN 114459344 A CN114459344 A CN 114459344A CN 202111496088 A CN202111496088 A CN 202111496088A CN 114459344 A CN114459344 A CN 114459344A
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- 238000003466 welding Methods 0.000 title claims abstract description 106
- 238000012544 monitoring process Methods 0.000 title claims abstract description 26
- 238000000034 method Methods 0.000 title claims abstract description 23
- 230000010365 information processing Effects 0.000 claims abstract description 29
- 238000012545 processing Methods 0.000 claims abstract description 7
- 238000003860 storage Methods 0.000 claims abstract description 5
- 238000003384 imaging method Methods 0.000 claims 4
- 238000005259 measurement Methods 0.000 claims 1
- 230000003068 static effect Effects 0.000 claims 1
- 238000004519 manufacturing process Methods 0.000 abstract description 4
- 238000010586 diagram Methods 0.000 description 7
- 238000001514 detection method Methods 0.000 description 3
- 230000005484 gravity Effects 0.000 description 2
- 238000009434 installation Methods 0.000 description 2
- 238000004804 winding Methods 0.000 description 2
- 230000009286 beneficial effect Effects 0.000 description 1
- 230000005540 biological transmission Effects 0.000 description 1
- 230000007547 defect Effects 0.000 description 1
- 230000007812 deficiency Effects 0.000 description 1
- 238000000691 measurement method Methods 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 238000005303 weighing Methods 0.000 description 1
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Classifications
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01B—MEASURING LENGTH, THICKNESS OR SIMILAR LINEAR DIMENSIONS; MEASURING ANGLES; MEASURING AREAS; MEASURING IRREGULARITIES OF SURFACES OR CONTOURS
- G01B11/00—Measuring arrangements characterised by the use of optical techniques
-
- G—PHYSICS
- G01—MEASURING; TESTING
- G01B—MEASURING LENGTH, THICKNESS OR SIMILAR LINEAR DIMENSIONS; MEASURING ANGLES; MEASURING AREAS; MEASURING IRREGULARITIES OF SURFACES OR CONTOURS
- G01B11/00—Measuring arrangements characterised by the use of optical techniques
- G01B11/02—Measuring arrangements characterised by the use of optical techniques for measuring length, width or thickness
Abstract
The invention discloses a welding wire monitoring system, a method and a medium based on laser vision, the system comprises a control device, an information processing device, a laser and a camera, wherein the laser is used for emitting laser to the surface of a welding wire disc, the camera is used for shooting an image formed by the laser emitted by the laser on the welding wire disc, the information processing device is respectively connected with the control device, the laser and the camera, is used for controlling the laser to emit laser and processing image data returned by the camera, and is responsible for transmitting the processed image data to the control device, and the control device is used for communicating with the information processing device, calculating the storage amount of a welding wire according to the image data and displaying the result. The invention is convenient to install, has high accuracy, can check the residual quantity of the welding wires in real time, can set the lower limit value of the residual quantity of the welding wires, and has certain significance for ensuring the welding quality and planning the production plan.
Description
Technical Field
The invention relates to the technical field of welding control, in particular to a welding wire monitoring system, a method and a medium based on laser vision.
Background
Currently, semi-automatic welding equipment is being used in a large number of manufacturing industries, and the equipment mostly consists of a welding power supply, a wire feeding device and a welding gun part. The wire feeding equipment comprises a wire reel, a wire wheel and other devices, the wire reel is mostly opaque, welding wires are uniformly wound on the wire reel, and workers cannot conveniently check the residual quantity of the welding wires in the welding process. When welding is started, welding wires are conveyed to a welding gun contact tip through the transmission of the wire wheel to be heated and melted into a molten pool, if workers do not find the welding wires in the welding wire disc in time when the welding wires are used up, the welding wire disc cannot be in a state of being out of service, and therefore reworking is needed, and the working efficiency is greatly reduced.
To avoid the situation, measures are needed to be taken to ensure that the welding wire allowance is real-time in the welding process, and when the welding wire is detected to be fed out or is about to be fed out, the industrial personal computer is alarmed to remind an operator to stop welding and replacing the welding wire. The existing device for detecting that the welding wire is fed completely and giving an alarm mostly adopts a mode of using a proximity switch or a weighing sensor for detection, some devices have certain inaccuracy, some devices cannot check the residual quantity of the welding wire in real time, and other devices have certain installation difficulty and use conditions.
CN204044945U discloses a detection and alarm device for the end of welding wire, which can detect the end of the wire feeding wheel as long as the welding wire in the wire reel is used up during the welding process, and remind the operator to stop welding and automatically turn off the power supply output of the welding power supply through a buzzer. However, the detection and alarm device for detecting the end of the welding wire has the following defects: 1. the scheme can only detect the use condition of the welding wire in the welding process and cannot display the residual quantity of the welding wire in real time; 2. the scheme directly closes the welding power supply when the welding wire is used up, is not high in applicability to a welding workstation containing an industrial robot, and easily causes the industrial robot to report errors.
Disclosure of Invention
In view of the above problems and the deficiencies of the prior art, the present invention provides a system, a method and a medium for monitoring a welding wire based on laser vision, wherein the system can monitor the residual amount of the welding wire in real time, and has the advantages of simple installation and high applicability.
In order to achieve the purpose, the welding wire monitoring system based on laser vision comprises a control device, an information processing device, a laser and a camera, wherein the laser is used for emitting laser to the surface of a welding wire disc, the camera is used for shooting an image formed by the laser emitted by the laser on the welding wire disc, the information processing device is respectively connected with the control device, the laser and the camera, is used for controlling the laser to emit laser and processing image data returned by the camera, and is responsible for transmitting the processed image data to the control device, and the control device is used for communicating with the information processing device, calculating the storage amount of the welding wire according to the image data and displaying the result.
A welding wire monitoring method based on the welding wire monitoring system based on the laser vision comprises the following steps:
step 1: the control device sends a monitoring command to the information processing device, and the information processing device starts the laser to emit laser;
step 2: the laser irradiates laser on the wire reel to form a strip-shaped laser image;
and step 3: shooting a strip-shaped laser image on the wire reel by a camera, and sending the strip-shaped laser image to an information processing device for processing;
and 4, step 4: based on the strip-shaped laser image, the information processing device analyzes the distance between each point on the strip-shaped image and the laser by adopting a triangulation method and sends the analysis data to the control device;
and 5: and the control device determines the residual quantity of the welding wire based on the analysis data, displays the residual quantity of the welding wire, and sends out a warning if the residual quantity of the welding wire is lower than a preset value.
A computer storage medium having stored thereon an executable program for execution by a processor to perform the steps of implementing the wire monitoring method.
Compared with the prior art, the invention has the beneficial effects that:
the high-precision welding wire monitoring system based on laser vision has strong robustness and anti-interference capability to the environment, is convenient to install and is not influenced by factors such as gravity center and the like;
the system is high in accuracy, can check the residual quantity of the welding wires on the industrial personal computer in real time, and has certain significance for ensuring the welding quality and planning production plan;
the lower limit of the welding wire residual quantity of the system is not invariable, and a user can set the welding wire residual quantity according to actual requirements.
Drawings
Fig. 1 is a schematic diagram of the position relationship of part of the equipment related to the invention.
Fig. 2 is a schematic diagram of a strip image on a wire reel according to the present invention.
Fig. 3 is a schematic view of the wire winding pattern on the wire reel according to the present invention.
Fig. 4 is a schematic diagram of a strip image taken by a camera according to the present invention.
FIG. 5 is a schematic diagram of a bar image model processed by an industrial personal computer according to the present invention.
In the figure: 1-an information processing apparatus; 2-a laser; 3-a camera; 4-laser; 5-wire reel.
Detailed Description
Reference will now be made in detail to embodiments of the present invention, examples of which are illustrated in the accompanying drawings, wherein like or similar reference numerals refer to the same or similar elements or elements having the same or similar function throughout. The embodiments described below with reference to the accompanying drawings are illustrative only for the purpose of explaining the present invention, and are not to be construed as limiting the present invention.
In the description of the present invention, it is to be noted that, unless otherwise explicitly specified or limited, the terms "mounted," "connected," and "connected" are to be construed broadly, e.g., as meaning either a fixed connection, a removable connection, or an integral connection; can be mechanically or electrically connected; they may be connected directly or indirectly through intervening media, or may be interconnected between two elements. The specific meaning of the above terms in the present invention can be understood according to specific situations by those skilled in the art.
As shown in FIG. 1, a high-precision welding wire monitoring system based on laser vision comprises an industrial personal computer, an information processing device 1, a laser 2, a camera 3 and a welding wire reel 5.
The information processing device 1 is respectively connected with an industrial personal computer, a laser 2 and a camera 3.
The information processing device 1 is used for controlling the laser 2 to emit laser 4 and processing image data returned by the camera 3, and is responsible for transmitting the processed image data to an industrial personal computer, and the industrial personal computer is used for communicating with the information processing device 1.
The laser device 2 is used for emitting laser 4 to the surface of the wire reel, the camera 3 is used for shooting laser emitted by the laser device 2, and the wire reel 5 is used for winding and storing welding wires to be used.
The laser 2 and the camera 3 are fixed together with the information processing device 1 and fixed through a tool, so that the laser and the wire reel 5 are kept relatively still in the measuring process, the straight line where the laser 4 emitted by the laser 2 is located passes through the circle center of the wire reel, and the length of the strip-shaped laser image is equal to the width of the wire reel.
The laser measurement method of the high-precision welding wire monitoring system based on laser vision comprises the following steps:
step 1: the industrial personal computer sends a command to the information processing device 1, the information processing device 1 commands the laser 2 to emit laser 4, if the welding wire on the wire reel is just replaced and not used, the laser 4 forms an image at a point D, if a part of the welding wire on the wire reel is used, the laser 4 forms an image at a point E, and if the welding wire on the wire reel is used up, the laser 4 forms an image at a point C;
step 2: the laser emits laser to the wire reel to form a strip-shaped image as shown in fig. 2, and since the welding wire is uniformly wound on the wire reel as shown in fig. 3 and is used layer by layer in the using process, most of the image shot by the camera 3 is as shown in fig. 4;
and step 3: the camera 3 shoots the strip-shaped image on the wire reel 5 and sends the strip-shaped image to the information processing device 1 for processing, as shown in fig. 1, when the wire reel 5 is in an unused state when the welding wire is just replaced, the image is imaged at a point D, the state of the wire reel 5 is that the welding wire is in use, the image is imaged at a point E, and when the wire reel 5 is in a used state, the image is imaged at a point C;
and 4, step 4: the information processing device 1 analyzes the distance between each point on the strip-shaped image and the laser 2 by using a triangulation method through the image, and sends data to an industrial personal computer, the industrial personal computer fits a model diagram shown in FIG. 5 according to the acquired image data and calculates the lengths of FG, GH and HI, wherein GH is the height of a layer of welding wire, FG is the residual width of the welding wire layer in use in the fitting model diagram of the industrial personal computer, and HI is the used width of the welding wire layer in use in the fitting model diagram of the industrial personal computer;
and 5: the industrial personal computer processes the distance data, the stock when the welding wire is not used is set as 100 percent, the stock after the welding wire is used is set as 0 percent, DF and DI can be directly measured by the laser sensor and sent to the industrial personal computer, and the stock of the welding wire at any moment can be obtained
And when the numerical value is 0 or a preset value, an alarm instruction is sent out.
The high-precision welding wire monitoring system based on laser vision and the laser measuring method thereof have strong robustness and anti-interference capability to the environment, are convenient to install and are not influenced by factors such as gravity center and the like; the system is high in accuracy, can check the residual quantity of the welding wires on the industrial personal computer in real time, and has certain significance for ensuring the welding quality and planning production plan; in addition, the lower limit of the residual welding wire amount of the system is not constant, and a user can set the lower limit according to actual requirements.
The above description is only for the purpose of illustrating the preferred embodiments of the present invention and is not to be construed as limiting the invention, and any modifications, equivalents or improvements made within the spirit and principle of the present invention should be included in the scope of the present invention.
Claims (10)
1. The welding wire monitoring system based on laser vision is characterized by comprising a control device, an information processing device, a laser and a camera, wherein the laser is used for emitting laser to the surface of a welding wire disc, the camera is used for shooting an image formed by the laser emitted by the laser on the welding wire disc, the information processing device is respectively connected with the control device, the laser and the camera, is used for controlling the laser to emit laser and processing image data returned by the camera, and is responsible for transmitting the processed image data to the control device, and the control device is used for communicating with the information processing device, calculating the storage amount of a welding wire according to the image data and displaying a result.
2. The laser vision-based welding wire monitoring system of claim 1, wherein the laser and the camera are fixed on the lower side of the information processing device through a tool, are positioned above the wire reel and are kept relatively static with the wire reel during the measurement process.
3. The laser vision-based welding wire monitoring system of claim 1, wherein the laser emits laser light in a straight line passing through the center of the wire reel, and the length of the laser light image projected onto the wire reel is equal to the width of the wire reel.
4. The laser-vision-based wire monitoring system as claimed in claim 1, wherein the information processing device processes the image data returned from the camera to triangulate the distance between each point on the strip image and the laser.
5. The laser-vision based wire monitoring system of claim 4 wherein said control means calculates from the image data the wire inventory as:
performing linear fitting according to the image data, wherein a fitting line segment comprises the residual width FG of the welding wire layer in use, the height GH of one layer of welding wire and the used width HI of the welding wire layer in use;
if the stock of the welding wire is 100% when the welding wire is not used and 0% after the welding wire is used, the stock of the welding wire is
Wherein, the point D is the imaging point of the laser when the welding wire is not used, and the point C is the imaging point of the laser when the welding wire is used up.
6. The laser-vision based wire monitoring system of claim 1, wherein the control device comprises an alarm unit to alert when the wire stock is less than a predetermined value.
7. The laser-vision-based welding wire monitoring system of claim 1, wherein the control device is an industrial personal computer.
8. A method of monitoring welding wire based on the laser vision based wire monitoring system of any one of claims 1 to 7, comprising the steps of:
step 1: the control device sends a monitoring command to the information processing device, and the information processing device starts the laser to emit laser;
step 2: the laser irradiates laser on the wire reel to form a strip-shaped laser image;
and step 3: shooting a strip-shaped laser image on the wire reel by a camera, and sending the strip-shaped laser image to an information processing device for processing;
and 4, step 4: based on the strip-shaped laser image, the information processing device analyzes the distance between each point on the strip-shaped image and the laser by adopting a triangulation method and sends the analysis data to the control device;
and 5: and the control device determines the residual quantity of the welding wire based on the analysis data, displays the residual quantity of the welding wire, and sends out a warning if the residual quantity of the welding wire is lower than a preset value.
9. The laser vision based welding wire monitoring method as claimed in claim 1, wherein the residual welding wire amount is
FG is the residual width of the welding wire layer in use, GH is the height of one layer of welding wire, HI is the used width of the welding wire layer in use, point D is the imaging point of the laser when the welding wire is not in use, and point C is the imaging point of the laser when the welding wire is used up.
10. A computer storage medium storing an executable program for execution by a processor to perform the steps of implementing the wire monitoring method of any one of claims 8-9.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN202111496088.7A CN114459344B (en) | 2021-12-08 | Welding wire monitoring system, method and medium based on laser vision |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN202111496088.7A CN114459344B (en) | 2021-12-08 | Welding wire monitoring system, method and medium based on laser vision |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| CN114459344A true CN114459344A (en) | 2022-05-10 |
| CN114459344B CN114459344B (en) | 2024-05-03 |
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