CN114888488A - Structured light sensor for welding deviation correction and weld joint surface quality detection - Google Patents

Structured light sensor for welding deviation correction and weld joint surface quality detection Download PDF

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Publication number
CN114888488A
CN114888488A CN202210528216.XA CN202210528216A CN114888488A CN 114888488 A CN114888488 A CN 114888488A CN 202210528216 A CN202210528216 A CN 202210528216A CN 114888488 A CN114888488 A CN 114888488A
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sensor
laser
filter
structured light
welding
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CN202210528216.XA
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CN114888488B (en
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王念峰
傅钰
张宪民
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South China University of Technology SCUT
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South China University of Technology SCUT
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K37/00—Auxiliary devices or processes, not specially adapted to a procedure covered by only one of the preceding main groups
    • 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
    • B23K31/00—Processes relevant to this subclass, specially adapted for particular articles or purposes, but not covered by only one of the preceding main groups
    • B23K31/12—Processes relevant to this subclass, specially adapted for particular articles or purposes, but not covered by only one of the preceding main groups relating to investigating the properties, e.g. the weldability, of materials
    • B23K31/125—Weld quality monitoring
    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
    • G01N21/00—Investigating or analysing materials by the use of optical means, i.e. using sub-millimetre waves, infrared, visible or ultraviolet light
    • G01N21/01—Arrangements or apparatus for facilitating the optical investigation
    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
    • G01N21/00—Investigating or analysing materials by the use of optical means, i.e. using sub-millimetre waves, infrared, visible or ultraviolet light
    • G01N21/84—Systems specially adapted for particular applications
    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
    • G01N2201/00—Features of devices classified in G01N21/00
    • G01N2201/06—Illumination; Optics
    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
    • G01N2201/00—Features of devices classified in G01N21/00
    • G01N2201/06—Illumination; Optics
    • G01N2201/061—Sources
    • G01N2201/06113—Coherent sources; lasers

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  • Engineering & Computer Science (AREA)
  • Physics & Mathematics (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Mechanical Engineering (AREA)
  • Health & Medical Sciences (AREA)
  • Chemical & Material Sciences (AREA)
  • Analytical Chemistry (AREA)
  • Biochemistry (AREA)
  • General Health & Medical Sciences (AREA)
  • General Physics & Mathematics (AREA)
  • Immunology (AREA)
  • Pathology (AREA)
  • Quality & Reliability (AREA)
  • Optics & Photonics (AREA)
  • Laser Beam Processing (AREA)

Abstract

The invention discloses a structured light sensor for welding deviation rectification and weld surface quality detection, which comprises a laser, a first reflecting mirror, a second reflecting mirror, an industrial camera, a spectroscope and a filter, wherein the laser emits a laser beam, a horizontal direction laser line and a vertical direction laser line are projected through the spectroscope, the horizontal direction laser line is reflected through the second reflecting mirror, and the vertical direction laser line is reflected through the first reflecting mirror and projected to the surface of an object to be detected. Two reflected laser lines reflected by the surface of the object to be measured are input into the two filter lenses, so that the reflected laser lines are incident into the industrial camera. The invention has simple and compact structure and strong adjustability, and can be suitable for occasions of complex workpieces in automatic robot welding.

Description

Structured light sensor for welding deviation correction and weld joint surface quality detection
Technical Field
The invention relates to the technical field of robot welding, in particular to a structured light sensor for welding deviation correction and weld joint surface quality detection.
Background
With the improvement of the industrial automation level, the requirement on the welding quality of the product is higher and higher. Vision-based automated welding has become a major development in industrial automated welding. In vision-guided automatic welding, the accurate positioning of the welding seam and the welding position of a deviation-correcting welding robot are the key points for ensuring the welding quality; meanwhile, the surface quality of the weld joint can be affected by wrong selection of the welding process. By detecting the quality of the surface of the welding seam in real time, the welding process can be adjusted in real time according to the detection result. Therefore, the welding deviation correction and weld joint surface quality detection sensor technology is the premise of improving the automatic welding quality.
At present, visual sensors applied to welding robots are various, but the active visual sensor is simple in structure and easy to realize. Active vision sensors need to be equipped with an imaging light source and then capture image information at the location where the light source is projected by an industrial camera. The line structured light has high brightness; the directivity is good, and the divergence is avoided; the device has the characteristics of good coherence, difficult interference and the like, can effectively overcome the influence of arc light, splashing, smoke and the like generated in the welding process, and is widely applied to the active vision sensor.
At present, most of laser sensors are fixed on a welding gun, only have the functions of welding seam identification and welding deviation correction, are large in size and cannot well correspond to complex workpiece welding scenes. Because only the functions of welding seam identification and welding deviation correction are provided, the quality detection of the welded welding seam surface can not be completed during welding, and the purpose of adjusting welding process parameters in real time is achieved.
Disclosure of Invention
In order to overcome the defects in the prior art, the invention provides a structured light sensor for welding deviation correction and weld joint surface quality detection.
The invention can emit two line structured lights by using only one structured light emitter, and the two line structured lights are respectively used for welding deviation correction and weld surface quality detection.
The invention adopts the following technical scheme:
the utility model provides a structured light sensor for welding is rectified and welding seam surface quality detects, includes laser instrument, first speculum, the second mirror, industry camera, spectroscope and optical filter, a bundle of laser line is launched to the laser instrument, throws out horizontal direction laser line and vertical direction laser line via the spectroscope, horizontal direction laser line reflects through the second mirror, vertical direction laser line is through first speculum reflection, and two optical filters of input after two reflection laser lines project the workpiece surface that awaits measuring, and industry camera gathers optical filter back laser line picture.
Further, the laser ray in the horizontal direction is reflected by the second reflecting mirror, and the reflected ray is emitted out at 10 degrees with the optical axis of the industrial camera;
the laser ray is reflected by the first reflector, and the reflected ray is emitted out at 35 degrees with the optical axis of the industrial camera.
Furthermore, the two filter lenses form an included angle of 120 degrees.
Furthermore, the central line of the spectroscope and the central line of the laser form an included angle of 45 degrees.
Furthermore, the central axis of the laser, the optical axis of the industrial camera, the central lines of the two reflectors, the central line of the filter and the central line of the spectroscope are all in the same plane.
Further, still include: the sensor comprises a sensor bottom plate, a sensor upper side plate, a sensor left side plate and a sensor right side plate;
the laser is fixed on the sensor base plate through laser sleeving, the industrial camera is fixed on the sensor base plate through a heat dissipation frame, and the filter is arranged on the sensor base plate;
the first reflector is fixed on the sensor top plate through a first reflector clamping mechanism, the second reflector is fixed through a second reflector clamping mechanism, the second reflector clamping mechanism is arranged on a rotary table top of a manual rotary table, and the manual rotary table is installed on the sensor bottom plate.
Further, the optical filter is arranged on the sensor base plate, and specifically comprises:
the filter is installed on detachable filter fixture, detachable filter fixture sets up at filter interface mechanism, filter interface mechanism sets up on the sensor bottom plate.
Further, still include the organic glass board, be the rectangle, two are on a parallel with the optical filter installation, the organic glass board sets up in the rectangle spout that can dismantle optical filter fixture.
Further, the welding gun device also comprises a sensor clamping block used for connecting the welding gun, and the sensor clamping block is arranged on the sensor bottom plate.
Furthermore, the sensor clamping block is divided into a left part and a right part, a semicircular groove is formed in the middle of the two parts, and the two parts are fixed through an insulating sleeve.
The invention has the beneficial effects that:
(1) the invention simultaneously finishes the work of welding deviation correction and welding surface quality detection, and realizes the simultaneous emission of two laser lines through the combination of the spectroscope and the reflector, and the laser lines are respectively used for welding deviation correction and welding seam surface quality detection. The robot can be guided to weld, the quality detection work of the welded seam can be completed, and theoretical reference is provided for real-time adjustment of welding process parameters.
(2) The invention has compact structure, realizes the effect of simultaneously emitting two laser lines by using one laser, has high price, can reduce the number of internal components and reduce the cost by using only one laser; the light path design of the spectroscope and the reflector is combined with the relative position of the camera, so that the internal space can be effectively saved, the structure is more compact, the size of the sensor is reduced, and the applicability to the welding scene of a complex workpiece is improved.
(3) The invention has detachable filter, which makes the filter system convenient to detach, specifically, the filter interface mechanism is provided with a notch on which a wave screw is arranged. The convex part is arranged on the filter support and provided with the groove, and during installation, the convex part of the filter support only needs to be rotated until the wave screw abuts against the groove of the convex part, and vice versa during disassembly.
Drawings
FIG. 1 is a schematic view of the overall structure of the present invention;
fig. 2 is a right side view of fig. 1.
Detailed Description
The present invention will be described in further detail with reference to examples and drawings, but the present invention is not limited to these examples.
Examples
As shown in fig. 1 and 2, a structured light sensor for welding deviation correction and weld surface quality detection includes: the sensor comprises a sensor bottom plate 21 for supporting and fixing various internal elements, a sensor upper side plate 1 for protecting the internal elements, a sensor left side plate 12, a sensor right side plate 3 and a sensor top plate 25, wherein the sensor top plate 25 is arranged perpendicular to the sensor upper side plate.
The structured light vision sensor also comprises a laser 19, a first reflecting mirror 11, a second reflecting mirror 15, an industrial camera 2, a spectroscope 14 and a filter 8, and the structured light vision sensor comprises the following components:
the laser 19 is arranged on a laser sleeve seat 20 for clamping and supporting the laser, and the laser sleeve seat 20 is fixed on a sensor bottom plate 21 through bolts.
The laser emits line-shaped red laser light.
The first mirror 11 is mounted on the sensor top plate 25 by a first mirror holding mechanism 10.
The second reflector is fixed on a second reflector clamping mechanism 16, the second reflector clamping mechanism is installed on a rotary table top of a manual rotary table 18 through a reflector connecting block 17, and the second reflector can rotate along with the rotary table top. The manual turntable 18 is mounted in a rectangular slot cut into the sensor base plate 21.
Further, the laser reflected by the two reflecting mirrors can respectively irradiate the lower visual fields on the left side and the right side of the industrial camera.
The spectroscope 14 is fixed by a clamping mechanism 13 and is arranged on a sensor top plate 25.
The industrial camera 2 is provided with a lens 5, is arranged on the heat dissipation frame 4 and is fixed on the sensor bottom plate 21 through the heat dissipation frame 4.
The filter 8 is arranged on the detachable filter clamping mechanism 7; the top end of the detachable filter clamping mechanism 7 is provided with a rigid bulge which is matched with the groove of the filter interface mechanism 6 and is limited by a wave bead positioning screw. When the device is used, the device can be manually rotated until the wave bead positioning screw slides into the limiting hole to be installed, and the device can be disassembled in the same way.
The filter interface mechanism 6 is fixed on the sensor base plate 21.
The detachable filter clamping mechanism 7 is also provided with a groove for arranging an organic glass plate 9 which is rectangular and used for blocking splashing during welding so as to avoid damaging a lens.
A sensor holder block 23 for attaching a welding torch 24 is provided on the lower side of the sensor base plate 21.
In order to better realize the function of simultaneously performing welding deviation correction and weld joint surface quality detection by the structure, the specific positions of the elements are defined as follows.
The central axis of the laser 19, the optical axis of the industrial camera 2, the central lines of the first reflecting mirror 11, the second reflecting mirror 15, the central line of the filter 8 and the central line of the beam splitter 14 are in one plane.
The relative positions of the laser 19, the industrial camera 2, the base of the manual turntable 18, and the welding gun 24 are fixed, all by means of a rectangular slot in the sensor base plate 21. The relative positions of the reflector clamping mechanism 10 and the spectroscope clamping mechanism 13 are fixed and are positioned through a rectangular groove on the top plate.
The central line of the beam splitter 14 and the central line of the laser 19 form an included angle of 45 degrees, so as to ensure that two laser lines projected from the beam splitter 14 are respectively in the horizontal direction and the vertical direction. The laser beam emitted in the horizontal direction passes through the second reflecting mirror 15, and the reflected beam is emitted at 10 degrees to the optical axis of the camera.
The angle of the second reflecting mirror 15 can be adjusted by adjusting the button of the manual rotating table 18, so that the laser emitting angle can be adjusted; the laser beam emitted in the vertical direction passes through the first reflecting mirror 11 and is emitted at 35 degrees to the optical axis of the camera.
The filter 8 is two pieces and is 120 degrees. Because the sensor projects the laser light obliquely onto the workpiece surface, the reflected light is obliquely incident on the horizontally disposed filter. This results in an increase in polarization dependent loss of the narrow band filter, and the peak and bandwidth of the band pass filter will shift towards the short wave, so that the filtering effect is greatly reduced. Therefore, two filters are placed at an angle to each other to ensure that as much of the laser line reflected light as possible enters the camera.
The organic glass plates 9 are two pieces and are installed in parallel with the filter 8. There is the rectangle spout in detachable optical filter fixture 7 in order to install organic glass board 9, and organic glass board 9 slides in the rectangular channel, fixes the hole of both ends extension through the tiny screw, accomplishes the spacing of glass board. The organic glass plate can transmit light and can block splashing during welding so as to protect the organic glass plate of the camera and the laser, and the organic glass plate is arranged in the sliding groove on the lower plate so as to be convenient to replace after being splashed and polluted by smoke.
The sensor clamping block 23 is divided into a left part and a right part, and a semicircular groove is formed in the middle of the sensor clamping block and used for mounting a welding gun 24. The sensor clamping block 23 and the sensor are isolated by a hard heat-resistant insulating plastic gasket 22 processed by a POM polyformaldehyde plate. And meanwhile, the left clamping block and the right clamping block are fixed through the insulating sleeves and the bolts. The insulation between the welding gun and the sensor is realized, and the sensor is damaged by high voltage and current during surface welding.
The upper part of the left part of the sensor clamping block is obliquely arranged along the direction close to the bottom plate.
The specific working process of the invention is as follows:
the sensor is fixed at the tail end of the welding gun, the laser is connected with the power supply, and the camera is connected with the computer. When the laser welding gun is used, the welding gun is moved to the position right facing a workpiece, power is supplied to the laser, and the laser is turned on.
The laser emits a beam of laser, transmits laser rays in the horizontal direction and the vertical direction after passing through the beam splitter, and projects the laser rays onto the surface of an object to be measured (a welding seam) after being reflected by the first reflector and the second reflector respectively. The laser beam reflected by the surface of the object to be measured is input into the filter lens and further enters the industrial camera. At the moment, the camera captures the light reflected by the workpiece, and the light is displayed as a laser line picture at the computer end. In the laser line picture, there are two laser lines (one for welding tracking and one for weld surface quality detection). And the computer end is used for respectively carrying out image processing on the two laser lines and respectively finishing welding tracking and welding seam surface quality detection.
The structure of the embodiment is compact, and the device can be suitable for various workpieces with complex structures; the adjustability is strong, can adjust the distance of laser line apart from welder according to actual conditions. The method can complete the searching of the welding starting position, the tracking of the welding seam, the deviation correction of the welding process and the visual detection of the welding surface quality at the same time, and provides help for the automation of welding and the optimization of the welding quality.
The above embodiments are preferred embodiments of the present invention, but the present invention is not limited to the above embodiments, and any other changes, modifications, substitutions, combinations, and simplifications which do not depart from the spirit and principle of the present invention should be construed as equivalents thereof, and all such changes, modifications, substitutions, combinations, and simplifications are intended to be included in the scope of the present invention.

Claims (10)

1. The utility model provides a structured light sensor for welding is rectified and welding seam surface quality detects, its characterized in that, includes laser instrument, first speculum, the second mirror, industry camera, spectroscope and optical filter, a bundle of laser line is launched to the laser instrument, throws out horizontal direction laser line and vertical direction laser line via the spectroscope, horizontal direction laser line reflects through the second mirror, vertical direction laser line is through first speculum reflection, and two optical filters of input after two reflection laser lines project the workpiece surface that awaits measuring, and industry camera gathers optical filter post laser line picture.
2. The structured light sensor of claim 1, wherein the horizontal laser light is reflected by a second mirror, the reflected light exiting at 10 degrees to the optical axis of the industrial camera;
the laser ray is reflected by the first reflector, and the reflected ray is emitted out at 35 degrees with the optical axis of the industrial camera.
3. A structured light sensor as claimed in claim 1 wherein the two filters are at a 120 degree angle.
4. A structured light sensor as claimed in claim 1 wherein the centreline of the beam splitter makes a 45 degree angle with the centreline of the laser.
5. A structured light sensor according to claim 1 wherein the central axis of the laser, the optical axis of the industrial camera, the centre lines of the two mirrors, the centre line of the filter and the centre line of the beamsplitter are all in the same plane.
6. A structured light sensor as claimed in any one of claims 1 to 5 further comprising: the sensor comprises a sensor bottom plate, a sensor upper side plate, a sensor left side plate and a sensor right side plate;
the laser is fixed on the sensor base plate through laser sleeving, the industrial camera is fixed on the sensor base plate through a heat dissipation frame, and the filter is arranged on the sensor base plate;
the first reflector is fixed on the sensor top plate through a first reflector clamping mechanism, the second reflector is fixed through a second reflector clamping mechanism, the second reflector clamping mechanism is arranged on a rotary table top of a manual rotary table, and the manual rotary table is installed on the sensor bottom plate.
7. A structured light sensor according to claim 6, wherein the filter is arranged on the sensor base plate, in particular:
the filter is installed on detachable filter fixture, detachable filter fixture sets up at filter interface mechanism, filter interface mechanism sets up on the sensor bottom plate.
8. A structured light sensor according to claim 7, further comprising a plexiglas plate, rectangular in shape, two plates mounted parallel to the filter, said plexiglas plate being disposed within the rectangular channel of the removable filter clamping mechanism.
9. The structured light sensor of claim 6, further comprising a sensor holder block for attachment to a welding torch, disposed on the sensor base plate.
10. The structured light sensor of claim 9, wherein the sensor holder is divided into left and right portions, a semicircular groove is formed between the left and right portions, and the left and right portions are fixed by the insulating sleeve.
CN202210528216.XA 2022-05-16 2022-05-16 A structure light sensor for welding rectify and weld surface quality detects Active CN114888488B (en)

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Citations (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN1748924A (en) * 2005-01-08 2006-03-22 湘潭大学 Automatic tracking control method for submerged-arc welding seam
CN101797665A (en) * 2010-01-20 2010-08-11 浙江理工大学 Visual detection sensing unit
CN207114420U (en) * 2017-07-18 2018-03-16 南京中车浦镇城轨车辆有限责任公司 A kind of paraxonic integrating device of laser welding on-line monitoring system sensor
CN108637435A (en) * 2018-05-16 2018-10-12 华南理工大学 A kind of three-dimensional seam tracking system and method for view-based access control model and arc voltage sensing
CN109676243A (en) * 2019-01-21 2019-04-26 苏州实创德光电科技有限公司 Weld distinguishing and tracking system and method based on dual laser structure light
CN112743198A (en) * 2020-12-18 2021-05-04 华南理工大学 Welding seam tracking sensor structure with compact structure
CN113894386A (en) * 2021-10-08 2022-01-07 上海钊晟传感技术有限公司 Dual-sensing dual-wavelength integrated weld joint tracking sensor and deviation rectifying method

Patent Citations (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN1748924A (en) * 2005-01-08 2006-03-22 湘潭大学 Automatic tracking control method for submerged-arc welding seam
CN101797665A (en) * 2010-01-20 2010-08-11 浙江理工大学 Visual detection sensing unit
CN207114420U (en) * 2017-07-18 2018-03-16 南京中车浦镇城轨车辆有限责任公司 A kind of paraxonic integrating device of laser welding on-line monitoring system sensor
CN108637435A (en) * 2018-05-16 2018-10-12 华南理工大学 A kind of three-dimensional seam tracking system and method for view-based access control model and arc voltage sensing
CN109676243A (en) * 2019-01-21 2019-04-26 苏州实创德光电科技有限公司 Weld distinguishing and tracking system and method based on dual laser structure light
CN112743198A (en) * 2020-12-18 2021-05-04 华南理工大学 Welding seam tracking sensor structure with compact structure
CN113894386A (en) * 2021-10-08 2022-01-07 上海钊晟传感技术有限公司 Dual-sensing dual-wavelength integrated weld joint tracking sensor and deviation rectifying method

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